Project Overview
This Worcester project is a sobering reminder of why annual HVAC maintenance is not optional — it is a safety necessity. A cracked heat exchanger is one of the most dangerous conditions that can develop in a gas furnace, because it allows carbon monoxide (an odorless, colorless gas) to enter the living space. CO poisoning can cause headaches, nausea, confusion, and in severe cases, death.
The homeowner in this case had done everything right as a layperson — changing filters regularly and keeping the area around the furnace clear. But a cracked heat exchanger is invisible without professional inspection tools. Our technicians use combustion analyzers on every maintenance visit specifically to catch conditions like this.
This story is not unusual. The Consumer Product Safety Commission estimates that over 300 people die from CO poisoning related to home heating every year in the United States, and thousands more are hospitalized. A $129 annual tune-up is the single most important thing a homeowner can do to protect their family.
The Challenge
This was a routine annual maintenance visit — the homeowner had no complaints about system performance. The furnace appeared to be running normally: producing heat, cycling on and off as expected, and showing no error codes. However, the 16-year-old furnace had never been inspected by a professional since installation. The homeowner had been changing filters regularly but had no way to inspect internal components. Without this scheduled maintenance visit, the dangerous condition discovered inside would have gone undetected until it caused a serious health emergency.
Our Solution
During our 21-point safety inspection, our technician used a combustion analyzer to measure flue gas composition. The readings immediately raised concern: elevated carbon monoxide levels in the flue indicated incomplete combustion. A visual inspection of the heat exchanger using a borescope camera revealed a 3-inch crack along the primary heat exchanger cell. This crack was allowing combustion gases — including carbon monoxide — to mix with the household air supply. We immediately shut down the furnace and installed temporary CO monitors while explaining the severity of the situation to the homeowner. Given the age and condition of the furnace, repair was not recommended. We provided an emergency replacement quote and had a new 96% AFUE furnace installed within 72 hours. Post-installation CO testing confirmed zero carbon monoxide presence in the living space.
Results & Outcomes
- Potentially life-threatening carbon monoxide leak detected and eliminated
- New high-efficiency furnace installed within 72 hours
- CO monitors installed on every level of the home
- Homeowner enrolled in annual maintenance plan to prevent future risks
Project Details
Service
HVAC Maintenance
Location
Worcester, MA
Duration
Same Day (inspection) + 72 Hours (replacement)
Equipment
Carrier
Scope
Residential
Result
Completed Successfully
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