The condensate trap is one of the most deceptive, trouble-prone and costly components in the HVAC system. When installed in a draw-through system (the type most commonly used in commercial, industrial and school facilities), it causes numerous problems, which—during the life of the system—may cost building owners/managers as much as the HVAC system itself.

Over the past several years, we have visited scores of facilities and inspected hundreds of HVAC systems, during the cooling seasons. Almost without exception, these systems were wet and dirty inside and contaminated with biological growth, as a result of dysfunctional condensate traps. These conditions are affecting millions of systems nationwide. In terms of service calls, maintenance effort, equipment damages, surrounding property damage and human health problems, these systems are, unnecessarily, costing building owners/managers billions of dollars annually.

Some within the industry—including many building owners/managers— accept these conditions as necessary evils, for which there is no remedy. Others like EPA, OSHA, ASHRAE and equipment manufacturers attribute these conditions to poor maintenance, by building maintenance personnel.

However, neither position is correct. It is true that this situation cannot be realistically resolved by building owners/managers, as long as their HVAC systems are equipped with condensate traps. Nor can the situation be remedied by instituting the extensive, and costly maintenance programs being advocated by EPA, OSHA, ASHRAE and equipment manufacturers.

As a result of the above situation, most building owners/managers have responded with what can be called an "On-Demand Program." That is, maintenance personnel service condensate traps only when problems are reported. This type program is not only ineffective it is also expensive, and it accounts for much of the exorbitant HVAC maintenance costs, imposed on building owners/users.

It is not claimed that the cost estimates shown in Table 2 are rigorous. There is, however, no doubt that the cost is significant and well known to facility managers. Our guess it that most facility managers would establish higher estimates.

No attempt has been made to estimate the cost of health problems caused by the condensate trap. But they certainly are not negligible. In fact, the cost of health problems may well exceed all others.

COST REMEDY

Fortunately, there is a remedy for the costly problems imposed by the condensate trap: the CostGard™ Condensate Drain Seal. By replacing the condensate trap with this drain seal, building owner and/or managers can virtually eliminate the excessive maintenance and repair costs associated with the condensate trap.  CostGard™ Condensate Drain Seal is unique in that it uses an air seal instead of a water seal; thus, it eliminates all water problems. It functions properly under all operating conditions. It is not affected by subfreezing outdoor temperatures or by winter cooling operations, as is a condensate trap.

The maintenance required by the CostGard™ Condensate Drain Seal is minimal to nil. The device is passive and has no definable failure modes. In more than seven years of field experience, not one device has become blocked to condensate flow, damaged by freezing or failed to operate properly.

Hence, it appears that the only preventive maintenance steps required are those necessary to ensure that the CostGard™ Condensate Drain Seal remains in place. That is, a periodic walk-by to ensure that service personnel, who often remove condensate traps—because they frequently become blocked—do not remove these devices.

SAVINGS COMPARISON

Clearly, the savings attainable by using the CostGard™ Condensate Drain Seal are appreciable. To realize this saving, the only effort required is that of replacing the condensate trap—on draw-through HVAC units—with CostGard™ Condensate Drain Seals.  This device has no moving parts and is virtually maintenance free.

Energy management programs have been eagerly embraced by many building owners/managers, in various types of facilities. The savings offered are tempting, but the major initial investment required (about $1400 per HVAC unit) and the long payback period (usually established at 10 years) absorbs much of the savings. This, of course, means that no real savings are realized for 10 years. After the payback period, the total savings per HVAC unit are $650, $1300 and $1950 after 15, 20 and 25 years respectively.

The cost savings offered by the CostGard™ Condensate Drain Seal are much more attractive. The initial cost is minimal. For units of 25 tons and less, the initial cost of the device, delivered and installed, is estimated to be no more than $80 each. Thus, the payback time is about one year and savings are realized in each of the following years. After 25 years of operation, the total savings resulting from use of the CostGard™ Condensate Drain Seal is $1920—virtually the same saving as for the energy management program ($1950). The difference, of course, is the initial investment: $1400 vs. $80 per HVAC unit and the time period before savings can be realized.

IMPLEMENTATION OF COST SAVING

Implementation of a CostGard™ Condensate Drain Seal cost saving program is quite simple. For most applications, our products are available from stock. Shipment is usually made within one day after receiving a purchase order. We provide installation and design support, as needed, to ensure successful incorporation of the CostGard™ Condensate Drain Seals on existing HVAC systems or on new systems being designed for existing or new buildings.

Existing System Installations

New System Designs