### APPENDIX 8-B. MAINTENANCE & REPAIR COST DETERMINATION

TABLE OF CONTENTS

8-B.1 INTRODUCTION ................................................................................................. 8-B-1 8-B.2 MAINTENANCE COSTS..................................................................................... 8-B-2 8-B.2.1 Electric Storage Water Heaters.............................................................................. 8-B-2 8-B.2.2 Oil-Fired Storage Water Heaters ........................................................................... 8-B-3 8-B.2.3 Instantaneous Gas-Fired Water Heaters................................................................. 8-B-4 8-B.2.4 Gas-Fired Pool Heaters.......................................................................................... 8-B-4 8-B.2.5 Direct Heating Equipment ..................................................................................... 8-B-5 8-B.3 REPAIR COSTS.................................................................................................... 8-B-5 8-B.3.1 Component Repair Cost Calculations.................................................................... 8-B-6 8-B.3.1.1 Pilot Ignition Repair Cost .................................................................... 8-B-6 8-B.3.1.2 Electronic Ignition Repair Cost ........................................................... 8-B-7 8-B.3.1.3 Combustion and Circulating Fan Repair Cost ..................................... 8-B-7 8-B.3.1.4 Heat Pump Water Heater Repair Cost ................................................. 8-B-8 8-B.3.2 Lifetime distributions for repair Costs................................................................... 8-B-8 8-B.3.3 Repair Cost Methodology Flowcharts by Product Type...................................... 8-B-15

LIST OF TABLES

Table 8-B.1.1 Example Maintenance/Repair Cost Table ................................................. 8-B-2 Table 8-B.2.1 HPWH Maintenance .................................................................................. 8-B-3 Table 8-B.2.2 Maintenance Contract Data Table ............................................................. 8-B-4 Table 8-B.2.3 Baseline Pool Heater Maintenance ............................................................ 8-B-5 Table 8-B.2.4 Advanced Design Pool Heater Maintenance ............................................. 8-B-5 Table 8-B.2.5 Data from GRI Report ............................................................................... 8-B-5 Table 8-B.3.1 Summary of Repair Component Cost Data ............................................... 8-B-6 Table 8-B.3.2 Pilot Light Ignition (Standing Pilot) Repair Cost ...................................... 8-B-7 Table 8-B.3.3 Pilot Light Ignition (Millivolt) Repair Cost for Pool Heaters.................... 8-B-7 Table 8-B.3.4 Electronic Ignition Repair Cost ................................................................. 8-B-7 Table 8-B.3.5 Electronic Ignition Repair Cost for Pool Heaters ...................................... 8-B-7 Table 8-B.3.6 Combustion and Circulating Air Fan Repair Cost..................................... 8-B-8 Table 8-B.3.7 Power Vent Fan Repair Cost for Pool Heaters .......................................... 8-B-8 Table 8-B.3.8 Heat Pump Compressor Repair Cost for Electric Water Heaters .............. 8-B-8 Table 8-B.3.9 Heat Pump Evaporator Fan Cost for Electric Water Heaters .................... 8-B-8 Table 8-B.3.10 Component Lifetime Data Gathered.......................................................... 8-B-9 Table 8-B.3.11 Mean Component Lifetime Used in Analysis.......................................... 8-B-10 Table 8-B.3.12 Parameters for Generating Weibull Distributions for different Component Lifetimes............................................................................... 8-B-10

LIST OF FIGURES

Figure 8-B.1.1 Methodology for Calculating Maintenance and Repair Costs................... 8-B-1

8-B-i

### Figure 8-B.1.2 Methodology for Determining Repair Cost for a Sampled Household ..... 8-B-2 Figure 8-B.3.1 Fraction of the Components with 5-Year Lifetime Failing ..................... 8-B-11 Figure 8-B.3.2 Cumulative Lifetime Length of Components with 5-Year Lifetime ....... 8-B-11 Figure 8-B.3.3 Fraction of the Components with 10-Year Lifetime Failing ................... 8-B-12 Figure 8-B.3.4 Cumulative Lifetime Length of Components with 10-Year Lifetime ..... 8-B-12 Figure 8-B.3.5 Fraction of the Components with 12-Year Lifetime Failing ................... 8-B-13 Figure 8-B.3.6 Cumulative Lifetime Length of Components with 12-Year Lifetime ..... 8-B-13 Figure 8-B.3.7 Fraction of the Components with 15-Year Lifetime Failing ................... 8-B-14 Figure 8-B.3.8 Cumulative Lifetime Length of Components with 15-Year Lifetime ..... 8-B-14 Figure 8-B.3.9 Methodology for Calculating Repair Cost for Gas Storage Water Heaters ..................................................................................................... 8-B-15 Figure 8-B.3.10 Methodology for Calculating Repair Cost for Electric Storage Water Heaters ..................................................................................................... 8-B-16 Figure 8-B.3.11 Methodology for Calculating Repair Cost for Gas Instantaneous Water Heaters ..................................................................................................... 8-B-17 Figure 8-B.3.12 Methodology for Calculating Repair Cost for DHE................................ 8-B-18 Figure 8-B.3.13 Methodology for Calculating Repair Cost for Pool Heaters.................... 8-B-19

8-B-ii

### APPENDIX 8-B. MAINTENANCE & REPAIR COST DETERMINATION

8-B.1 INTRODUCTION
The maintenance cost is the price of regular scheduled product maintenance ($/year). The repair cost is the price to repair the product when it fails ($). These costs cover all labor and material costs associated with the maintenance or repair of existing products. The determination of the repair cost involves determining the cost and the service life of the components that are likely to fail and includes the labor and the materials associated with the replacement.

Many maintenance and repair costs are estimated using cost tables similar to the ones used in RS Means. 1, 2 

### Figure 8-B.1.1 shows the methodology for calculating maintenance and repair costs and Table 8-B.1.1 offers an example maintenance/repair cost calculation. All labor 2 

### costs are derived using the latest 2008 RS Means labor cost by crew type. All repair and maintenance cost tables include a trip charge which is often charged by contractors and 2 

### calculated to be equal to one half hour of labor per crew member. Labor hours (or person-hours) are based on RS Means data, expert data, or engineering judgment. 2008 Bare Costs are all the costs without any markups. Material costs are based on RS Means data, expert data, or internet sources. The total includes overhead and profit (O&P), which is calculated using labor and material markups from RS Means. 1, 2

Total Repair Cost Various Sources

(EqpLT +1 yr) > CompLT > Warranty Component Lifetime (Weibull distribution)

Component Lifetime (CompLT) Equipment Lifetime (Weibull distribution)

Equipment Lifetime (Eqp LT) Various Sources

TRUE FALSE RECS Sampled

Household

Total Repair Cost (applied at component lifetime year) No Repair Cost

Equipment Warranty 

### Figure 8-B.1.1 Methodology for Calculating Maintenance and Repair Costs

8-B-1

### Table 8-B.1.1 Example Maintenance/Repair Cost Table

Description Crew PersonHours 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge CREW1 0.5 $0 $23 $0 $23 $35 Description of Maintenance or Repair CREW1 0.5 $0 $23 $0 $23 $35
Totals 1.0 $0 $47 $0 $47 $70



### The determination of the repair cost also involves determining the service life of the components that are likely to fail and comparing it to the lifetime of the equipment. Figure 8­ B.1.2 shows the methodology for determining repair cost for an individual sampled household. Both component and equipment lifetime are given by Wiebull distributions. During the lifetime of the equipment only a fraction of the sampled households will see a repair cost. Repair lifetime distribution derivations are explained in section 8-B.3.2.

Total Repair Cost Various Sources

(EqpLT +1 yr) > CompLT > Warranty Component Lifetime (Weibull distribution)

Component Lifetime (CompLT) Equipment Lifetime (Weibull distribution)

Equipment Lifetime (Eqp LT) Various Sources

TRUE FALSE RECS Sampled

Household

Total Repair Cost (applied at component lifetime year) No Repair Cost

Equipment Warranty 

### Figure 8-B.1.2	 Methodology for Determining Repair Cost for a Sampled Household

8-B.2 MAINTENANCE COSTS
DOE did not include any maintenance cost for residential electric and gas-fired storage water heaters. It did include maintenance costs for heat pump water heaters, oil-fired water heaters, gas-fired instantaneous water heaters, pool heaters, and DHE.
8-B.2.1 Electric Storage Water Heaters
DOE determined that there is virtually no maintenance of electric resistance water heaters. For a heat pump water heater, maintenance includes annual cleaning of the air filter and

8-B-2

### a preventative maintenance cost to check the evaporator and refrigeration system. The literature recommends that no professional help is needed for this maintenance. 3, 4 

### DOE believes there are instances in which such help is needed; thus, for certain heat pump water heater installations it added a preventative maintenance cost to check the evaporator and refrigeration system. For locations where the HPWH might be more exposed to the outdoor environment, such as garages and crawlspaces, DOE applied a 5-year preventative maintenance cost based on Australian HPWH outdoor installations. 5, 6 

### DOE estimated that 27% of these exposed installations would 7 

### require this maintenance, based on a survey conducted for central air conditioners. For heat pump water heaters that are located indoors or in basements, the maintenance requirements are considered to be the same as other similar indoor appliances such as refrigerators and room heaters, which don’t have any additional maintenance costs 8, 9 

### For this maintenance cost, DOE based the labor hours and costs on RS Means. 1, 2 

### The average cost of this maintenance is $81. (See Table 8-B.2.1)

Table 8-B.2.1 HPWH Maintenance

Description Crew PersonHours 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 PLUM* 0.5 $0 $23 $0 $23 $35 Clean evaporator, drain pan, fans, motors, and drain piping 1 PLUM 0.38 $0 $18 $0 $18 $27 During operation of unit, check refrigerant pressure, add refrigerant as necessary 1 PLUM 0.272 $0 $13 $0 $13 $19
Totals 1.152 $0 $54 $0 $54 $81
* 1 PLUM means a crew of 1 plumber.


### 8-B.2.2 Oil-Fired Storage Water Heaters
Oil-fired water heaters and burners are cleaned and maintained regularly. Maintenance is most frequently performed under annual maintenance contracts, which typically includes repair of failed components. The maintenance contracts apply to all energy efficiency levels and no separate repair cost was included.

To derive the cost of the maintenance contract for water heaters DOE collected maintenance contract prices gathered from web sites that represent oil-fired product suppliers in the eastern U.S (see Table 8-B.2.2). This cost varies widely, depending on the presence of other oil-fired products in the residence. The maintenance cost of the oil-fired water heater is usually an additional cost added to the total oil-fired equipment contract. Costs may go down if multiple oil-fired appliances in a household are on the same contract. DOE estimated the average cost of the oil-fired water heater maintenance contract by including half of the average cost of the oil equipment contract and the average cost for the water heater contract option. The average cost of maintenance contracts is $152.59 per year.

8-B-3

### Table 8-B.2.2 Maintenance Contract Data Table

Company Location Description Cost of Oil Eqp Contract (2007$) Cost of WH Option (2007$) Brennan Oil RI, MA Oil Rite Plan $175.00 $75.00 Noonan Energy MA Basic Plan $109.95 $35.00 Heritage Energy NY Traditional Home Oil Plan $189.95 $119.95 Hi-Ho Petroleum CT Main Burner $185.00 $85.00 Drum Oil & Propane NY Oil Heating System - Plan A $184.95 $94.95 Richard T. Layton Co. CT Oil Burner Service Contract $164.95

-- Stadium Oil Heat MA Service Contract $169.00 $50.00 Williams Service Company PA Oil Hot Water Heater Service Plan

-- $91.95 Solliday Oil Company MD Certified Comfort Plan #1 $125.00

-- Slomin's NY, VA Econo Pak $99.00 $26.95 Springbrook Ice & Fuel Service CT $180.00

-- Warthen Fuel MD PLAN B - Standard Maintenance Agreement $139.50

-- Kero-Del MD

-- $89.95 Average $156.57 $74.31 Half of Cost of Oil Equipment + WH Option $152.59



### 8-B.2.3 Instantaneous Gas-Fired Water Heaters
The analysis assumes that there is an annual maintenance of residential instantaneous 10 

### water heaters associated mainly with de-liming the heat exchanger. DOE used a uniform distribution of values from $70 to $100 per year for all energy efficiency levels. 10, 11



### 8-B.2.4 Gas-Fired Pool Heaters
Most pool owners do not perform any pool heater maintenance except when the heater does not come on. In such situations, the maintenance work includes verifying controls operation, cleaning burners, cleaning heat exchanger, starting the heater, and measuring water temperature rise. In addition, for advanced design pool heaters it also includes measuring combustion differential pressure. DOE used an average maintenance cost of $351 ($491 for advanced designs), and estimated that the maintenance occurs in the fifth year of the pool heater 11 

### lifetime if the pool heater lifetime is 6 years or longer.

12 

### Consultant provided average number of hours for maintenance and 2008 RS Means was used to calculate the labor rates. (See Table 8-B.2.3 and Table 8-B.2.4)

8-B-4

### Table 8-B.2.3 Baseline Pool Heater Maintenance

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 2 Plum* 1 Ea. $0 $47 $0 $47 $70 Verifying control operations, clean burners, clean HX, start up heater, check temperature rise 2 Plum 4 Ea. $0 $187 $0 $187 $281
Total 5 Ea. $0 $234 $0 $234 $351
* 2 PLUM means a crew of 2 plumbers.


### Table 8-B.2.4 Advanced Design Pool Heater Maintenance

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 2 Plum 1 Ea. $0 $47 $0 $47 $70 Verifying control operations, clean burners, clean HX, measure combustion differential pressure, start up heater, check temperature rise 2 Plum 6 Ea. $0 $280 $0 $280 $421
Total 7 Ea. $0 $327 $0 $327 $492



### 8-B.2.5 Direct Heating Equipment
For direct heating equipment, DOE used the maintenance cost data from the 2007 13 

### Furnace/Boiler rulemaking. The costs were derived from a 1994 Gas Research Institute (GRI) report based on field survey sponsored by several gas utilities that repair and service furnace and 14 

### boiler equipment. The survey estimated the average cost per service call as the average total service charge (parts, labor, and other charges). The average total service charge is $214. DOE used a maintenance frequency of once every five years for all DHE product classes. (See Table 8-B.2.5)

Table 8-B.2.5 Data from GRI Report Description Cost (1992$) Cost (2007$) Case 1 (5-years) $145 $214

8-B.3 REPAIR COSTS
The repair cost reflects the cost to the consumer for a service call when the product fails. In some cases, if the equipment fails residential consumers tend to replace the equipment rather than having them serviced. This is especially true for water heaters. However, there are design options considered for which the components may encounter repair cost during the lifetime of the equipment.

Components most likely to be repaired include ignition system, gas valve, circulating or combustion blower, electronics/controls/switches, vent system components, and heat

8-B-5

### exchangers. 9, 11 

### DOE analyzed the repair costs of ignition systems, circulating blower, and combustion blower, as well as the cost of the compressor and evaporator fan components for the heat pump water heater design option.

RS Means and consultants provided average number of hours for labor and materials costs. RS Means was used to calculate the labor rates.
8-B.3.1 Component Repair Cost Calculations
Table 8-B.3.1 shows the components most likely to be repaired for each product, as well as cost information and source.

Table 8-B.3.1 Summary of Repair Component Cost Data Component Products Used Material Cost Information Cost (2007$) Source

Pilot Ignition (Standing Pilot) Gas Storage and Instantaneous Water Heaters, DHE (All) $36 Average value from internet
survey 15

, 16

, 17

, 18 

### Pilot Ignition (Millivolt) Pool Heaters $20 Consultant PH Report 12 

### Electronic Ignition (IID or Direct Spark) Gas (Instantaneous) Water Heaters, Pool Heaters, DHE (All) $42* Average value from internet
survey 19

, 20

, 21 

### Electronic Ignition (Hot Surface Ignition) Gas (Storage) Water Heaters

Combustion Fan (Power Vent or Induced Draft) Gas Storage and Instantaneous Water Heaters, Pool Heaters, DHE (All), $110* Average Value from Consultant WH Report 22 

### Main Circulating Air Blower Motor DHE (FWF, FF, RH)

Heat Pump Compressor Component Electric Water Heaters $110 Average value from internet survey** 23

, 24

, 25 

### Heat Pump Evaporator Fan Component Electric Water Heaters $18 Average value from internet
survey 26

12 

### * For pool heaters electronic ignition cost is $50 and combustion fan is $175 from consultant report. . ** Prices for Embraco Compressor (model #FF10HBK), which was used in ECR WatterSaver model.


### 8-B.3.1.1 Pilot Ignition Repair Cost
Table 8-B.3.2 shows the repair cost for pilot light ignition (standing pilot) and Table 8­ B.3.3 shows the repair cost for pilot light ignition (millivolt). DOE estimated that the repair cost for the pilot light ignition (standing pilot) equals $162, while the cost for pilot light ignition (millivolt) is $145.
8-B-6

### Table 8-B.3.2 Pilot Light Ignition (Standing Pilot) Repair Cost

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Pilot Light Ignition 1 Plum 1.25 Ea. $36 $58 $0 $94 $127
Totals 1.75 Ea. $36 $82 $0 $117 $162



### Table 8-B.3.3 Pilot Light Ignition (Millivolt) Repair Cost for Pool Heaters

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Pilot Light Ignition 1 Plum 1.25 Ea. $20 $58 $0 $78 $110
Totals 1.75 Ea. $20 $82 $0 $102 $145



### 8-B.3.1.2 Electronic Ignition Repair Cost
Table 8-B.3.4 shows the repair cost for electronic ignition ( intermittent ignition, direct spark, and hot surface types 

### ) and Table 8-B.3.5 shows the repair cost for electronic ignition for pool heaters. DOE estimated that the repair cost for the electronic ignition equals $204, while the cost for electronic ignition for pool heaters is $213.

Table 8-B.3.4 Electronic Ignition Repair Cost

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Electronic Ignition 1 Plum 1.75 Ea. $42 $82 $0 $124 $169
Totals 2.25 Ea. $42 $105 $0 $147 $204



### Table 8-B.3.5 Electronic Ignition Repair Cost for Pool Heaters

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Electronic Ignition 1 Plum 1.75 Ea. $50 $82 $0 $132 $178
Totals 2.25 Ea. $50 $105 $0 $155 $213



### 8-B.3.1.3 Combustion and Circulating Fan Repair Cost
Table 8-B.3.6 shows the repair cost for combustion or circulating air fan and Table 8­ B.3.7 shows the repair cost for power vent fan. DOE estimated that the repair cost for the combustion or circulating air fan equals $297, while the cost for the power vent fan is $368.

8-B-7

### Table 8-B.3.6 Combustion and Circulating Air Fan Repair Cost

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Combustion/Circulating Fan 1 Plum 2 Ea. $110 $93 $0 $203 $261
Totals 2.5 Ea. $110 $117 $0 $227 $297



### Table 8-B.3.7 Power Vent Fan Repair Cost for Pool Heaters

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Power Vent Fan 1 Plum 2 Ea. $175 $93 $0 $268 $333
Totals 2.5 Ea. $175 $117 $0 $292 $368



### 8-B.3.1.4 Heat Pump Water Heater Repair Cost
The repair cost of the heat pump water heater represents the cost of replacing the compressor and the evaporator fan. Table 8-B.3.8 shows the repair cost for the compressor and Table 8-B.3.9 shows the repair cost for the evaporator fan. The estimated average compressor repair cost is $290 and the estimated average fan repair cost is $126.

Table 8-B.3.8 Heat Pump Compressor Repair Cost for Electric Water Heaters

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Compressor 1 Plum 1 Ea. $168 $47 $0 $215 $255
Totals 1.5 Ea. $168 $70 $0 $238 $290



### Table 8-B.3.9 Heat Pump Evaporator Fan Cost for Electric Water Heaters

Description Crew PersonHours Unit 2008 Bare Costs (2007$) Total incl. O&P Mat. Labor Equip. Total Trip Charge 1 Plum 0.5 Ea. $0 $23 $0 $23 $35 Repair Evaporator Fan 1 Plum 1 Ea. $18 $47 $0 $65 $91
Totals 1.5 Ea. $18 $70 $0 $89 $126



### 8-B.3.2 Lifetime distributions for repair Costs
DOE determined the lifetime of the different product components from several sources. Table 8-B.3.10 lists the gathered lifetime data and the data sources.

8-B-8

### Table 8-B.3.10 Component Lifetime Data Gathered Component Mean (Median) Lifetime Data Source Reference

Standing Pilot Ignition System (Boiler) 9.1 (8.0) survey 1994 GRI Report 14 

### Standing Pilot Ignition System (Furnace) 8.1 (8.0) survey 1994 GRI Report Standing Pilot thermocouple 10.2 survey 1993 TSD 9 

### Intermittent Ignition (IID) 14 estimate 1993 TSD IID Electronic Ignition (Boiler) 10.1 (10.0) survey 1994 GRI Report IID Electronic Ignition (Furnace) 8.8 (10.0) survey 1994 GRI Report Direct Spark Ignition (Boiler) 13.2 (15.0) survey 1994 GRI Report Direct Spark Ignition (Furnace) 10.3 (10.0) survey 1994 GRI Report Hot Surface Ignitor (Boiler) 16.1 (20.0) survey 1994 GRI Report Hot Surface Ignitor (Furnace) 4.6 (6.0) survey 1994 GRI Report Ignition (pool heaters) 5.0 estimate Consultant 12 

### Main Circulating Air Blower Motor (Boiler) 14.2 (10.0) survey 1994 GRI Report Main Circulating Air Blower Motor (Furnace) 11.4 (12.0) survey 1994 GRI Report Induced Draft – Non-Condensing(Boiler) 16.2 (15.0) survey 1994 GRI Report Induced Draft - Condensing(Boiler) 22.6 (15.0) survey 1994 GRI Report Induced Draft – Non-Condensing(Furnace) 14.8 (15.0) survey 1994 GRI Report Induced Draft - Condensing(Furnace) 13.8 (15.0) survey 1994 GRI Report Combustion Fan 11.1 survey 1993 TSD Electronics/Controls/Switches (Boiler) 10.0 (10.0) survey 1994 GRI Report Electronics/Controls/Switches (Furnace) 8.7 (10.0) survey 1994 GRI Report Gas Valves (Boiler) 14.9 (15.0) survey 1994 GRI Report Gas Valves (Furnace) 14.0 (15.0) survey 1994 GRI Report Heat Pump Compressor 19 estimate Based on average Refrigerator lifetime 27, 28 

### Heat Pump Evaporator Fan 19 estimate

DOE used the lifetimes in Table 8-B.3.11 for each component analyzed.

8-B-9

### Table 8-B.3.11 Mean Component Lifetime Used in Analysis Component Mean Lifetime (years) Products Used

Pilot Ignition (Standing Pilot) 10 Gas (Storage) Water Heater, Gas (Instantaneous) WH, DHE (All) Pilot Ignition 5 Pool Heaters Electronic Ignition (IID or Direct Spark) 10 Gas (Instantaneous) WH, Pool Heater, DHE (All) Electronic Ignition (Hot Surface Ignition) 15 Gas (Storage) Water Heater Combustion Fan (Power Vent or Induced Draft) 15 Gas (Storage) Water Heater, Gas (Instantaneous) WH, Pool Heaters, DHE (All) Main Circulating Air Blower Motor 12 DHE (FWF, FF, RH) Heat Pump Compressor 19 Electric Water Heaters Heat Pump Evaporator Fan 19 Electric Water Heaters

Table 8-B.3.12 shows the average, minimum and maximum lifetime, as well as the maximum percentile values used to determine the parameters for Weibull distributions. See Appendix J for more information about the derivation of the Weibull distribution parameters. DOE setup the maximum percentile used in the analysis at 99%.

Table 8-B.3.12	 Parameters for Generating Weibull Distributions for different Component Lifetimes

Component Failure Year Expert Opinion Values Weibull Parameters

Minimum

(years) Average (years) Maximum (years) Maximum percentile (%) Alpha (scale) Beta (shape) 5 Year 0 5 10 99 5.6257 2.6548
10 Year 0 10 20 99 11.2513 2.6548
12 Year 0 12 24 99 13.5016 2.6548 15 Year 0 15 30 99 16.8770 2.6548
19 Year 0 19 38 99 21.3775 2.6548



### Figure 8-B.3.1 to Figure 8-B.3.8 show the Weibull distribution as well as the cumulative Weibull distribution for each water heater type.

8-B-100% 2% 4% 6% 8% 10% 12% 14% 16% 18% 20%

0 2 4 6 8 10 12 14 Age of Equipment (Years)Probability of Failure (%)



### Figure 8-B.3.1 Fraction of the Components with 5-Year Lifetime Failing

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0 2 4 6 8 10 12 14 Age of Equipment (Years)Probability (%)



### Figure 8-B.3.2 Cumulative Lifetime Length of Components with 5­ Year Lifetime

8-B-110% 2% 4% 6% 8% 10%

0 2 4 6 8 10 12 14 16 18 20 22 24 Age of Equipment (Years)Probability of Failure (%)



### Figure 8-B.3.3 Fraction of the Components with 10-Year Lifetime Failing

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0 2 4 6 8 10 12 14 16 18 20 22 24 Age of Equipment (Years)Probability (%)



### Figure 8-B.3.4 Cumulative Lifetime Length of Components with 10-Year Lifetime

8-B-120% 2% 4% 6% 8%

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Age of Equipment (Years)Probability of Failure (%)



### Figure 8-B.3.5 Fraction of the Components with 12-Year Lifetime Failing

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Age of Equipment (Years)Probability (%)



### Figure 8-B.3.6 Cumulative Lifetime Length of Components with 12-Year Lifetime

8-B-130% 2% 4% 6%

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 Age of Equipment (Years)Probability of Failure (%)



### Figure 8-B.3.7 Fraction of the Components with 15-Year Lifetime Failing

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 Age of Equipment (Years)Probability (%)



### Figure 8-B.3.8 Cumulative Lifetime Length of Components with 15-Year Lifetime

8-B-148-B.3.3 Repair Cost Methodology Flowcharts by Product TypeFigure 8-B.3.9 to Figure 8-B.3.13 provide the repair cost methodology flowcharts for each product type.Repair Cost at Household LevelDesign OptionBill of ChargesPilot Light RepairTrip Charge = $35.12Labor (1.25 hrs) = $87.80Material Costs = $39.32TOTAL= $162.23Electronic Ignition RepairTrip Charge = $35.12Labor (1.75 hrs) = $122.91Material Costs = $46.43TOTAL= $204.46Power Vent Fan RepairTrip Charge = $35.12Labor (2 hrs) = $140.47Material Costs = $121.00TOTAL= $296.59Pilot Light IgnitionAvg. Repair Year = 7.7Fraction Repaired = 58.2%Electronic IgnitionAvg. Repair Year = 8.5Fraction Repaired = 28.5%Power VentAvg. Repair Year = 8.5Fraction Repaired = 28.5%Total AverageRepair Cost =$94.40Total AverageRepair Cost =$142.72EffLevels0-2EffLevels3-6RECS SampleHouseholdEquipmentWarranty= 1 yearLifetime Average = 15 yearsLifetime Average = 10 yearsLifetime Average = 15 yearsEquipmentLifetime Average= 12 yearsRepair Fraction andRepair Frequency2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrMaterials Markup = 10%ComponentFails withinlifetime ofEquipmentAverage Repair Cost for All Households SampledFigure 8-B.3.9 Methodology for Calculating Repair Cost for Gas Storage Water Heaters8-B-15Repair Cost at Household LevelDesign OptionBill of ChargesNo Repair CostCompressorTrip Charge = $35.12Labor (1 hrs) = $70.24Material Costs = $184.67TOTAL= $290.02Evaporator FanTrip Charge = $35.12Labor (1 hrs) = $70.24Material Costs = $20.34TOTAL= $112.01No Repair CostCompressorAvg. Repair Year = 11.1Fraction Repaired = 19.6%CompressorAvg. Repair Year = 11.1Fraction Repaired = 19.6%Total AverageRepair Cost = $0Total AverageRepair Cost =$77.79Electric Resistance WHHeat PumpWater HeaterRECS SampleHouseholdEquipmentWarranty= 1 yearLifetime Average = 19 yearsLifetime Average = 19 yearsEquipmentLifetime Average= 14 yearsRepair Fraction andRepair Frequency2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrMaterials Markup = 10%ComponentFails withinlifetime ofEquipmentAverage Repair Cost for All Households SampledFigure 8-B.3.10 Methodology for Calculating Repair Cost for Electric Storage Water Heaters8-B-16Repair Cost at Household LevelDesign OptionBill of ChargesPilot Light RepairTrip Charge = $35.12Labor (1.25 hrs) = $87.80Material Costs = $39.32TOTAL= $162.23Electronic Ignition RepairTrip Charge = $35.12Labor (1.75 hrs) = $122.91Material Costs = $46.43TOTAL= $204.46Power Vent Fan RepairTrip Charge = $35.12Labor (2 hrs) = $140.47Material Costs = $121.00TOTAL= $296.59Pilot Light IgnitionAvg. Repair Year = 9.7Fraction Repaired = 90.7%Electronic IgnitionAvg. Repair Year = 9.7Fraction Repaired = 90.7%Power VentAvg. Repair Year = 11.9Fraction Repaired = 70.2%Total AverageRepair Cost =$147.16Total AverageRepair Cost =$185.33Pilot IgnitionElecIgnitionPower VentRECS SampleHouseholdEquipmentWarranty= 1 yearLifetime Average = 15 yearsLifetime Average = 10 yearsLifetime Average = 10 yearsEquipmentLifetime Average= 20 yearsRepair Fraction andRepair Frequency2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrMaterials Markup = 10%ComponentFails withinlifetime ofEquipmentTotal AverageRepair Cost =$393.59Average Repair Cost for All Households SampledFigure 8-B.3.11 Methodology for Calculating Repair Cost for Gas Instantaneous Water Heaters8-B-17Repair Cost at Household LevelDesign OptionBill of ChargesPilot Light RepairTrip Charge = $35.12Labor (1.25 hrs) = $87.80Material Costs = $39.32TOTAL= $162.23Electronic Ignition RepairTrip Charge = $35.12Labor (1.75 hrs) = $122.91Material Costs = $46.43TOTAL= $204.46Combustion Fan RepairTrip Charge = $35.12Labor (2 hrs) = $140.47Material Costs = $121.00TOTAL= $296.59Pilot Light IgnitionAvg. Repair Year = 8.7Fraction Repaired = 80.5%Electronic IgnitionAvg. Repair Year = 8.7Fraction Repaired = 80.5%Air Distribution FanAvg. Repair Year = 9.2Fraction Repaired = 65.0%Total AverageRepair Cost =$130.60Total AverageRepair Cost =$164.59RECS SampleHouseholdEquipmentWarranty= 1 yearLifetime Average = 15 yearsLifetime Average = 10 yearsLifetime Average = 10 yearsEquipmentLifetime Average= 15 yearsRepair Fraction andRepair Frequency2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrMaterials Markup = 10%ComponentFails withinlifetime ofEquipmentAverage Repair CostAir Distribution Fan RepairTrip Charge = $35.12Labor (2 hrs) = $140.47Material Costs = $121.00TOTAL= $296.59Lifetime Average = 12 yearsCombustion FanAvg. Repair Year = 9.5Fraction Repaired = 46.6%Total AverageRepair Cost =$192.78Total AverageRepair Cost =$138.21Figure 8-B.3.12 Methodology for Calculating Repair Cost for DHE8-B-18Repair Cost at Household LevelAverage Repair Cost for All Households SampledMethodology for Calculating Repair Cost for Pool HeatersDesign OptionBill of ChargesPilot Light RepairTrip Charge = $35.12Labor (1.25 hrs) = $87.80Material Costs = $22.00TOTAL= $144.91Electronic Ignition RepairTrip Charge = $35.12Labor (1.75 hrs) = $122.91Material Costs = $55.00TOTAL= $213.03Power Vent Fan RepairTrip Charge = $35.12Labor (2 hrs) = $140.47Material Costs = $192.50TOTAL= $368.09Pilot Light IgnitionAvg. Repair Year = 4.2Fraction Repaired = 54.5%Electronic IgnitionAvg. Repair Year = 5.6Fraction Repaired = 13.8%Power VentAvg. Repair Year = 6.0Fraction Repaired = 5.4%Total AverageRepair Cost =$78.98Total AverageRepair Cost =$29.40Pilot IgnitionElecIgnitionPower VentRECS SampleHouseholdEquipmentWarranty= 1 yearLifetime Average = 15 yearsLifetime Average = 5 yearsLifetime Average = 10 yearsEquipmentLifetime Average= 6 yearsRepair Fraction andRepair Frequency2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrMaterials Markup = 10%ComponentFails withinlifetime ofEquipmentTotal AverageRepair Cost =$19.95Figure 8-B.3.138-B-19

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