C-1.i

APPENDIX C-1. DATA REQUEST FORMS - MANUFACTURING 

COSTS AND ENERGY CHARACTERISTICS FOR ELECTRIC AND 

GAS-FIRED STORAGE WATER HEATERS

TABLE OF CONTENTS

TABLES

Table C-1.1 Manufacturing Cost Data Request - Electric Water Heaters . . . . . . . . . . . . . C-1.2

Table C-1.2 Energy Characteristics - Electric Water Heaters . . . . . . . . . . . . . . . . . . . . . . C-1.3

Table C-1.3 Manufacturing Cost Data Request - Gas-Fired Water Heaters . . . . . . . . . . . C-1.4

Table C-1.4 Energy Characteristics - Gas-Fired Water Heaters . . . . . . . . . . . . . . . . . . . . C-1.5
C-1.1

APPENDIX C-1. DATA REQUEST FORMS - MANUFACTURING 

COSTS AND ENERGY CHARACTERISTICS FOR ELECTRIC AND 

GAS-FIRED STORAGE WATER HEATERS

This Appendix reproduces the data request forms used to gather manufacturer cost and

energy characteristics data for residential electric and gas-fired water heaters. These forms were

developed by Arthur D. Little Inc. and were provided to water heater manufacturers by the U.S.

Department of Energy on November 17, 1997.
C-1.2

Table C-1.1 Manufacturing Cost Data Request - Electric Water Heaters

Appliance Type: Water 

Heater Electric

Yearly Production Volume (

Appliance Class(anticipated):Rated Volume 50 gallons

 Variable Costs Total Cost Uncertainty Range Conversion Costs (Fixed) Total C

Costs per Unit (a) Variable Variable Costs Total (millions of dollars) Fixed 

Material Labor Transportation Overhead Costs (e) (+/- percentage) (f) Capital Product (i) Costs (j) 

(b) (c) (d) ($ per Unit) Maximum Minimum Costs(g),(h) Design Costs (millions) M

DOE Design Options [1] [2] [3] [4] [5] [6] [7] [8] [9] 

1 Baseline2 Heat Traps3 Increased Insulation

(1st level)

4 Increased Insulation

(2nd level)

5 Plastic Tank6 Insulated Tank Bottom
C-1.3

Table C-1.2 Energy Characteristics - Electric Water Heaters

Appliance Type: Water 

Heater Electric

Appliance Class(anticipated):Rated Volume: 50 gallons

Energy Data (when applied directly to Baseline) (l) Uncertainty Range

EF RE

(ηr)

UA On-Cycle Off-Cycle Total EF Energy

Data

Comments Estimated

(m) (n) (o) Elec (p) Elec (q) (+/- percentage) (r) Source (s) Notes Increase in

W W Maximum Minimum Retail Price

DOE Design Options [12] [13] [14] [15] [16] [17] [18] [19] [20] [21]

1 Baseline2 Heat Traps3 Increased Insulation

(1st level)

4 Increased Insulation

(2nd level)

5 Plastic Tank
C-1.4

Table C-1.3 Manufacturing Cost Data Request - Gas-Fired Water Heaters

Appliance Type: Water

Heater

Yearly Production Volume (a) =

Appliance Class(anticipated):

Gasfired

Rated Volume: 40

gallons

 Variable Costs Total Cost Uncertainty

Range

Conversion Costs (Fixed) Total Cost Unc

Costs per Unit (a) Variable Variable Costs Total (millions of dollars) Fixed Fix

Material Labor Transportation Overhead Costs (e) (+/- percentage) (f) Capital Product (i) Costs (j) (+/- per

(b) (c) (d) ($ per Unit) Maximum Minimum Costs(g),(h) Design Costs (millions) Maximum 

DOE Design Options [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] 

1 Baseline2 Heat Traps3 Increased Insulation (1st

level)

4 Increased Insulation (2nd

level)

5 Plastic Tank6 Improved Flue Baffle7 Multiple Flues8 Improved Combustion

Chamber

9 Submerged Combustion

Chamber

10 Flue Damper (electromechanical)11 Side Arm Heater12 Two Phase

Thermosiphon

13 IID14 Direct Vent15 Induced Draft16 Induced Draft w/ Flue

Gas Dilution
C-1.5

Table C-1.4 Energy Characteristics - Gas-Fired Water Heaters

Appliance Type: Water 

Heater

Appliance Class(anticipated):

Gas-fired

Rated Volume: 40 gallons

Energy Data (when applied directly to Baseline) (l) Uncertainty Range

EF RE

(ηr)

UA On-Cycle Off-Cycle Total EF Energy

Data

Comments Estimated

(m) (n) (o) Elec (p) Elec (q) (+/- percentage) (r) Source (s) Notes Increase in

W W Maximum Minimum Retail Price

DOE Design Options [12] [13] [14] [15] [16] [17] [18] [19] [20] [21]

1 Baseline2 Heat Traps3 Increased Insulation

(1st level)

4 Increased Insulation

(2nd level)

5 Plastic Tank6 Improved Flue Baffle7 Multiple Flues8 Improved Combustion

Chamber

9 Submerged Combustion

Chamber

10 Flue Damper (electromechanical)11 Side Arm Heater12 Two Phase

Thermosiphon

13 IID14 Direct Vent15 Induced Draft16 Induced Draft w/ Flue

Gas Dilution