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 Gas-Fired Storage Water Heaters .......................................................................... 8-B-2 

8-B.2.2 Electric Storage Water Heaters.............................................................................. 8-B-3 

8-B.2.3 Oil-Fired Storage Water Heaters ........................................................................... 8-B-4 

8-B.2.4 Gas-Fired Instantaneous Water Heaters................................................................. 8-B-5 

8-B.2.5 Direct Heating Equipment ..................................................................................... 8-B-5 

8-B.2.6 Gas-Fired Pool Heaters .......................................................................................... 8-B-5 

8-B.3 REPAIR COSTS.................................................................................................... 8-B-6 

8-B.3.1 Component Repair Cost Calculations.................................................................... 8-B-7 

8-B.3.1.1 Pilot Ignition Repair Cost .................................................................... 8-B-7 

8-B.3.1.2 Electronic Ignition Repair Cost ........................................................... 8-B-8 

8-B.3.1.3 Pilot Ignition Repair Cost .................................................................... 8-B-8 

8-B.3.1.4 Power Vent Fan Repair Cost................................................................ 8-B-9 

8-B.3.1.5 Heat Pump Water Heater Repair Cost ................................................. 8-B-9 

8-B.3.2 Lifetime Distributions for Repair Costs............................................................... 8-B-10 

8-B.3.3 Repair Cost Methodology Flowcharts by Product Type...................................... 8-B-16 

LIST OF TABLES 

Table 8-B.1.1 Example Maintenance/Repair Cost Table ................................................. 8-B-2
 

Table 8-B.2.1 Heat Pump Water Heater Maintenance...................................................... 8-B-4
 

Table 8-B.2.2 Maintenance Contract Data Table ............................................................. 8-B-5
 

Table 8-B.2.3 Data from GRI Report ............................................................................... 8-B-5
 

Table 8-B.2.4 Baseline Pool Heater Maintenance ............................................................ 8-B-6
 

Table 8-B.2.5 Advanced Design Pool Heater Maintenance ............................................. 8-B-6
 

Table 8-B.3.1 Summary of Repair Component Cost Data ............................................... 8-B-7
 

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

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

Table 8-B.3.4 Electronic Ignition Repair Cost ................................................................. 8-B-8
 

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

Table 8-B.3.6 Power Vent Fan Repair Cost...................................................................... 8-B-9
 

Table 8-B.3.7 Power Vent Fan Repair Cost for Pool Heaters .......................................... 8-B-9
 

Table 8-B.3.8 Heat Pump Compressor Repair Cost for Electric Water Heaters .............. 8-B-9
 

Table 8-B.3.9 Heat Pump Evaporator Fan Cost for Electric Water Heaters .................. 8-B-10
 

Table 8-B.3.10 Component Lifetime Data Gathered........................................................ 8-B-10
 

Table 8-B.3.11 Mean Component Lifetime Used in Analysis.......................................... 8-B-11
 

Table 8-B.3.12 Parameters for Generating Weibull Distributions for Different
 

Component Lifetimes............................................................................... 8-B-11
 

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LIST OF FIGURES 

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

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-12 

Figure 8-B.3.2 Cumulative Lifetime Length of Components with 5-Year Lifetime ....... 8-B-12 

Figure 8-B.3.3 Fraction of the Components with 10-Year Lifetime Failing ................... 8-B-13 

Figure 8-B.3.4 Cumulative Lifetime Length of Components with 10-Year Lifetime ..... 8-B-13 

Figure 8-B.3.5 Fraction of the Components with 12-Year Lifetime Failing ................... 8-B-14 

Figure 8-B.3.6 Cumulative Lifetime Length of Components with 12-Year Lifetime ..... 8-B-14 

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

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

Figure 8-B.3.9 Methodology for Calculating Repair Cost for Gas-Fired Storage Water 

Heaters ..................................................................................................... 8-B-16 

Figure 8-B.3.10 Methodology for Calculating Repair Cost for Electric Storage Water 

Heaters ..................................................................................................... 8-B-17 

Figure 8-B.3.11 Methodology for Calculating Repair Cost for Gas-Fired Instantaneous 

Water Heaters........................................................................................... 8-B-18 

Figure 8-B.3.12 Methodology for Calculating Repair Cost for Direct Heating 

Equipment................................................................................................ 8-B-19
 

Figure 8-B.3.13 Methodology for Calculating Repair Cost for Pool Heaters.................... 8-B-20
 

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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 calculation 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 

costs are derived using the latest 2008 RS Means labor costs by crew type.2 All repair and 

maintenance cost tables include a trip charge which is often charged by contractors and 

calculated to be equal to one half hour of labor per crew member.2 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 

1, 2 material markups from RS Means. Labor cost factors are calculated for each census division 

and four large state (see appendix 8-A for details). 

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 

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

Description Crew 

PersonHours 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge CREW1 0.5 0.00 23.00 0.00 23.00 $35.00 

Description of Maintenance or Repair CREW1 0.5 0.00 23.00 0.00 23.00 $35.00 

Total 1.0 0.00 47.00 0.00 47.00 $70.00 

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 product. Figure 8-B.1.2 

shows the methodology for determining repair costs for an individual sampled household. Both 

component and equipment lifetimes are given by Weibull 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 included maintenance costs for all heating products. This section outlines the 

maintenance costs determined for each product class. 

8-B.2.1 Gas-Fired Storage Water Heaters 

DOE included maintenance cost for gas-fired water heaters. Manufacturers recommend 

that water heaters be drained and flushed annually to minimize deposition of sediment, maintain 

operating efficiency, and prolong product life. The available evidence indicates that this practice 

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is done in 10 percent of households, and mostly in locations with hard water.3 DOE assumed 

that, of this 10 percent, only 25 percent of consumers hire a contractor to perform the 

maintenance work. For this maintenance cost, the labor hours are determined from a 

3 1, 2 consultant’s report. The labor cost is based on RS Means. The total cost is $109 per year and 

is applicable to 2.5 percent of installations. 

In addition, all new gas-fired storage water heaters are equipped with Flammable Vapor 

Ignition Resistant (FVIR), which manufacturers recommend be maintained annually. The 

available evidence indicates that 25 percent of households are likely to hire a contractor to 

perform this work.4 For this maintenance cost, the labor hours are determined from a 

3 1, 2 consultant’s report. The labor cost is based on RS Means. The total cost is $146 per year and 

is applicable to 25 percent of installations. 

8-B.2.2 Electric Storage Water Heaters 

Manufacturers recommend that electric storage water heaters be drained and flushed 

annually to minimize deposition of sediment, maintain operating efficiency, and prolong product 

life. The available evidence indicates that this practice is done in 10 percent of households, 

mostly in locations with hard water.3 DOE assumed that of this 10 percent fraction only 25 

percent hire a contractor to due the maintenance work. For this maintenance cost, labor hours 

and costs are based on RS Means1, 2 and are equal to $105 per year for 2.5 percent of the 

installations. 

DOE determined that there is virtually no maintenance of electric resistance water 

heaters. For heat pump water heaters, maintenance includes annual cleaning of the air filter and a 

preventative maintenance cost to check the evaporator and refrigeration system. The literature 

recommends that no professional help is needed for this maintenance.5, 6 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.7, 8 DOE estimated that 27 percent of these exposed installations 

would require this maintenance, based on a survey conducted for central air conditioners.9 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 

10, 11 heaters, which don’t have any additional maintenance costs For this maintenance cost, DOE 

1, 2 based the labor hours and costs on RS Means.

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Table 8-B.2.1 Heat Pump Water Heater Maintenance
 

Description Crew 

PersonHours 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge 1 PLUM* 0.5 0.00 25.11 0.00 25.11 $35.12 

Clean evaporator, drain pan, fans, motors, 

and drain piping 1 PLUM 1.0 18.49 18.49 0.00 68.70 $90.58 

During operation of unit, check refrigerant 

pressure, add refrigerant as necessary 1 PLUM 1.0 167.88 50.21 0.00 218.09 $254.90 

Total 1.5 186.37 125.53 0.00 311.90 $380.60 

* 1 PLUM means a crew of 1 plumber. 

8-B.2.3 Oil-Fired Storage Water Heaters 

Oil-fired storage 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 which 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 storage 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. 

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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.2.4 Gas-Fired Instantaneous Water Heaters 

The analysis assumes that there is an annual maintenance of residential instantaneous 

water heaters associated mainly with de-liming the heat exchanger.12 DOE used a uniform 

12, 13 distribution of values from $70 to $100 per year for all energy efficiency levels.

8-B.2.5 Direct Heating Equipment 

For direct heating equipment, DOE used the maintenance cost data from the 2007 

Furnace/Boiler rulemaking.14 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 

boiler equipment. 15 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 $223. DOE 

used a maintenance frequency of once every five years for all DHE product classes. (See Table 

8-B.2.3) 

Table 8-B.2.3 Data from GRI Report 

Description Cost (1992$) Cost (2008$) 

Case 1 (5-years) $145 $223 

8-B.2.6 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 

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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 estimated that the maintenance occurs in the fifth year of 

the pool heater lifetime if the pool heater lifetime is 6 years or longer.13 

A consultant provided average number of hours for maintenance16 and 2008 RS Means 

was used to calculate the labor rates. 

Table 8-B.2.4 Baseline Pool Heater Maintenance 

Description Crew 

Labor 

Hours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge 1 Plum* 0.5 Ea. 0.00 27.72 0.00 27.72 $41.68 

Measure millivolt signal, clean 

burners, clean HX, start up heater, 

check temperature rise 1 Plum 4.0 Ea. 0.00 221.72 0.00 221.72 $333.47 

Total 4.5 Ea. 0.00 249.44 0.00 $234 $375.15 

* 2 PLUM means a crew of 2 plumbers. 

Table 8-B.2.5 Advanced Design Pool Heater Maintenance 

Description Crew 

Labor 

Hours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge 1 Plum 1.0 Ea. 0.00 27.72 0.00 27.72 $41.68 

Measure ignition signal, clean 

burners, clean HX, measure 

combustion differential pressure, 

start up heater, check temperature 

rise 

1 Plum 6.0 Ea. 0.00 332.58 0.00 332.58 $500.21 

Total 7.0 Ea. 0.00 360.30 0.00 360.30 $541.89 

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 costs during the lifetime of 

the equipment. 

Components most likely to be repaired include the ignition system, gas valve, circulating 

or combustion blower, electronics/controls/switches, vent system components, and heat 

11, 13 exchangers. DOE analyzed the repair costs of ignition systems, circulating blowers, and 

combustion blowers, 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 the average number of hours for labor and materials 

costs. RS Means was also used to calculate the labor rates. 

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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 

(2008$) 

Source 

Pilot Ignition (Standing 

Pilot) 

Gas Storage and Instantaneous 

Water Heaters, DHE (All) $36 

Average value 

from internet 

survey 

17, 18, 19, 20 

Pilot Ignition (Millivolt) Pool Heaters $20 Consultant PH 

Report16 

Electronic Ignition (IID or 

Direct Spark) 

Gas (Instantaneous) Water 

Heaters, Pool Heaters, DHE 

(All) $42* 

Average value 

from internet 

survey 

21, 22, 23 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 Report4 Main Circulating Air Blower 

Motor 

DHE (Gas Wall Fan, Gas Floor, 

Gas Room) 

Electric Resistance Heating 

Element 

Electric Water Heaters $16 Consultant 

Report 

Heat Pump Compressor 

Component 

Electric Water Heaters 

$110 

Average value 

from internet 

survey**24, 25, 26 

Heat Pump Evaporator Fan 

Component 

Electric Water Heaters 

$18 

Average value 

from internet 

survey 

27 

16 * 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). 

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

Description Crew 

Labor 

Hours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge 1 Plum 0.5 Ea. 0.00 15.35 0.00 15.35 $23.08 

Repair Pilot Light Ignition 1 Plum 2.0 Ea. 58.87 61.39 0.00 120.26 $157.09 

Total 2.5 58.87 76.74 0.00 135.61 $180.17 

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

Description Crew 

Labor 

Hours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge 1 Plum 0.50 Ea. 0.00 27.72 0.00 27.72 $41.68 

Repair Pilot Light Ignition 1 Plum 1.25 Ea. 20.00 69.29 0.00 89.29 $126.21 

Total 1.75 20.00 97.00 0.00 117.00 $167.89 

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. 

Table 8-B.3.4 Electronic Ignition Repair Cost 

Description Crew PersonHours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. O&P Labor Equip. Total 

Trip Charge 1 Plum 0.5 Ea. 0.00 15.35 0.00 15.35 $23.08 

Repair Electronic Ignition 1 Plum 2.0 Ea. 104.00 61.39 0.00 165.39 $206.73 

Total 2.5 104.00 76.74 0.00 180.74 $229.82 

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

Description Crew 

PersonHours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. Labor Equip. Total O&P 

Trip Charge 1 Plum 0.5 Ea. 0.00 27.72 0.00 27.72 $41.68 

Repair Electronic Ignition 1 Plum 1.75 Ea. 50.00 97.00 0.00 147.00 $200.89 

Total 2.25 50.00 124.72 0.00 174.72 $242.58 

8-B.3.1.3 Pilot Ignition Repair Cost 

The repair cost of the electric water heater includes the cost of replacing the heating 

element. Based on available information, DOE estimated that the heating element fails on 

3 average in the 5th year of operationa for 20 percent of the households. The estimated average 

heating element repair cost is $105. 

a DOE used a triangular distribution with a mean of 5 years and a maximum of 9 and minimum of 1 year. 

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8-B.3.1.4 Power Vent Fan Repair Cost 

Table 8-B.3.6 shows the repair cost for a power vent fan for water heaters and Table 8­

B.3.7 shows the repair cost for a power vent fan for pool heaters. 

Table 8-B.3.6 Power Vent Fan Repair Cost 

Description Crew PersonHours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. O&P Labor Equip. Total 

Trip Charge 1 Plum 0.5 Ea. 0.00 15.35 0.00 15.35 $23.08 

Repair Blower Assembly 1 Plum 2.0 Ea. 165.63 76.74 0.00 242.37 $297.61 

Total 2.5 Ea. 165.63 92.09 0.00 257.72 $320.69 

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

Description Crew PersonHours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. O&P Labor Equip. Total 

Trip Charge 1 Plum 0.5 Ea. 0.00 27.72 0.00 27.72 $41.68 

Repair Power Vent Fan 1 Plum 2.0 Ea. 250.00 110.86 0.00 360.86 $441.74 

Total 2.5 Ea. 250.00 138.58 0.00 388.58 $483.42 

8-B.3.1.5 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. 

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

Description 

Crew PersonHours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. O&P Labor Equip. Total 

Trip Charge 1 Plum 0.5 Ea. 0.00 25.11 0.00 25.11 $35.12 

Repair Compressor 1 Plum 1.0 Ea. 167.88 50.21 0.00 218.09 $254.90 

Total 1.5 Ea. 167.88 75.32 0.00 243.20 $290.02 

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

Description 

Crew PersonHours Unit 

2008 Bare Costs (2008$) Total 

incl. 

Mat. O&P Labor Equip. Total 

Trip Charge 1 Plum 0.5 Ea. 0.00 25.11 0.00 25.11 $35.12 

Repair Evaporator Fan 1 Plum 1.0 Ea. 18.49 50.21 0.00 68.70 $90.58 

Total 1.5 Ea. 18.49 75.32 0.00 93.81 $125.69 

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. 

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 Report15 

Standing Pilot Ignition System (Furnace) 8.1 (8.0) survey 1994 GRI Report 

Standing Pilot thermocouple 10.2 survey 1993 TSD11 

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 Consultant16 

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 

Electric Resistance Heating Element 5 estimate Consultant 

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 

28, 29 Heat Pump Evaporator Fan 19 estimate 

8-B-10 

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

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 

Electric Resistance Heating Element 5 Electric Water Heaters 

Electronic Ignition (IID or Direct Spark) 12 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 8-C for more information about the derivation of the Weibull distribution parameters. 

DOE setup the maximum percentile used in the analysis at 99 percent. 

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-11 

EE-2006-STD-0129 COMMENT 56.10
 

 

 

 

 

0% 

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-12 

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0% 

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-13 

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0% 

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-14 

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0% 

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-15 

EE-2006-STD-0129 COMMENT 56.10
8-B.3.3 Repair Cost Methodology Flowcharts by Product Type 

Figure 8-B.3.9 to Figure 8-B.3.13 provide the repair cost methodology flowcharts for each product type. 

Repair Cost at Household Level 

Pilot Light Repair 

Trip Charge = $35.12 Labor (1.25 hrs) = $87.80 Material Costs = $39.32 

TOTAL = $162.23 

Electronic Ignition Repair 

Trip Charge = $35.12 

Labor (1.75 hrs) = $122.91 Material Costs = $46.43 

TOTAL = $204.46 

Power Vent Fan Repair 

Trip Charge = $35.12 

Labor (2 hrs) = $140.47 

Material Costs = $121.00 

TOTAL = $296.59 

Pilot Light Ignition 

Avg. Repair Year = 7.7 Fraction Repaired = 58.2% 

Electronic Ignition 

Avg. Repair Year = 8.5 Fraction Repaired = 28.5% 

Power Vent 

Avg. Repair Year = 8.5 Fraction Repaired = 28.5% 

Levels 

0-2 

Eff 

Levels 

3-6 

RECS Sample 

Household 

Equipment 

Warranty 

= 1 year 

Lifetime Average = 15 years Lifetime Average = 10 years Lifetime Average = 15 years 

Equipment 

Lifetime Average 

= 12 years 

Repair Fraction and 

Repair Frequency 

Component 

Fails within 

lifetime of 

Equipment 

Average Repair Cost for All Households 

Eff 

Design Option 

2008 RS Means Info 

Labor Type = One Plumber Labor Rate = $46.70/hr Labor Markup = 50.4%
 Total Labor Rate = $70.24/hr Bill of Charges
 Materials Markup = 10%
 

Figure 8-B.3.9 Methodology for Calculating Repair Cost for Gas-Fired Storage Water Heate

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EE-2006-STD-0129 COMMENT 56.10
Repair Cost at Household Level 

No Repair Cost 

Compressor 

Trip Charge = $35.12 

Labor (1 hrs) = $70.24 Material Costs = $184.67 

TOTAL = $290.02 

Evaporator Fan 

Trip Charge = $35.12 

Labor (1 hrs) = $70.24 

Material Costs = $20.34 

TOTAL = $112.01 

No Repair Cost 

Compressor 

Avg. Repair Year = 11.1 Fraction Repaired = 19.6% 

Compressor 

Avg. Repair Year = 11.1 

Fraction Repaired = 19.6% 

Electric Resistance WH 

Heat Pump 

Water Heater 

RECS Sample 

Household 

Equipment 

Warranty 

= 1 year 

Lifetime Average = 19 years Lifetime Average = 19 years 

Equipment 

Lifetime Average 

= 14 years 

Repair Fraction and 

Repair Frequency 

Component 

Fails within 

lifetime of 

Equipment 

Average Repair Cost for All Households 

Design Option 

2008 RS Means Info 

Labor Type = One Plumber Labor Rate = $46.70/hr Labor Markup = 50.4%
 Total Labor Rate = $70.24/hr Bill of Charges
 Materials Markup = 10%
 

Figure 8-B.3.10 Methodology for Calculating Repair Cost for Electric Storage Water Heaters 

8-B-17 

EE-2006-STD-0129 COMMENT 56.10
Repair Cost at Household Level 

Pilot Light Repair 

Trip Charge = $35.12 Labor (1.25 hrs) = $87.80 Material Costs = $39.32 

TOTAL = $162.23 

Electronic Ignition Repair 

Trip Charge = $35.12 

Labor (1.75 hrs) = $122.91 Material Costs = $46.43 

TOTAL = $204.46 

Power Vent Fan Repair 

Trip Charge = $35.12 

Labor (2 hrs) = $140.47 

Material Costs = $121.00 

TOTAL = $296.59 

Pilot Light Ignition 

Avg. Repair Year = 9.7 Fraction Repaired = 90.7% 

Electronic Ignition 

Avg. Repair Year = 9.7 Fraction Repaired = 90.7% 

Power Vent 

Avg. Repair Year = 11.9 Fraction Repaired = 70.2% 

Pilot Ignition 

Elec 

Ignition 

Power Vent 

RECS Sample 

Household 

Equipment 

Warranty 

= 1 year 

Lifetime Average = 15 years Lifetime Average = 10 years Lifetime Average = 10 years 

Equipment 

Lifetime Average 

= 20 years 

Repair Fraction and 

Repair Frequency 

Component 

Fails within 

lifetime of 

Equipment 

Average Repair Cost for All Households 

Design Option 

2008 RS Means Info 

Labor Type = One Plumber Labor Rate = $46.70/hr Labor Markup = 50.4%
 Total Labor Rate = $70.24/hr Bill of Charges
 Materials Markup = 10%
 

Figure 8-B.3.11 Methodology for Calculating Repair Cost for Gas-Fired Instantaneous Water 

8-B-18 

EE-2006-STD-0129 COMMENT 56.10
Repair Cost at Household Level 

Average Repair Cost 

Design Option 

Bill of Charges 

Pilot Light Repair 

Trip Charge = $35.12 Labor (1.25 hrs) = $87.80 Material Costs = $39.32 

TOTAL = $162.23 

Electronic Ignition Repair 

Trip Charge = $35.12 

Labor (1.75 hrs) = $122.91 Material Costs = $46.43 

TOTAL = $204.46 

Combustion Fan Repair 

Trip Charge = $35.12 

Labor (2 hrs) = $140.47 

Material Costs = $121.00 

TOTAL = $296.59 

Pilot Light Ignition 

Avg. Repair Year = 8.7 Fraction Repaired = 80.5% 

Electronic Ignition 

Avg. Repair Year = 8.7 Fraction Repaired = 80.5% 

Air Distribution Fan 

Avg. Repair Year = 9.2 Fraction Repaired = 65.0% 

RECS Sample 

Household 

Equipment 

Warranty 

= 1 year 

Lifetime Average = 15 years Lifetime Average = 10 years Lifetime Average = 10 years 

Equipment 

Lifetime Average 

= 15 years 

Repair Fraction and 

Repair Frequency 

2008 RS Means Info 

Labor Type = One Plumber Labor Rate = $46.70/hr Labor Markup = 50.4% Total Labor Rate = $70.24/hr Materials Markup = 10% 

Component 

Fails within 

lifetime of 

Equipment 

Air Distribution Fan Repair 

Trip Charge = $35.12 

Labor (2 hrs) = $140.47 

Material Costs = $121.00 

TOTAL = $296.59 

Lifetime Average = 12 years 

Combustion Fan 

Avg. Repair Year = 9.5 Fraction Repaired = 46.6% 

Figure 8-B.3.12 Methodology for Calculating Repair Cost for Direct Heating Equipment
 

8-B-19 

EE-2006-STD-0129 COMMENT 56.10
Repair Cost at Household Level 

Pilot Light Repair 

Trip Charge = $35.12 Labor (1.25 hrs) = $87.80 Material Costs = $22.00 

TOTAL = $144.91 

Electronic Ignition Repair 

Trip Charge = $35.12 

Labor (1.75 hrs) = $122.91 Material Costs = $55.00 TOTAL = $213.03 

Power Vent Fan Repair 

Trip Charge = $35.12 

Labor (2 hrs) = $140.47 

Material Costs = $192.50 

TOTAL = $368.09 

Pilot Light Ignition 

Avg. Repair Year = 4.2 Fraction Repaired = 54.5% 

Electronic Ignition 

Avg. Repair Year = 5.6 Fraction Repaired = 13.8% 

Power Vent 

Avg. Repair Year = 6.0 Fraction Repaired = 5.4% 

Pilot Ignition 

Elec 

Ignition 

Power Vent 

RECS Sample 

Household 

Equipment 

Warranty 

= 1 year 

Lifetime Average = 15 years 

Lifetime Average = 5 years 

Lifetime Average = 10 years 

Equipment 

Lifetime Average 

= 6 years 

Repair Fraction and 

Repair Frequency 

Component 

Fails within 

lifetime of 

Equipment 

Average Repair Cost for All Households 

Design Option 

2008 RS Means Info 

Labor Type = One Plumber Labor Rate = $46.70/hr Labor Markup = 50.4%
 Total Labor Rate = $70.24/hr Bill of Charges
 Materials Markup = 10%
 

Figure 8-B.3.13 Methodology for Calculating Repair Cost for Pool Heaters 

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