### 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

8-B-i

### 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

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 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

8-B-1

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

Description Crew PersonHours 2008 Bare Costs (2008$) Total

incl.

O&P Mat. Labor Equip. Total

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

8-B-2

### 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 Means 1, 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.

8-B-3

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

Description Crew PersonHours 2008 Bare Costs (2008$) Total

incl.

O&P Mat. Labor Equip. Total

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.

8-B-4

### 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

8-B-5

### 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 maintenance 16 

### 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.

O&P Mat. Labor Equip. Total

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.

O&P Mat. Labor Equip. Total

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.

8-B-6

### 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

Report 16



### 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 Report 4 

### 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).

8-B-7

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

Description Crew Labor

Hours Unit 2008 Bare Costs (2008$) Total

incl.

O&P Mat. Labor Equip. Total

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.

O&P Mat. Labor Equip. Total

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.

O&P Mat. 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.

O&P Mat. Labor Equip. Total

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 operation a 

### 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.

8-B-8

### 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.

O&P Mat. 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.

O&P Mat. 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.

O&P Mat. 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

8-B-9

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

Description Crew PersonHours Unit 2008 Bare Costs (2008$) Total

incl.

O&P Mat. 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 Report 15



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

Standing Pilot thermocouple 10.2 survey 1993 TSD 11



### 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 16



### 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

### 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-110% 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-120% 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-130% 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-140% 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-158-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 LevelPilot 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 =$142.72Levels0-2EffLevels3-6RECS SampleHouseholdEquipmentWarranty= 1 yearLifetime Average = 15 yearsLifetime Average = 10 yearsLifetime Average = 15 yearsEquipmentLifetime Average= 12 yearsRepair Fraction andRepair FrequencyComponentFails withinlifetime ofEquipmentAverage Repair Cost for All Households SampledEffDesign Option2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrBill of ChargesMaterials Markup = 10%Figure 8-B.3.9 Methodology for Calculating Repair Cost for Gas-Fired Storage Water Heaters8-B-16Repair Cost at Household LevelNo 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 FrequencyComponentFails withinlifetime ofEquipmentAverage Repair Cost for All Households SampledDesign Option2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrBill of ChargesMaterials Markup = 10%Figure 8-B.3.10Methodology for Calculating Repair Cost for Electric Storage Water Heaters8-B-17Repair Cost at Household LevelPilot 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 FrequencyComponentFails withinlifetime ofEquipmentTotal AverageRepair Cost =$393.59Average Repair Cost for All Households SampledDesign Option2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrBill of ChargesMaterials Markup = 10%Figure 8-B.3.11Methodology for Calculating Repair Cost for Gas-Fired Instantaneous Water Heaters8-B-18Repair Cost at Household LevelAverage Repair CostDesign 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 ofEquipmentAir 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.3.12Methodology for Calculating Repair Cost for Direct Heating Equipment8-B-19Repair Cost at Household LevelPilot 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 FrequencyComponentFails withinlifetime ofEquipmentTotal AverageRepair Cost =$19.95Average Repair Cost for All Households SampledDesign Option2008 RS Means InfoLabor Type = One PlumberLabor Rate = $46.70/hrLabor Markup = 50.4%Total Labor Rate = $70.24/hrBill of ChargesMaterials Markup = 10%Figure 8-B.3.13Methodology for Calculating Repair Cost for Pool Heaters8-B-20

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