8

- B

- i APPENDIX 8

- B

. INSTALLATION COST DE TERMINATION FOR FURNACES

TABLE OF CO NTENTS

8

- B.1 INTRODUCTION

................................ ................................ ................................ . 8

- B

- 1

8

- B.2 NON

- WEATHERIZED GAS FURN ACES

................................ .......................... 8

- B

- 2

8

- B.2.1 Introduction

................................ ................................ ................................ ............ 8

- B

- 2

8

- B.2.2 Basic Installation Costs

................................ ................................ .......................... 8

- B

- 4

8

- B.2.3 Venting

................................ ................................ ................................ ................... 8

- B

- 6

8

- B.2.3.2 Replacement Installations

................................ .............................. 8

- B

- 8

8

- B.2.3.3 New Construction Installations

................................ .................... 8

- B

- 19

8

- B.2.4 Condensate Removal for Condensing Furnaces

................................ .................. 8

- B

- 21

8

- B.2.5 Advanced Controls

................................ ................................ ............................... 8

- B

- 22

8

- B.2.6 Summary of NWGF Installation Costs

................................ ................................ 8

- B

- 22

8

- B.3 MANUF ACTURED HOME GAS FUR NACES

................................ ................. 8

- B

- 2 3

8

- B.3.1 Basic Installation Costs

................................ ................................ ........................ 8

- B

- 23

8

- B.3.2 Venting

................................ ................................ ................................ ................. 8

- B

- 23

8

- B.3.3 Condensate removal

................................ ................................ ............................. 8

- B

- 24

8

- B.3.4 Additional Costs Associated with Space Constraints

................................ .......... 8

- B

- 24

8

- B.4 OIL

- FIRED FURNACES

................................ ................................ .................... 8

- B

- 25

8

- B.4.1 Basic Installation

................................ ................................ ................................ .. 8

- B

- 25

8

- B.4.2 Venting

................................ ................................ ................................ ................. 8

- B

- 25

8

- B.4.3 Condensate Removal

................................ ................................ ........................... 8

- B

- 25

8

- B.4.4 Additional Labor for Condensing Furnaces

................................ ......................... 8

- B

- 26

8

- B.5 RS MEANS 2010 REGION AL LABOR COSTS

................................ ............... 8

- B

- 26

8

- B.6 CONSULTANT REPORT (E ER CONSULTING)

................................ ............. 8

- B

- 28

8

- B.6.1 FURNACE Installation Requirements

................................ ................................ . 8

- B

- 28

8

- B.6.1.2 Furnace Installation Issues

................................ ........................... 8

- B

- 32

8

- B.6.2 Furnace Installat ion Costs

................................ ................................ .................... 8

- B

- 36

8

- B.6.2.1 Additional Installation Costs

................................ ........................ 8

- B

- 37

8

- B.6.3 Regional Differences

................................ ................................ ........................... 8

- B

- 37

8

- B.6.4 Furnace Installation Locations

................................ ................................ ............. 8

- B

- 38

8

- B.6.5 Fraction of Common Vents

................................ ................................ .................. 8

- B

- 40

8

- B.6.6 Additional Information about Weathe rized Furnaces

................................ .......... 8

- B

- 40

8

- B.6.7 Appendix A: Examples of vent and chimney sizing based on the National Fuel

Gas Code table

................................ ................................ ................................ ..... 8

- B

- 40

LIST OF TABLES

Table 8

- B.1.1 Example Installation Cost Table

................................ ................................ 8

- B

- 1
Table 8

- B.2.1 Summary of GRI 1992 Study on Furnace Installation Locations

.............. 8

- B

- 4
Table 8

- B.2.2 Comparison of Furnace Installation Location Fractions

............................ 8

- B

- 4
Table 8

- B.2.3 Basic Installation Cost: New Construction

................................ ................ 8

- B

- 5
Table 8

- B.2.4 Basic Installation Costs: Replacement

................................ ....................... 8

- B

- 5
Table 8

- B.2.5 Fraction of Existing Masonry Chimn ey Installations

................................ 8

- B

- 98

- B

- ii Table 8

- B.2.6 Fraction of Commonly Vented Furnace and Water Heater Installations

... 8

- B

- 9
Table 8

- B.2.7 RECS 2005 Furnace Equipment Age Data

................................ .............. 8

- B

- 11
Table 8

- B.2.8 Fraction of Natural Draft Non

- Condensing Non

- Weatherized Gas Furnace for 2006 through 2010

................................ ................................ 8

- B

- 12
Table 8

- B.2.9 Non

- Condensing to Non

- Condensing Venting Issues, Fraction Impacted, and Average Installation Cost

................................ ................. 8

- B

- 12
Table 8

- B.2.10 Chimney Relining or Vent Resizing (Non

- Condensing to Non

Condensing)

................................ ................................ ............................. 8

- B

- 13
Table 8

- B.2.11 Vent Connector Costs (Furnace): Replacement

................................ ....... 8

- B

- 13
Table 8

- B.2.12 Vent Connector Costs (Water Heater): Replacement

.............................. 8

- B

- 14
Table 8

- B.2.13 Condensing Non

- Weatherized Gas Furnace Vent Length: Replacement 8

- B

- 15
Table 8

- B.2.14 Plastic (PVC) Venting Costs: Replacement Cost Example

..................... 8

- B

- 15
Table 8

- B.2.15 Fraction of Direct Vent Condensing Furnace Installations

...................... 8

- B

- 16
Table 8

- B.2.16 Plastic (PVC) Venting Costs: Replacement Cost Example

..................... 8

- B

- 16
Table 8

- B.2. 17 Concealing Ductwork Costs: Replacement Cost Example

...................... 8

- B

- 17
Table 8

- B.2.18 Non

- Condensing to Condensing Venting Issues, Fraction I mpacted and Average Installation Cost

................................ ................................ .. 8

- B

- 18
Table 8

- B.2.19 Chimney Relining or Vent Resizing (Orphaned Water Heater)

.............. 8

- B

- 18
Table 8

- B.2.20 Vent Connector Costs (Furnace): Replacement

................................ ....... 8

- B

- 19
Table 8

- B.2.21 Vent Co nnector Costs (Water Heater): Replacement

.............................. 8

- B

- 19
Table 8

- B.2.22 Non

- condensing Venting Costs (Typical 2

- Story House): New

Construct ion

................................ ................................ ............................. 8

- B

- 20
Table 8

- B.2.23 Plastic Venting Costs: New Construction

................................ ................ 8

- B

- 20
Table 8

- B.2.24 Installation Fractions and Average Costs for Condensate Removal

........ 8

- B

- 21
Table 8

- B.2.25 Repla cement Installations: Average Installation Costs for Non

Weatherized Gas Furnaces

................................ ................................ ....... 8

- B

- 22
Table 8

- B.2.26 New Construction Installati ons: Average Installation Costs for Non

Weatherized Gas Furnaces

................................ ................................ ....... 8

- B

- 23
Table 8

- B.3.1 Installation Fractions for Condensing Furnaces that Encounter Space

Constraints

................................ ................................ ............................... 8

- B

- 24
Table 8

- B.4.1 Stainless Steel Venting Installation Fractions by AFUE level

................ 8

- B

- 25
Table 8

- B.5.1 RS Means 2010 National Average Labor Costs by Crew (Standard Union)

................................ ................................ ................................ ...... 8

- B

- 26
Table 8

- B.5.2 RS Means Lab or Costs Markups by Trade (Standard Union)

................. 8

- B

- 26
Table 8

- B.5.3 Final Labor Cost Factors by Census Division and Four Large States

..... 8

- B

- 27
Table 8

- B.5.4 Final Labor Cost Factors and Fraction of Households in RECS 2005 Sample

................................ ................................ ................................ ...... 8

- B

- 28
Table 8

- B.6.1 Furnace Installation Requirements (New Construction)

.......................... 8

- B

- 30
Table 8

- B.6.2 Furnace Installation Requireme nts (Replacement)

................................ .. 8

- B

- 31
Table 8

- B.6.3 Additional Installation Issues and Frequencies

................................ ........ 8

- B

- 32
Table 8

- B.6.4 Differences of Direct Vent fractions by location

................................ ..... 8

- B

- 34
Table 8

- B.6.5 Scenarios for Ve nting Systems and Frequencies

................................ ..... 8

- B

- 35
Table 8

- B.6.6 Estimated Furnace Installations, 2009

................................ ..................... 8

- B

- 388

- B

- iii LIST OF FIGURES

Figure 8

- B.2.1 Furnace Installation Locations by Region

................................ ................. 8

- B

- 3 Figure 8

- B.2.2 Relationship Between Labor Hours and Gas Furnace Input Capacity (RS Means)

................................ ................................ ................................ 8

- B

- 6 Figure 8

- B.2.1 Masonry Chimney Venting Installation (Non

- Condensing Furnace)

........ 8

- B

- 7 Figure 8

- B.2.2 Metal Venting Installation (Non

- Condensing Furnace)

............................ 8

- B

- 8 Figure 8

- B.2.3 Plastic PVC Installation (Condensing Furnace)

................................ ........ 8

- B

- 88

- B

- 1 APPENDIX 8

- B. INSTALLATION COST DE TERMINATION FOR FURNACES

8

- B.1 IN TRODUCTION

This appendix provides further details about the derivation of installation cost s for

furnaces

. The installation cost is the price to the consumer of labor and materials (other than the cost of the actual product) needed to install a furnace product.

The Department of Energy (DOE) estimated installation costs for furnaces bas ed on RS Means, a well known and respected construction cost estimation method , as well as manufacturer

literature and info rmation from expert consultants. Table 8

- B.1.1 offers an example of the installation cost calculation. All labor costs are derived using the latest residential 2010 RS Means labor costs by crew type. 1 Replacement installati on 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. Labor hours (or person

- hours) are based on RS Means data, expert data, or engineering judgment. Bare c osts 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. Values reported in this appen dix are based on national average labor costs. The labor costs shown in the tables in this appendix are the national average values. In its analysis, DOE used regional labor costs to more accurately estimate installation costs by region. Section 8

- B.5 describes the derivation of regional labor costs. DOE then applied the appropriate regional labor cost to each RECS sample household. The total costs include O&P. (Not e that the unit “L.F.” in the tables means “linear foot.”)

Table 8

- B.1.1 Example Installation Cost Table

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Material Labor Total

Trip Charge CREW1 0.5

- 0.00 23.00 23.00 1 35.00

Description of Installation Item CREW1 0.5 Ea. 15.00 23.00 48.00 1 51.50

Total 1.0 15.00 46.00 71.00 86.50

The installation cost calculations for furnaces encompass a broad array of product classes, installation sizes, and venting configurations

, including :

**•** n on

- weatherized gas furnaces, mobile home gas furnaces, and oil

- fired furnaces ;

**•** n ew and replacement markets ;

**•** s ingle

- family

, multi

- family , and mobile home dwellings ;

**•** v enting systems that are C ategor y I (non

- condensing), Category III (stainless vents), and Category IV (condensing) ;

**•** various v ents , such as m asonry chimneys , type B metal, or plastic ( polyvinylchloride ( PVC ) ) ;8

- B

- 2 **•** s ingle

- wall or double

- wall vent connectors;

**•** g as or o il w ater h eater s that are v ented in common w ith a f urnace or isolated ; and

**•** s pecia l situations , such as the need to reline a c himney or vent an orphaned water heater

.

Applying the RS Means methodology to a furnace installation requires knowledge of its

detail s , including the vent length, venting material, vent type, diameter, number of elbows, etc. To estimate these quantities, DOE reviewed relevant literature, data, and installation manuals.

Each estimate was a distribution of values derived from available data ; a Crystal Ball Monte

Carlo simulation a

8

- B.2 NON

- WEATHERIZED GAS FURN ACES was used to model the resultant costs for each individual household

.

8

- B.2.1 Introduction

DOE developed i nstallation cost data for gas furnaces using RS Means cost data , DOE

te chnical support documents, an d consultant report s prepared for this analysis. 2, 3, 4, 5, 6 2, 3, 4, 5, 6

The installation cost wa s divided into the following four components:

**•** b asic i nstallation

,

**•** v enting

,

**•** c ondensate r emoval , and

**•** a dvanced c ontrols

.

The following information about market shares , technologies, and installation location helped to shape the installation cost calculations.

New Construction and Replacement Market Shares. As determined in the shipment analysis portion of the national impact analysis ( NIA ) (see Chapter 9), f or non

- weatherized gas furnaces approximately 25 % of the market will be new construction and 75 % will be replacement s in 2016

.

Non

- Weatherized Gas Furnace Technologies. There are two main furnace designs :

non

- condensing and condensing. Almost all of the non

- con densing furnaces have an annual fuel

u tili zation e fficiency ( AFUE ) of 80 % , which represents the analysis baseline. Condensing

furnaces have a n AFUE of 90 % or greater. N on

- condensing furnaces usually use Category I venting system s, while condensing furnaces are vented using Category IV venting systems. A Category I venting system relies on negative pressure and uses either a masonry chimney or a metal vent. A Category I V venting system uses positive pressure and a plastic (PVC) vent.

a See Chapter 8 for a description of the Monte Carlo simulation methodology.8

- B

- 3 In stallation Locations. Figure 8

- B.2.1 shows the fraction of installations by installation location in the North and South regions. The installation fractions are der ived using RECS 2005

household characteristics together with the following assumptions: 7

1) If a household has a basement , then the furnace is installed in the basement

. 2) If a household has an attic and was built after 1980, t hen the majority of the furnace s are installed in the attic ( 75 % of the time ) . If a household has an attic and was built before 1980, then the furnaces are installed in the attic 25 % of the time. 3) If the household has a crawl spa ce , then the furnace is installed in the crawl space 75 % of

the time. 4) If the household has a garage , then the furnace is installed in the garage 75 % of the time. 5) For all other cases the furnace is assumed to be installed indoors.

Figure 8

- B.2.1 Furnace Installation L ocations by Region

For comparison, DOE reviewed a nother reference that examined furnace installation s. 8

Table 8

- B.2.1 shows a summary of the study results. Th is survey was completed in 1992 and is 

### Unheated
North: 0.5%
South: 1.5%

Garage,
North: 5.0%
South: 21.4% Indoor
North: 16.2%
South: 29.3%

Unheated

Basement
North: 16.7%
South: 6.7% Heated

Basement
North: 49.9%
South: 15.0% Heated
North: 2.1%
South: 12.0%

Crawl Space

North: 9.4%
South: 13.6% Attic8

- B

- 4 based on unweighted regional field data. Although directly comparing the data from the two

references is difficult

, the overall national results appear to be similar (see Table 8

- B.2.2)

. Table

8

- B.2.2 also includes n umbers provided by the consultant report (see Table 8

- B.7.6).

Table 8

- B.2.1 Summary of GRI 1992 Study on Furnace Installation Locations

Furnace
Location Northwest (n = 219) Mid w est (n = 60) Northeast (n = 734) South (n = 114) Southern

California (n = 204) Overall (n=1408)

Basement 41.55% 68.33% 79.29% 14.91% 57.32%

Closet 14.61% 6.67% 1.77% 18.42% 65.20% 14.42% Garage 25.57% 1.67% 0.41% 21.05% 16.18% 8.31% Crawl Space 2.74% 0.82% 7.02% 1.42% Utility 5.48% 18.33% 6.27% 4.90%

Other 9.13% 5.00% 11.17% 33.33% 7.84% 11.36%

Attic 0.91% 0.27% 5.26% 10.78% 2.27%

Table 8

- B.2.2 Comparison of Furnace Installation Location Fractions

Furnace
Location GRI 1992 Study [ Overall (n=1408) ] Consultant Report DOE Fractions

80%

AFUE HH 90%+

AFUE HH

Basement 57.32% 40 % 67% 48.47% Garage 8.31% 8% 5% 14.09 % Crawl Space 1.42% 11% 10% 12.43% Utility 4.90%

Other 11.36%

Attic 2.27% 27% 8% 3.68%

Indoor 14.42% 13% 9% 21.33%

Exterior 1% 1%

8

- B.2.2 Basic Installation Costs

For non

- weatherized gas furnaces, DOE estimated basic installation costs that are applicable to both replacement and new home installations. These costs, which apply to both condensing and non

- condensing gas furnaces, include putting in place and setting u p the furnace, gas piping, ductwork, electrical hookup for the thermostat, permit, removal or disposal fees, and, where applicable, additional labor hours for an attic installation. Table 8

- B.2.3 show s the installation costs for new construction calculated using RS Means. Table 8

- B.2.4 shows the basic installation cost for replacement cases. In addition to the costs presented in the table, f or installati ons in the attic DOE assumed an additional labor hour ($48.21) for replacements and

half an hour ($32.54) for new construction.8

- B

- 5 Table 8

- B.2.3 Basic Installation Cost : New Construction

Description Crew Labor

Hours Unit Bare Costs (2009$) Quantity Total

incl.

O&P Material Labor Total

Furnace Installation Q9 5.25 * Ea. $0.00 $153.01 $153.01 1 $341.65

Gas Piping 1 Plum 0.698 Ea. $17.56 $23.98 $41.54 1 $79.13

Ductwork Q10 0.102 Ea. $0.47 $2.97 $3.44 1 $87.21

Electrical Hookup (Thermostat) 1 Elec 0.4 Ea. $12.30 $13.14 $25.44 1 $47.13

Totals 6.45 $555.11

* Labor hours var y by input capacity.

Table 8

- B.2.4 Basic Installation Costs : Replacement

Description Crew Labor

Hours Unit Bare Costs (2009$) Quantity Total

incl.

O&P Material Labor Total

Trip Charge Q9 1.00 Ea. $0.00 $29.15 $29.15 1 $48.21

Remove Furnace Q9 2.62 Ea. $0.00 $76.50 $76.50 1 $126.54

Furnace Installation Q9 5.25 * Ea. $0.00 $153.01 $153.01 1 $253.07

Unit Start

- up, Check, and Clean up Q9 2.00 Ea. $0.00 $58.30 $58.30 1 $96.43

Gas Piping 1 Plum 0.698 Ea. $17.56 $23.98 $41.54 1 $58.61

Ductwork Q10 0.102 Ea. $0.47 $2.97 $3.44 1 $64.60

Electrical Hookup (Thermostat) 1 Elec 0.4 Ea. $12.30 $13.14 $25.44 1 $34.91

Removal/Disposal and Permit Fees

- $50.00

Totals 12.07 $732.37

* Labor hours var y by input capacity.

Furnace installation cost varies by the furnace’s input capacity . Based on 2010 RS

Means

, DOE applied the following relationship shown in Figure 8

- B.2.2 between labor hours for

the “Furnace Installa tion” item and input capacity

. 1 Larger input capacity furnace are usually heavier and have larger dimensions, which require more labor hours.8

- B

- 6 Figure 8

- B.2.2 Relationship Between Labor Hours and G as Furnace Input Capacity (RS Means)

8

- B.2.3 Venting

Estimating v enting costs is complex

, because there are a large variety of installation

scenarios that are possible. DOE calculated venting costs for each household in the RECS
furnace sample. To determine venti ng costs for both new construction and replacement installations, DOE used a number of parameters that have an impact on the venting installation

cost , including vent location, installation type (replacement or new construction)

, region, vent s (metal or p lastic)

, vent connectors, and chimney type

.

Non

- condensing furnaces exhaust high

- temperature flue gas, which heats the inside of the vent above the dew point to ensure that water vapor in the flue gas does not condense; if it does

condense and doesn’ t re

- evaporate quickly during the furnace firing cycle, it could corrode the

vent

, the furnace heat exchanger, or both, thus reducing the lifetime of the vent system or the

furnace itself

. T ypically a small amount of condensate at cold startup is acceptable as long as it dries out quickly. More efficient low

- temperature condensing furnaces condense the water vapor in a secondary heat exchanger, thus increasing furnace efficiency by reducing latent heat loss.

The condensate is fed to a drain. Beca use t he flue gas temperature is relatively low, condensing

furnaces can be vented through PVC piping. 

### y = 0.0168x + 3.2329
R2 = 0.9945

0 1 2 3 4 5 6 7

0 50 100 150 200Labor Hours (hours)



### Input Capacity (kBtu/h)8

- B

- 7 Masonry chimneys, metal vents, and PVC piping are the most common venting

assemblies . Details of these types of installation follow.

Masonry Chimney

. Some non

- condensing furnaces are vented using masonry chimneys

, either lined or unlined. Figure 8

- B.2.1 shows a lined masonry chimney venting a non

- condensing

furnace and a water heater. For unlined chimneys, the flexible liner shown is not present, and a clay tile liner is used instead . Since the 1970s chimney construction techniques have changed. For newer chimneys, the chimney and clay tile liner is usually replaced by a masonry facade on

the exterior that covers a wooden chase with a flexible metal l iner on the interior

. ( T hese are faster to build compared to brick by brick

. ) If the water heater is isolated b , the common water

heater vent shown in Figure 8

- B.2.1 would not be present.

Figure 8

- B.2.1 Masonry Chimney Venting Installation (Non

Condensing Furnace)

Metal Vents . Some non

- condensing furnaces are vented using metal vents

, either single wall or Type B double wall. Figure 8

- B.2.2 shows a Type B double

- wall metal vent. The combination of wall thimbles, storm collar, and flashing replace the chimney. Mos t metal vents go straight through the roof. If the water heater is isolated, the common water heater vent shown w ould not be present.

b There are a number of water heater types that would not be vented in common with a furnace. These include electric, gas direct side

- vented, and gas power

- vented water heaters. In this appendix, the term “isolated” water

heater is defined to include all of these possibilities, but only the most prevalent (more than 90%) option

– electric

water heaters

– is modeled.8

- B

- 8 Figure 8

- B.2.2 Metal Venting Installation (Non

- Condensing Furnace)

Plastic PVC

. All condensing furnaces are vented using PVC vents

, either horizontal or vertical. Figure 8

- B.2.3 shows a horizontal side

- wall plastic vent. T he furnace installation shown below

utilizes a two

- plastic

- pipe venting system. One of the v ents exhaust s the flue gases and the other brings combustion air from the outside to th e furnace. Flue gas piping is sloped downward

toward the furnace so that condensate drips back into the furnace condensate drain. This

installation includes a gas water heater (analogous to the common vented scenario above), which requires a separate flue gas exhaus t vent . If the water heater is isolated , this exhaust vent will not be present.

Figure 8

- B.2.3 Plastic PVC Installation (Condensing Furnace)

8

- B.2.3.2 Replacement Installations

For replacements

, DOE eval uated two cases

. One involves switching from a non

c ond ensing natural draft furnace ( less than 75% AFUE) to a n on

- condensing fan

- assisted furnace8

- B

- 9 ( 80% AFUE) and the other involves switching from a non

- c ond ensing ( natural draft and fan

assisted) to a c ond ensing furnace (90% or greater AFUE)

.

Table 8

- B.2.4 provides the fraction of existing masonry chimneys and metal vent installations by region, based on the 199 4 GR I Furnace Survey

. 8

Table 8

- B.2.5 Fraction of Existing Masonry Chimney Installations

Venting Type North South

Masonry 7 1.8 % 1 6.4 %

Metal Vent 28 .2 % 8 3.6 %

Table 8

- B.2.5 provides the fraction of existing non

- condensing installations that are commonly vented with gas water heaters, based on the 199 1 GTI Water Heater Survey. 9

Table 8

- B.2.6 Fraction of Commonly Vented Furnace and Water Heater Installations

Common Venting North east Midwest South West

Common 78 % 68 % 22% 65%

Isolated 22 % 32 % 78% 35%

8

-

B.2.3.2.2 Non

- Cond ensing to Non

- Condensing Furnace Installations

Many non

- condensing to non

- condensing furnace replacement installations require venting modifications to meet current safety requirements

. There are two main issues that can

arise when replacing a non

- condensing furnace with a more efficient non

- condensing furnace: relining an unlined chimney and resizing an existing venting system.

Chimney Relining

There are two types of masonry chimney

— interior and exterior. Exterior chimneys are usually exposed on three sides; they are less insulated by the structure, lowering the internal temperature and making it more likely that exhaust gases will condense inside . Interior chimneys are s urrounded by the heated building ; the temperature in the chimney tends to be higher , making flue gases less likely to condense. Because of these different insulating

pr operties, the National Fuel Gas Code (NFGC) 10 has different lining requirements for interior and exterior chimneys . These requirements are important

, becaus e the cost of chimney relining is a major component of a furnace installation cost.

Exterior Chimneys . In Table 13.11 of the Code, 10 the minimum allowable input rating

for appliances that are vented in exterior masonry chimneys is 150 kB tu /hour . This rating is the8

- B

- 10 upper limit for input capacity for almost all residential furnaces sold today. Therefore, DOE ’s analysis assumes that all exterior lined chimney s will require a re

- lining upon replacement.

Interior Chimneys . T he NFGC mandate s that all interior chimneys be relined when the furnace is isolated from the water heater (NFGC Tables 13.3 and 13.4)

. 10 When a furnace is

vented in common with a water heater

, the vertical vent upsizing / 7X rule applies. This rule specifies that the flow area of the vertical vent shall not exceed seven times (7X) the flow area of

the smallest vent connector

— the vent connector for the water heater , for example . Water heater vents are typically 3 inches in diameter, so an interior masonry chimney cannot exceed 49 square inches, corresponding to a n 8 x 8 nominal chimney liner size. DOE assumed that all interior chimneys would need to be relined

, if built before 199 5 and if the existing furnace is a natural

draft furnace.

DOE determined which furnace installations of the entire furnace sample would require

chim ney relining

, based on RECS 2005 equipment age data and the fraction of chimney installations (see Table 8

- B.2.3)

. Table 8

- B.2.7 shows the equipment age bin data provided by

RECS 2005. For each bin DOE assigned an equipment installation year using a unif orm distribution with the ranges shown in the table. Finally, using the fraction of chimney

installation s shown in Table 8

- B.2.3, DOE determined if the household had a chimney

installation. To determine if a household had a n unlined chimney

, DOE used the following two
criteria:

1) F urnace exhaust gases are vented through a chimney

. 2) The e xisting furnace was installed before 199 5 when building codes requiring the relining of chimneys w ere not yet in place

.

Based on these criteria, DOE calculated that 26 % of households in the RECS 2005 sample had a n unlined chimney. DOE determined that half of these would be relined already by 2016, based on furnace equipment retirements from 2005 to 2016

. ( B y 2016 the existing furnaces

that would require relining would be 26 years old or older). Therefore, t he analysis resulted in

13 % of the stock need ing to be relined in 2016.8

- B

- 11 Table 8

- B.2.7 RECS 2005 Furnace Equipment Age Data

RECS Age Bin Installation Year

Uniform Distribution Fraction of RECS Households

North South National

Less than 2 years old 2004

- 2005 13.3% 13.1% 13.2%

2 to 4 years old 2001

- 2003 13.0% 13.8% 13.3%

5 to 9 years old 1996

- 2000 22.5% 19.5% 21.3%

10 to 19 years old 1986

- 1995 26.8% 27.4% 27.0%

20 years or older 1965

- 1985 16.8% 19.3% 17.8%

U nknown 1965

- 2005 7.7% 6.9% 7.4%

Vent Resizing

Vent resizing occurs when the existing vent diameter is too large for the new gas furnace or for the commonly vented furnace and gas water heater. Two solutions are possible: 1) vent connector resizing (most common) or 2) vent resizing (less common). There are three main types of vent connectors: Type B double wall, single

- wall gal vanized steel, and single

- wall

aluminum. A double

- wall vent uses a galvanized steel outer tube to surround an aluminum inner tube and is sold in multiple section lengths

. T he air gap in between the tubes provides insulation

, which reduces the likelihood of condensation in the vent connector. A s ingle

- wal l galvanized steel vent is simply a zinc

- coated steel tube vent. Aluminum single

- wall vent connectors are

similar to galvanized steel single

- wall vent s and are found in some regions. C ondensing furnaces do not require vent connector s

.

The vent connector portion of the vent is the horizontal part of the masonry and metal
vent systems shown in Figure 8

- B.2.1 and Figure 8

- B.2.2, respectively

. In each figure there are two vent connectors shown: one for the water heater, and one for the furnace. As water h eater capacity is typically less than furnace capacity, in many cases the water heater vent conn ector
diameter will be less than the furnace vent connector diameter. DOE assumes that the furnace

diameter is 4 inches on average, while the water heater vent connector is 3 inches on average.

For this analysis, DOE assumed that vent resizing occurs only when a non

- condensing

fan

- assisted furnace ( an AFUE of 80% or greater ) replaces a natural draft non

- condensing furnace ( an AFUE of less than 7 5%). Although fa n

- assisted furnaces have been the only installed

non

- condensing designs since the early 1990s, there is still a fraction of the stock that includes

natural draft non

- condensing furnaces

, b ased on RECS 2005 equipment age (see Table 8

- B.2.7)

and historical shipments by efficiency from GAMA and AHRI shown in 8

- B.2.8

. 11, 12 Using this data, DOE determined that natural draft furnaces will account for about 6 % of the stock in 2016.

Based on the consultant report (see section 8

- B.6 ) , DOE assumed that 75 % of the venting systems with existing natural draf t furnaces would need replace ment of the vent connectors,

while in an additional 10 % of the installations the entire venting system would have to be

resized.8

- B

- 12 Table 8

- B.2.8 Fraction of Natural Draft Non

- Condensing Non

- Weatherized Gas Furnace for 2006 through 2010

Furnace Installation

Year North
% South

% National

%

1994

- 2005 0.0% 0.0% 0.0%

1993 0.8% 1.0% 0.9%

1992 2.2% 3.0% 2.6%

1991 39.2% 50.6% 43.8%

1990 44.4% 54.7% 48.5%

1989 54.1% 66.0% 58.9%

1988 51.6% 63.8% 56.5%

1987 55.1% 66.8% 59.8%

1986 68.6% 73.9% 70.7%

1985 64.7% 73.3% 68.2%

1984 62.6% 71.9% 66.4%

1983 68.4% 82.3% 74.0%

1982 71.6% 83.3% 76.3%

1981 74.8% 84.2% 78.6%

1980 78.0% 85.2% 80.9%

1979 88.9% 92.7% 90.5%

1978 97.3% 97.3% 97.3%

1977 98.2% 98.2% 98.2%

1976 99.1% 99.1% 99.1%

1965

- 1975 100.0% 100.0% 100.0%

Table 8

- B.2. 9 summarizes the three different venting issues associated with non

condensing furnaces including the frequency of installation requirements

, the fraction of installed

furnaces that could be impacted, the fraction impacted ( Frequency * Fraction Possibly Impacted ), and the average additional installation cost.

Table 8

- B.2.9 Non

- Condensing to Non

- Condensing Venting Issues, Fraction Impacted

, and Average Installation Cost

Existing

Furnace Replacement

Furnace Installatio n Requirement Frequency Fraction Possibly Impacted Fraction Impacted Avg.

Cost

Chimney

installed

before 1990 80% AFUE Relining all unlined chimneys 100% 13% 13% $681

Natural

Draft 80 % AFUE Installing New Vent

Connectors ( Convert ing from single

- wall to Type B
double

- wall ) 75% 6% 4% $199

Natural

Draft 80% AFUE Resizing Vent System 10% 6% 1% $5768

- B

- 13 Table 8

- B.2. 10 shows the installation cost details for chimney relining or vent resizing

. Vent length is determined by taking into account the furnace installation location and the number

of floors above the furnace. To determine the length of the vent, t he number of floors is multiplied by the floor height

, which varies from 8 to 10 feet

. ( F o r the example shown in Table

8

- B.2. 10 the total vent length is 16 feet

. )

Table 8

- B.2.10 Chimney Relining or Vent Resizing (Non

- Condensing to Non

Condensing)

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erial Labor Total

Aluminum Flexible Vent (4” Diameter, includes vent kit) Q9 0.235 L.F. 10.53 6.85 17.38 16 366.67

Vent Connector ( Furnace, 4”

Diameter ) Q9 0. 706 Ea. 22.45 20.58 43.03 1 $ 152.24

Vent Connector ( Water Heater, 3”

Diameter ) Q9 0. 666 Ea. 18.60 19.41 38.01 1 $ 110.63

Total 0.71 59.70 31.10 90.80 $ 600.90

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

Table 8

- B.2. 11 shows the installation cost details for installing a vent connec tor for a

furnace.

Table 8

- B.2.11 Vent Connector Costs (Furnace): Replacement

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erial Labor Total

Vent Connector (Vent chimney, double wall, type B, 4 " Diameter) Q9 * 0.2 35 L.F. 6.70 6.85 13.55 6 $ 112.20

Vent Connec tor (Type B Elbows, 45 degree, 4 " Diameter) Q9 0.4 71 Ea. 15.75 13.73 29.48 1 $ 40.03

Total 0.706 $ 152.24

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

Table 8

- B.2. 12 shows the installation cost details for installing a vent connector for a

water heater.8

- B

- 14 Table 8

- B.2.12 Vent Connector Costs ( Water Heater ): Replacement

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erial Labor Total

Vent Connector (Vent chimney, double wall, type B, 3" Diameter) Q9 * 0.2 35 L.F. 5.35 6.47 11.82 6 $ 74.65

Vent Connector (Type B Elbows, 45 degree, 3" Diameter) Q9 0.4 71 Ea. 13.25 12.94 26.19 1 $ 35.98

Total 0.706 $ 110.63

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

8

-

B.2.3.2.3 Non

- Condensing to Condensing

The standard cases that DOE considered in the analysis represent condensing furnace designs at 90% AFUE or greater

. DOE’s analysis assumes that , when replacing an exist ing condensing furnace with another condensing furnace, the venting requirements would be the

same.

DOE estimated that nationally in 2016 the majority of the replace ment installation s would be from non

- condensing to condensing furnaces

. The next four se ctions explain the changes to the venting systems that would be required when installing condensing furnaces and provide information about the frac tions of impacted installations. The sections address the following four installation issues :

**•** condensing flu e vent (PVC) ;

**•** combustion air vent;

**•** concealing vents in indoor installations ; and

**•** i nstallation with o rphaned water heaters

.

Condensing Flue Vent (PVC)

When replacing an existing non

- condensing furnace with a condensing furnace, the existing metal vent is replaced with a plastic (PVC) flue vent. The installation cost of the condensing furnace flue vent takes into account the following:

**•** furnace location;

**•** house ceiling height and number of floors (determined for each furnace household in RECS 2005 sample ) ;

**•** furnace distance from wall or roof , and whether to install a vertical vent (through the roof) or a horizontal vent (through the wall) ; and

**•** wall type , w hich determine s the cost of penetrati n g the wall.

Table 8

- B.2. 13 shows the 5 th percentile, average, and 95 th percentile vent length results from the RECS 2005 household sample and the fraction of installations with vertical or

horiz ontal vents

.8

- B

- 15 Table 8

- B.2.13 Condensing Non

- Weatherize d Gas Furnace Vent Length: Replacement

Vent Run Vent Length, ft Fraction of Installations

5 th Pct Average 95 th Pct

Horizontal 7 17 28 67%

Vertical 13 19 29 33%

Table 8

- B.2.1 4 illustrates the development of installation cost components for plastic (PVC) venting for a condensing furnace in the replacement cases . The number of elbows required varies from 1 to 6 (presented as a uniform distribution ) . The vent termination is

assumed to be the same cost as an elbow. The cost o f drilling a hole through the building envelope is dependent on the type of outside wall material used for each household

, a s given in

RECS 2005.

Table 8

- B.2.14 Plastic (PVC) Venting Costs: Replacement Cost Example

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P

Mat. Labor Total
PVC, couplings 10' O.C., hangars 3 per 10', schedule 40 (2" Diameter) Q1 * 0.08 1 L.F. 3.25 2.50 5.75 16 $12 2.89

Elbow

- PVC, schedule 40, socket joints, 90" elbow, 1/2" (2" diameter) Q1 0.44 Ea. 2.47 13.61 16.08 1 $ 25.02

Termination

- PVC, schedule 40, socket joints, 90" elbow, 1/2" (2" diameter) Q1 0.44 Ea. 2.47 13.61 16.08 1 $ 25.02

Knockouts to 8' high, metal boxes & enclosures (With hole saw, 2" pipe size) 1

ELEC ** 0. 30 Ea. 35.35 14.43 14.43 1 $42.95

Total $ 330.57

* 1 Q 1 means a crew comprised of 2 plumbers and 1 plumber a pprentice.

* * 1 ELEC means a crew of 1 electrician

.

Combustion Air Vent (PVC)

A fraction of the condensing furnace installations are direct

- vent installations, which uses

c ombustion air s upp lied from the outdoor air

. F or each household in the RECS 2005 sample

DOE considered the following factors when calculat ing the installation cost of the combustion air vent for condensing furnace s in the replacement market:

**•** vent length

, which is the same as flue pipe length ; and

**•** vent installation fraction , which depen ds on the installation location

.

Table 8

- B.2.1 5 shows the fraction of direct vent installations by installation location,

based on the consultant r eport in section 8

- B.6. As show n in the table

, nationally about 6 2.1 % of the condensing furnace installations are d irect vent

. The fraction of direct

- vent con densing

furnace installations for the North and South regions are also shown in the table.8

- B

- 16 Table 8

- B.2.15 Fraction of Direct Vent Conde nsing Furnace Installations

ID Installation Location Fraction of

Direct Vent

Installations Fraction of Installations

North South Nat ional

1 Basement (Conditioned) 67% 50.2% 14.6% 36.0%

2 Basement (Unconditioned) 33% 16.4% 6.5% 12.5%

3 Crawl Space 33% 10.1% 16.0% 12.4%

4 Garage 100% 5.5% 27.0% 14.1%

5 Indoor (Closet, Alcove, Utility Room) 67% 16.1% 29.2% 21.3%

6 Attic (Conditioned) 67% 0.3% 0.8% 0.5%

7 Attic (Unconditioned) 33% 1.4% 5.9% 3.2%

Total Fraction of Installations that are Direct Vent 59.3% 66.3% 62.1%

Table 8

- B.2.1 6 illustrates the development of installation cost components for plastic (PVC) venting for a condensing furnace in the replacement cases.

Table 8

- B.2.16 Plastic (PVC) Venting Costs: R eplacement Cost Example

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P

Mat. Labor Total
PVC, couplings 10' O.C., hangars 3 per 10', schedule 40 (2" Diameter) Q1 * 0.08 1 L.F. 3.25 2.50 5.75 16 $12 2.89

Elbow

- PVC, schedule 40, socket joints, 90" elbow, 1/2" (2" diameter) Q1 0.44 Ea. 2.47 13.61 16.08 1 $ 25.02

Termination

- PVC, schedule 40, socket joints, 90" elbow, 1/2" (2" diameter) Q1 0.44 Ea. 2.47 13.61 16.08 1 $ 25.02

Knockouts to 8' high, metal boxes & enclosures (With hole saw, 2" pipe size) 1

ELEC ** 0. 30 Ea. 35.35 14.43 14.43 1 $42.95

Total $ 330.57

* 1 Q 1 means a crew comprised of 2 plumbers and 1 plumber a pprentice.

* * 1 ELEC means a crew of 1 electrician

.

Concealing Vent Pipes

For a fraction of indoor installations, DOE added an installation cost to conceal the PVC
vent p ipes

— putting in place structures to mask vents that pass through the living space . DOE
assumed that half of the indoor horizontally ven ted condensing furnace installations would require such modifications . Table 8

- B.2.1 7 illu strates the development of the installation cost components for concealing the vent piping in such cases.8

- B

- 17 Table 8

- B.2.17 Concealing Ductwork Costs: Replacement Cost Example

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erials Labor Total

Trip Charge 1

CARP * 0.5 Ea. 0.00 15.12 15.12 1 24.47

Knockouts to 8' high, metal boxes & enclosures (With hole saw, 2" pipe size) 1 Elec 2.222 Ea. 35.35 72.99 108.34 1 157.64

Wallboard repair 8"

- 12" (cut square, patch san and repair finish) 1 CARP 0.5 C.L.F. 3.04 20.72 23.76 8 222.54

Total $ 404.65

* 1 CARP means a crew of 1 carpenter

.

Orphaned Water Heaters

– Chimney Relining and Vent Resizing

When a condensing furnace replaces an existing non

- condensing gas furnace that is commonly vented with a gas water heater , the water heater after the installation becomes “orphaned”. Many of these “orphaned water heaters” require venting modifications to meet safety requirements . S uch requirements include upgrading the vent connector, r esizing m etal

vents, or m ason ry chimney relin ing

. Based on the consultant report (see section 8

- B.6), DOE

assumed that 100 % of the venting systems with existing natural draft furnaces would need to

have the vent connectors replaced for the orphaned water h eater , while an additional 4 0 % would

need to have the entire venting system of the orphaned water heater resized or upgraded

. DOE assumed that all orphaned water heater chimneys would need to be relined if built before 1990 and if the existing furnace is a natural draft furnace. Based on the consultant report (see section

8

- B.6), DOE also assumed that 20 % of the venting systems with existing fan assisted non

condensing furnaces would need to have the entire vent of the orphaned water heater resized or upgraded

.

Table 8

- B.2.1 8 summarizes the four different scenarios that might be encountered in such replacement installations. The table shows the scenario description and the analysis results about

the frequency of applying these requirements, fraction o f installed furnaces that could be impacted, the fraction impacted ( Frequency * Fraction Possibly Impacted), and the average

additional installation cost.8

- B

- 18 Table 8

- B.2.18 Non

- Condensing to Condensing Venting Issues, Fraction Impacted and Average Installation Cost

Existin g Non

Condensing

Furnace Replacement

Furnace Installation Requirement Frequency of applying requirements Fraction Possibly Impacted Fraction Impacted Avg.

Cost

Natural Draft Condensing

Furnace Convert Water Heater from single wall to B Type vent

Connector 100% 2% 2% $114

Natural Draft Condensing

Furnace Resizing Orphaned

Water Heater Chimney or upgrading Metal

Vent 40% 3% 1% $531

Natural Draft Condensing

Furnace Reline all unlined chimneys for Orphaned Water

Heater 100% 7% 7% $555

Fan Assisted Condensing

Furnace Resizing Orphaned

Water Heater Chimney or upgrading Metal

Vent 20% 38% 8% $540

Table 8

- B.2.19 shows the installation cost details for chimney relining or vent resizing

for an orphaned water heater

.

Table 8

- B.2.19 Chimney Relining or Vent Resizing ( Orphaned Water Heater )

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erial Labor Total

Aluminum Flexible Vent (4” Diameter, includes vent kit) Q9 0.235 L.F. 10.53 6.85 17.38 16 366.67

Vent Connector ( Furnace, 4”
Diameter ) Q9 0. 706 Ea. 22.45 20.58 43.03 1 $ 152.24

Vent Connector ( Water Heater, 3”
Diameter ) Q9 0. 666 Ea. 18.60 19.41 38.01 1 $ 110.63

Total 0.71 59.70 31.10 90.80 $ 600.90

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

Table 8

- B.2.20 shows the installation cost details for installing a vent connector for a

furnace.8

- B

- 19 Table 8

- B.2.20 Vent Connector Costs (Furnace): Replacement

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erial Labor Total

Vent Connector (Vent chimney, double wall, type B, 4 " Diameter) Q9 * 0.2 35 L.F. 6.70 6.85 13.55 6 $ 112.20

Vent Connec tor (Type B Elbows, 45 degree, 4 " Diameter) Q9 0.4 71 Ea. 15.75 13.73 29.48 1 $ 40.03

Total 0.706 $ 152.24

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

Table 8

- B.2.21 shows the installation cost details for installing a vent connector for a

water heater.

Table 8

- B.2.21 Vent Connector Costs ( Water Heater ): Replacement

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Quantity Total

incl.

O&P Mat erial Labor Total

Vent Connector (Vent chimney, double wall, type B, 3" Diameter) Q9 * 0.2 35 L.F. 5.35 6.47 11.82 6 $ 74.65

Vent Connector (Type B Elbows, 45 degree, 3" Diameter) Q9 0.4 71 Ea. 13.25 12.94 26.19 1 $ 35.98

Total 0.706 $ 110.63

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

8

- B.2.3.3 New Construction Installations

For furnace installation s in new construction, DOE accounted for the installation cost of a new venting system for both non

- condensing furnace s (80% AFUE, baseline) and condensing

furnaces (AFUE of 90% and greater , standard cases).

Table 8

- B.2.14 illustrates the typical installa tion cost for venting a non

- condensing

furnace in new construction

. As in the r eplacement case , vent length is determined by taking into

account the furnace installation location and the number of floors above the furnace.8

- B

- 20 Table 8

- B.2.22 Non

- condensing Venting Costs (T ypical 2

- Story House) : New

Construction

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Total

incl.

O&P Mat. Labor Total

Vent chimney, double wall, galvanized steel (4" Diameter) Q9 * 0.2 4 L.F. 5.95 10.35 16.30 $346.52

Double Wall, Galvanized Steel Adjustable Length piece, to 12" Q9 0.47 Ea. 11.45 20.75 32.20 $44.53

Type B Wall Thimble, 4" to 7" Adjustable(4" Diameter) Q9 0.47 Ea. 13.90 20.75 34.65 $94.46

Vent Connector (Type B Elbows, 45 degree, 4" Diameter) Q9 0.47 Ea. 13.95 20.75 34.70 $47.28

Roof Flashing (4" Diameter) Q9 0.47 Ea. 8.05 20.75 28.80 $40.79

Tee (4" Diameter) Q9 0.6 2 Ea. 30.00 27.10 57.10 $149.40

Tee Cap (4" Diameter) Q9 0.38 Ea. 2.34 16.79 19.13 $28.41

Top (4" Diameter) Q9 0.36 Ea. 11.45 16.04 27.49 $37.28

Total 334.09 186.43 520.52 $788.67

* 1 Q 9 means a crew comprised of 1 sheet metal worker and 1 sheet metal worker a pprentice.

* * 1 CARP means a crew of 1 carpenter

.

Table 8

- B.2.14 illustrates the typical insta llation cost for venting a condensing furnace in

new construction. DOE accounted for the installation of the plastic PVC flue vent

, as well as for

the combustion air vent in direct

- vent systems.

Table 8

- B.2.23 Plastic Venting Costs: New Construction

Description Crew Labor

Hours Unit Bare Costs ( 2009$ ) Total

incl.

O&P Mat. Labor Total

PVC, couplings 10' O.C., hangars 3 per 10', schedule 40 (2" Diameter) Q1 * 0.08 L.F. 1.21 3.69 4.90 $128.52

PVC, schedule 40, socket joints, 90" elbow, 1/2" (2" diameter) Q1 0.44 Ea. 2.18 20.03 22.21 $64.91

Total 0.52 3.39 23.72 27.11 $193.43

* 1 Q 1 means a crew comprised of 2 plumbers and 1 plumber a pprentice.

In the new construction cases, DOE also accounted for the installation costs of commonly vented furnaces (together with a water heater). When installing a condensing furnace in new

construction

, 100% of the cost of the venting system is assigned to the orphaned water heater installation. When a commonly vented non

- condensing furnace and water heater are installed, then the venting cost is equally divided bet ween the two appliances. Therefore, for commonly

vented non

- condensing furnace installations, DOE subtracted half of the venting system

installation cost

, while in the condensing furnace installations with orphaned water heater s DOE
added half of the ven ti ng system installation cost of the orphaned water heater

.8

- B

- 21 8

- B.2.4 Conden sate R emoval for Condensing Furnaces

Condensate removal is required for all condensing furnace installations in both replacement and new construction cases

. DOE considered the following when assessing the cost

of condensate removal :

**•** Condensate Pipe: For condensing furnaces, excess condensate must be deposited in a

drain. Therefore, for all installations DOE applied the cost of adding condensate pipe (on average 15 feet)

.

**•** Condensate Pump : If a drain is not near, then the condensate must be pumped to a remote

drain. If a central air

- conditioner is present

, then DOE assumes that already there is either a drain nearby or a pump already exis ts to remove the condensate from the air

conditioner dur ing the cooling season. DOE assumes that a condensate pump is required

for half of the installations without a central air conditioner.

**•** Condensate Freeze Protection: If the condensate is exposed t o freezing temperatures

, then heat tape and pipe insulation is required . DOE assumes that heat protection is required in all unconditioned attics.

**•** Drip Pan : S ome codes require a drip pan. DOE assumed that a drip is required for all

attic installations or furnaces installed in a 2 nd floor or above.

**•** Additional Elect rical Outlet : DOE assumed that half of installations requiring a

condensate pump or heat tape would also require an additional electricity outlet. DOE
included this additional cost

Table 8

- B.2.24 summarizes the condensate removal adders assoc iated with condensing

furnaces. The table shows the criteria

, the frequency of applying these criteria, the fraction of

installed furnaces that could be possibly impacted, the fraction impacted ( Frequency * Fraction Possibly Impacted), and the average additional inst allation cost.

Table 8

- B.2.24 Installation Fractions and Average Costs for Condensate Removal

Installation Cost Description Criteria Frequency of applying

criteria Fraction Possibly Impacted Fraction Impacted Averag

e Cost

Pipe All installations 100% 100% 100% $13

Drip Pans Attics or higher floor

installations 100% 7% 7% $45

Pump Installations without AC 50% 11% 6% $208

Heat Tape and

Insulation Installations in

Unconditioned Attic 100% 5% 5% $98

Electrical Outlet (additional) Installations requiring a Pump or Heat Tape 50% 8% 4% $1368

- B

- 22 In addition to the installation costs, the e lectricity use of the pump and heat tape is taken into account (45 watts for Heat Tape and 60 watts for the condensate pump) in the energy use calculations (see c hapter 7).

8

- B.2.5 Advanced Controls

DOE assumed that the more a dvanced c ontrols found in two

- stage and modulating

furnaces will require additional labor hours to install the more complex thermostat and related
components

. DOE applied an average cost of $19 to all furnaces with two

- stage or modulating

controls.

8

- B.2.6 Summary of NWGF Installation Costs

Table 8

- B.2.25 (for replacements) and Table 8

- B.2.26 (for new construction) show the

fraction of the impacted installations

, the avera ge cost of each installation, and the resulting

average total cost for all furnace installations

.

Table 8

- B.2.25 Replacement Installations: Average Installation Costs for Non

Weatherized Gas Furnace s

Installation Cost Adder Criteria Installations Impacted

% Average

Cost 2009$ Total

Cost 2009$

Non

- Condensing Furnaces

Basic Installation All Installations 100 690 690

Flue Vent Connectors 75% of natural draft vent systems 4 199 8 Chimney Relining 100% of unlined chimneys 13 681 87 Vent Resizing 10% of natural draft vent systems 1 576 4

TOTAL $789
Condensing Furnaces

Basic Installations 100% of installations 100 690 690 New Flue Venting (PVC) All Installations 100 306 306 Combustion Air Venting (PVC) 62% of installations 62 301 186 Concealing Vent Pipes 50% of indoor horizontal vented 5 302 15 Orphaned Water Heater Chimney Relining & Resizing 18 501 89

Condensate Removal 100% of installations 100 71 71

TOTAL $1,3578

- B

- 23 Table 8

- B.2.26 New Construction Installations: Average Installation Costs for Non

Weatherized Gas Furnaces

Installation Cost Adder Criteria Installations Impacted

% Average

Cost 2009$ Total

Cost 2009$

Non

- Condensing Furnaces

Basic Installation All Installations 100 509 509

New Flue Vent All Installations 100 1,036 1036 Common Venting credit 1⁄2 common venting cost is credited 48

- 405

- 195

TOTAL $1,350
Condensing Furnaces

Basic Installations 100% of installations 100 509 509 New Flue Venting (PVC) All Installations 100 247 247 Combustion Air Venting (PVC) 60% of installations 60 239 144 Common Venting Adder 1⁄2 of common venting cost is added 48 405 195

Condensate Removal 100% of installations 100 13 13

TOTAL $1,108

8

- B.3 MANUFACTURED HOME GA S FURNACES

DOE developed i nstallation costs for manufactured home gas furnaces using RS Means
cost data

, information for industry experts, and a consultant report (see section 8

- B.6 )

. DOE developed separate costs for new construction and replacement markets. Based on the shipment s model (see chapter 9 ), DOE assumed a 50% new construction f raction in 2016. 2, 3, 4, 5, 6 2, 3, 4, 5, 6

8

- B.3.1 Basic Installation Costs

Basic i nstallation costs w ere developed using t he same approach as was used for non

weatherized gas furnaces (see 8

- B.2.2 ). The average basic installation cost for replacement s is $597 and for new construction is $376

.

8

- B.3.2 Venting

HUD code requires sealed combustion (Direct

- Vent) for all installations of manufactured home furnaces. According to industry experts and product literature

, PVC piping for condensing

furnaces is usually combined with a metal vent system

.

DOE determined that the average cost for adding PVC venting in the replacement market

i s $279. For new construction market, DOE determined that installing the metal vent for non

condensing applications would cost $302 , while the PVC venting cost on average would be $364

.8

- B

- 24 8

- B.3.3 Condensat e removal

DOE assumed that all condensing furnaces require c ondensate piping and freeze protection (heat tape and pipe insulation). These costs are applied to both replacement and new

construction markets. For half of the installations, DOE assumed an additional electrical outlet was required for the condensate hea t tap e

. Conde n sate piping, freeze protection (heat tape and pipe insulation), and electrical outlet costs were developed using the same approach as was used

for non

- weatherized gas furnaces

. The average installation cost adder for r eplacement s is $185

and for new construction is $141.

8

- B.3.4 Additional Costs Associated with Space Constraints

M obile home furnace s are usually installed in very tight spaces and often require s pace modification s if the furnace dimensions are larger than the existing furnace. Manufactu rer literature shows that many condensing furnaces are much larger than existing non

- condensing

furnaces.

Table 8

- B.3.1 shows the approximate fraction of condensing furnaces that have larger dimensions compared to non

- condensing mobile home furnaces

. DOE grouped the available condensing models listed in the 2010 AHRI Directory by effic iency (90%, 92%, and 96% AFUE). All 90% AFUE models are manufactured by Nordyne

, and their dimensions are the same as existing non

- condensing furnaces. Only half of the 92% A FUE models are manufactured by Nordyne

, and the remaining half have larger dimensions than the existing non

- condensing

furnaces. At the 96% AFUE level, all models listed in the 2010 AHRI Directory have larger dimensions than the existing non

- condensing fur naces

Table 8

- B.3.1 Installation Fractions for Condensing Furnaces that Encounter Space

Constraints

Efficiency Criteria Installations impacted

90% AFUE Nordyne models only 0%

92% AFUE All manufacturers except Nordyne are larger 50%

96% AFUE All listed models are larger 100%

For condensing mobile furnace replacements with space constraints DOE applied a $200

- $600 space constraint adder.

For the condensing mobile furnace new construction market, DOE assumed that the decreased living space has a net cost. To calculate this effect, DOE used July 2010 U.S. census data on the average cost of a mobile home in July 2010 ( $64,000 ) and average square foota ge (800 sq. ft.). DOE th en assumed that the extra space required for a larger condensing furnace is 2 sq. ft. based on available model data. This resulted in an average cost adder of $160 ($64,000 * 2 sq ft / 800 sq ft).8

- B

- 25 8

- B.4 OIL

- FIRED FURNACES

DOE developed i nstallation cost data for oil

- fired furnaces using RS Means data

, industry
experts , and a consultant report. DOE developed separate costs for the new construction and replacement markets. Based on the shipm ent s model (see chapter 9), DOE assumed a 10% new construction f raction in 2016

. 2, 3, 4, 5, 6 2, 3, 4, 5, 6

8

- B.4.1 Basic Installation

Basic i nstallation costs w ere developed using the same approach as was used for non

weatherized gas furnaces

. The average basic installation cost for replacements is $ 475 and for new construction is $350.

8

- B.4.2 Venting

DOE considered the additional v enting cost associated with stainless steel venting for a

f raction of installations between 83% AFUE and 85% AFUE based on the fractions shown in

T able 8

- B.4.1. For the fraction of i nstallations at 82 % to 85% AFUE that are already part of the

base case , D OE assumed that no stainless steel vent is required.

Table 8

- B.4.1 Stainless Steel Venting Installation Fractions by AFUE level

Efficiency,

AFUE Faction Requiring

Stainless Steel Vent

82% 0%

83% 25%

84% 50%

85% 75%

The average installation cost for stainless steel venting is $1,285. For condensing oil

- fired furnaces, 100 % of installations are assumed to require direct

- vent PVC piping, with an average cost of $512. In addition, all condensing oil

- fired furnace installations that include a n oil

- fired

water heat er were assumed to incur the cost for redoing the venting system for the orphaned

water heater . This resulted in an average addit ional cost of $1,081 for 15 % of the installations.

8

- B.4.3 Condensate Removal

Condensate r emoval installation costs (p ipe, pump, heat tape, and insulation ) were also incuded, as was done for the non

- weatherized gas furnaces. The average cost was $180

.8

- B

- 26 8

- B.4.4 Additional Labor for C ondensing F urnaces

DOE assumed that additional l abor would be needed to install a condensing furnace

, because of the additional labor hours required to tune up its combustion system ; on average two
additional hours would be needed at a cost of $104)

.

8

- B.5 RS MEANS 2010 REGION AL LABOR COSTS

DOE used regional labor costs to more accurately estimate installation costs by region. RS Means provides average national installation costs for different trade groups as shown in

Table 8

- B

. 5 .1. Bare costs are given in RS Means, while labor costs including overhead and profit (O&P) are the bare costs multiplied by the RS Means mark ups by trade shown in Table 8

- B

. 5 .2

.

Table 8

- B.5.1 RS Means 20 10 National Average Labor Costs by Crew (Standard Union)

Crew Type Crew Description Laborers per Crew Cost per Labor

- Hour

Bare Costs Incl. O&P * 2 Plum (Crew L

- 1) 2 Plumbers 2 $46.70 $70.24

1 Elec 1 Electrician 1 $ 47.00 $ 69.94 Q1 1 Plumber, 1 Plumber Apprentice 2 $42.03 $63.21
1 Carp 1 Carpenter 1 $38.10 $59.28

* Q&P includes markups in Table 8

- A.8 .2

Table 8

- B.5.2 RS Means Labor Costs Markups by Trade (Standard Union)

Trade Workers Comp. Aver

Fixed

Overhead Overhead Profit Total

Plumber 8.1% 16.3% 16.0% 10.0% 50.4%

Electrician 6.5 % 16.3% 16.0% 10.0% 48.8 % Carpenter 18.3% 16.3% 11.0% 10.0% 55.6%

RS Means also provides labor cost factors for 295 cities and towns in the U.S. To derive average labor cost values by s tate, DOE weighted the price factors by city or town population size using 200 8 census data. Since RECS 2005 household location is identified by the nine census divisions and 4 large States, DOE then population weighted the State data using 2008 Census data into the appropriate nine census divisions and 4 large States. Table 8

- B.5 .3 shows the final regional price factors used in the analysis.8

- B

- 27 Table 8

- B.5.3 Final Labor Cost Factors by Census Division and Four Large States

Census Division and 4 large states Census Division Name States Labor Cost

Factor

1 New England Connecticut, Maine, Massachusetts, New Hampshire, Rhode Island, Vermont 1.18

2 Middle Atlantic* New Jersey, Pennsylvania 1.27

3 East North Central Indiana, Illinois, Michigan, Ohio, Wisconsin 1.12

4 West North Central Iowa, Kansas, Minnesota, Missouri, Nebraska,

North Dakota, South Dakota 0.97

5 South Atlantic** Delaware, District of Columbia, Georgia, Maryland, North Carolina, South Carolina, Virginia, West Virginia 0.73

6 East South Central Alabama, Kentucky, Mississippi, Tennessee 0.75

7 West South Central*** Arkansas, Louisiana, Oklahoma 0.66

8 Mountain Arizona, Colorado, Idaho, New Mexico, Montana, Utah, Nevada, Wyoming 0.82

9 Pacific**** Alaska, Hawaii, Oregon, Washington 1.06

10 New York 1.66

11 California 1.25

12 Texas 0.66

13 Florida 0.72

* Includes New York, which is separated out as a large state. ** Includes Florida, which is separated out as a large state. *** Includes Texas, which is separated out as a large state. **** Includes California, which is separated out as a large state.

The distribution of each RECS 2005 product class sample is different, so the average labor cost weighted by RECS 2005 sample weights is different from the RS Means national average (i.e., labor co st factor of 1.00). Table 8

- A.5 .4 shows the fraction of househo lds in each division and four large states for each product class sample and the resulting average labor cost.8

- B

- 28 Table 8

- B.5.4 Final Labor Cost Factors and Fraction of Households in RECS 2005 Sample

Census Division

and 4 large states Labor

Cost

Factor Fraction of Households in RECS 2005 Sample

NWGF MHGF O F

1 1.19 3.6% 2.9% 44%

2 1.28 8.3% 4.7% 24%

3 1.12 20.2% 12.0% 0%

4 0.99 9.1% 5.4% 0%

5 0.73 7.9% 22.4% 2%

6 0.75 3.7% 11.5% 0%

7 0.66 4.1% 4.3% 0%

8 0.82 9.4% 4.6% 0%

9 1.08 2.7% 6.6% 0%

10 1.66 4.8% 1.3% 31%

11 1.23 17.4% 2.0% 0%

12 0.66 7.6% 7.7% 0%

13 0.73 1.3% 14.8% 0%

Average Labor Cost Factor 1.04 0.87 1.34

8

- B.6 CONSULTANT REPORT (EER CONSULTING)

The following is the furnace installation report prepared by EER Consulting, LLC., for Lawrence Berkeley National Laboratory (LBNL) on October 1, 2010.

8

- B.6.1 FURNACE Installation Requirements

In general, furnaces must be installed within the scope of their approvals as listed in the installation instructions and applicable local and/or natio nal installation codes such as The National Fuel Gas Code, Z223.

The following tables are a summary of the major tasks required to install a furnace in a new construction and replacement application.

Additionally, many installations will include a humidifier for winter use. A small portion of installations will have zoning systems with separate temperature control of specific areas of the home or business. Many commercial applications of weatherized equipment will have accessory parts added to the unit for ventilation, power saver (outdoor air) cooling

, and building pressure relief. Ventilation systems are commonly tied to non

- weatherized equipment and are becoming more prevalent in residential installations.

Most incorporated areas require a permit and inspection process for both new construction and furnace replacement. The inspections are based on provisions of the manufacturer’s instructions, the Fuel Gas code, ANSI Z223/NFPA 54, and local building code. Unincorporated areas may or may no t require permits and inspection, generally depending on

state law.8

- B

- 29 Manufactured (mobile) homes have their furnaces, ductwork

, and venting installed in the factory as the home is being assembled and

, as such, are not covered in typical new permitting

a nd inspection programs. The installation requirements for these units are a combination of HUD, UL, or ANSI Z21.47 codes.

All states are required to have an energy code for new construction ; however, many smaller states have not complied at this point i n time. Generally, the energy code is adopted, sometimes with exceptions, from the Residential Building Code. California and Florida are notable exceptions with individual state codes. The codes must contain provisions to use standard efficiency equipme nt for construction and specify additional system factors such as insulation value on ductwork. Texas sets and allows preapproved tradeoffs in construction packages, generally including duct insulation thickness, window characteristics, equipment

efficien cy, etc. The California code, Title 24

, requires system proof of nominal performance

with such requirements as airflow testing of installations and duct leakage testing, both on new construction and replacements.8

- B

- 30 Table 8

- B.6.1 Furnace Installation Requirements (New Co nstruction)

Gas Oil

non

- weatherized Weatherized Manufactured non

weatherized

<+80

AFUE >=90

AFUE Home

New Construction

Load calculation, equipment selection

, duct and vent/air intake design x x x X x Bid and sell the job x x x X x Procure equipment

, supplies and permit x x x X x Deliver materials for rough

- in to the jobsite x x x X x install supply air duct system

- plenum, trunk, runs, boots and registers x x x X x install return air duct system

- plenum or duct, panning, runs, registers x x x x
install air filtration x x x x install vent system and terminal x x X x install intake air system and terminal o install combustion air supply x o X x install fuel supply and shutoff x x x X install fuel supply line and tank x connect to line voltage electrical supply x x x X x
install room thermostat and wire x x x X x install condensate drain and/or pump x x rough in code installation inspection (if permits were pulled) x x x x
install hanger system for horizontal

installations x x install mounting frame, above grade applications o
install combustible base for downflow if required o o o install secondary drain pan for AC and 90% upflow and horizontal x x x
install furnace cabinet x x x X x
install AC coil x x X x Startup and checkout x x x X x Perform Title 24 or equivalent tests x x x ? x final code inspection (if permits were pulled) x x x x x= applicable to most installations o= optional with circumstances8

- B

- 31 Table 8

- B.6.2 Furnace Installation Requirements (Replacement)

Gas Oil

non

- weatherized Weatherized Manufactured

non

weatherized <+80

AFUE Replacement >=90

AFUE Home Load calculation, equipment selection, duct and vent/air intake design x x x X x Bid and sell the job x x x X x Procure equipment

, supplies and permit x x x X x Deliver materials to the jobsite x x x X x modify or replace supply plenum and AC coil mount if necessary x x x X x modify return duct or plenum if necessary x x x x modify air filtration if necessary x x x x reuse or modify vent system and terminal or reinstall as required x x X x reuse or modify intake air system and terminal or reinstall as required o review, and if necessary, install

combustion air supply x o X x disconnect and reconnect fuel supply and

shutoff x x x X disconnect and reconnect fuel supply line

and tank x disconnect and reconnect line voltage electrical supply x x x X x disconnect and reconnect or replace room thermostat as required x x x X x
reconnect or install condensate drain and/or pump x modify hanger system for horizontal installations if necessary x x install mounting frame, above grade applications o
install combustible base for downflow if required o o o install secondary drain pan for AC and 90% upflow and horizontal if needed x x x
install furnace cabinet x x x X x Startup and checkout x x x X x Perform Title 24 or equivalent tests o o o ? o Educate owner on equipment and
operation x x x X x
final installati on inspection o o o O o x= applicable to most installations o= optional with circumstances8

- B

- 32 8

- B.6.1.2 Furnace Installation Issues

The following table lists installation issues and occurrence frequencies.

Table 8

- B.6.3 Additional Installation Issues and Frequencies

Original

furnace New

Furnace New
Plastic

vent New Plastic

combustion

air pipe Water

Heater
Oversize

Common

Vent Furnace
Oversized

vent or chimney Heating

condensate

disposal Condensate

freeze

- u p Modify existing

combustion air supply

65 AFUE 78 AFUE Some Some

65 AFUE 90 AFUE Yes Some Some Some Some Some

78 AFUE 90 AFUE Yes Some Some Some Some Some

8

-

B.6.1.2.2 Plastic vent length for condensing equipment

Currently, the majority of condensing furnaces are being installed in basements

, with a smaller number in crawl spaces, garages

, and attics in the northern parts of the United States

. Typically, the furnace is installed near the center of the basement or crawl space.

In new cons truction, the venting can be vertical or horizontal. On vertical installations, the exhaust pipe (and air intake pipe when used) are easily framed into the structure walls and terminated above the roof, leaving a more attractive sidewall appearance and re ducing the chances of blockage due to snowdrifts. A reasonable estimate is 60% of installations are

vertical. The remainder is horizontal, with the vent generally running through the floor joists to a termination on the outside of the sill plate. Two

- st ory homes that have an upstairs and downstairs furnace generally have them both located in the basement ; however, mount ing the upstairs unit in the attic is becoming more common

.

The a verage length of run for vertical and horizontal installations in new construction is around 20 feet. An example is a 4

- foot rise off the furnace and a 12

- to 15

- foo t horizontal run to the sidewall of the house. In many instances a foot or two of pipe is required on the outside of

the home for clearance to normal snowfall. A typical single

- story vertical vent is 4 feet to the first floor, 8 feet through the first floor

, 7 feet in the attic

, and one foot above the roof. A t wo

story vertical vent would be another 9 feet longer than the average single story, and in a

multifa mily building it would typically be 5 to 10 feet shorter.

About 75 % to 80% of replacement furnaces in the current market are condensing units

that are sidewall vented, with the intake and exhaust pipes running horizontally through the ceiling joists and exiting the sill plate. In some instances, a PVC vent and intake may be installed in the dormant vertical vent or chimney.

Pipe material is generally PVC, Schedule 40

, or other grades as specified by the furnace manufacturer, with diameters of 2, 2.5

, or 3 inches depending on the manufacturer’s instructions for pressure drop, input (flow)

, and physical layout.8

- B

- 33 If an increasing number of States adopt th e requirement to install condensing furnaces

, as proposed in the joint agreement, homes in more southern areas will fall under this requirement

, providing an estimated 10 %

- 20% increase in the number of horizontal or downflow furnaces , as opposed to upflow, in the total condensing market balance. Horizontal furnaces in attics and downflow furnaces in closets or garages in single

- story homes generally will be vented vertically rather than horizontally.

8

-

B.6.1.2.3 Combustion air piping for condensing equipment (new plas tic pipe and modifying existing combustion air supply)

Many of the most common “standard” models of condensing furnaces today are certified to be installed as either a Central Furnace with only an exhaust pipe and predefined termination,

or as a Direct

- V ent (sometimes called separated combustion) central furnace with an intake air pipe and predefined termination in addition to the exhaust requirements of the central furnace. The “better” tier of furnace offerings ha s the same venting flexibility, and the “best” generally

are direct vent.

The standard and better units installed as Central Furnaces must meet the code requirements for c ombustion and dilution air. Specific requirements are found in local codes, a manufacturer’s instruction s, or the Natio nal/International Fuel Gas codes.

Basically, the codes require no specific combustion air supply if the furnace is installed in a large volume room and the house is not unusually “tight” in terms of leakage of outdoor air

into the house. If the home a nd furnace room do not meet the volume and tightness requirements, a combustion air supply must be installed in order for the furnace to be installed as a Central Furnace (exhaust pipe only) or it must be installed as a Direct Vent (intake air and

exhaust pipes). Direct vent is often also selected where the combustion air supply may contain contaminants that would add to the corrosiveness of the condensate, such as home shops used for finishing furniture or commercial cleaning operations.

To meet the co mbustion air volume requirement, a 75,000

- B tuh

- furnace and 35,000

- Btuh

- water heater installation would require a room about 25 ft x 25 ft x 8 ft. To satisfy the combustion air requirement totally by a duct (or ducts) to the outside for combustion air delivery to the furnace and water heater requires a 7

- inch

- diameter duct located at the top of the closet. Some jurisdictions will allow a combination of the volume method and combustion air duct for compliance. Hopefully this gives a feel for the typica l code requirements, and more information can be developed as needed.

N ationwide from 50% to 60% of all condensing furnace installation s are estimated to be

direct vent , with the rest being central furnace installations . The adoption of regional standar ds may shift this ratio slightly toward more central furnace installations.8

- B

- 34 Table 8

- B.6.4 Differences of Direct Vent fractions by location

Installation Location Fraction of Installations Requiring

Direct Vent

Basement Heated 67

Basement Unheated 33 Crawlspace 33 Indoor (Closet, Alcove, Utility Room, etc.) 67

Attic Conditioned 67

Attic Unconditioned 33 Garage 100

Current generation “good” and “better” furnaces are certified to be installed as either

direct vent or central furnaces. The installation selection is typically Central Furnace except where special situations exist such as : 1) the additional cost of direct vent versus providing a combustion air supply ; 2) the presence of corrosive materials in the indoor air supply ; and 3) the

acoustics , or the indoo r combustion air noise

, of the installation. “Best” models are generally certified only as Direct Vent.

8

-

B.6.1.2.4 Chimney Relining & Water heater oversizing in common vent situations (Orphaned water heater)

When a condensing furnace is installed as a replacemen t for a Category I (natural draft or induced draft) furnace that is common ly vent ed with a gas water heater, the common vent may be oversized for the remaining (orphaned) water heater.

A past estimate of common ly vented furnaces and water heaters was a bout half of all Category I installations. The common vent is traditionally either a metal “B” vent or a masonry chimney. Across the U nited S tates , metal B vents are used about three to four times more often

than are masonry chimneys. The ratio is lower , perhaps 2:1 or 3:1 in areas with older homes, particularly in the northeastern parts of the U nited S tates . The introduction of i nduced draft

furnaces and boilers in the 1980s led to extensive research on common vents and new code provisions to prevent oversizing of the vents for orphaned water heaters

, while severely limiting the use of external masonry chimneys and vents. Vent connectors from the appliances also generally necessitat e a change from a single

- wall pipe requirement to a double

- wall (B ven t) specification. ( S ee Appendix A for examples of vent and chimney sizing based on the National

Fuel Gas Code table

. ) The most likely homes to require a new vent for an orphaned water heater originally had a large capacity natural draft furnace and in many cases a masonry common vent. Over time, the heat load of the home was reduced with insulation, sealing, new windows, and other measures

, permitting the furnace input size to be reduced. When the older furnace is removed, the existing

common vent is over sized for the water heater.

The “fixes” that are applied for an orphaned water heater are usually selected for the economics of completing the installation, and some will be influenced by future operating costs.8

- B

- 35 The m ost common fix is to install a new , smaller B vent in the existing common metal vent or masonry chimney chase. However, some relining of masonry chimneys with cast

- in

- place liners

may also be done. Power

- vent water heaters or tankless water heaters with sidewall venting are

another more cost ly option employed whe n the customer is energy conscious and willing to pay

also for a new, more expensive water heater. In 5 % to 10% of these instances, a new, electric water heater is installed to replace the gas unit , because this is a less expens ive alternate to a separately vented water heater. A reasonable estimate would be that from 20 % to 25% of common vents result in orphaned water heaters. The following table shows the s cenarios for venting systems and frequencies.

Table 8

- B.6.5 Scenarios for Venting Systems and Frequencies Existing Equipment Replacement Equipment Installation Requirement Frequency

65% AFUE 80 % AFUE Convert from single wall to B Type

vent Connectors 75%

65% AFUE 80% AFUE Resizing Vent System 10%

65% AFUE 90% AFUE Convert Water H eater from single wall to B Type vent Connector 100%

65% AFUE 90% AFUE Resizing Orphaned Water Heater Chimney or upgrading Metal Vent 40%

80% AFUE 90% AFUE Resizing Orphaned Water Heater Chimney or upgrading Metal Vent 20%

As mentioned above, the weatherization of homes can create a reduction in furnace input size when replacements are installed.

8

-

B.6.1.2.5 Condensate

Condensate Removal from Condensing Furnace

. If there is no drain close to a newly installed condensing furnace (about 20% of installations) through which condensate can be removed, then adding a pump is common . However, if an evaporator coil exists that has already a condensate

pump , then that pump is usually used to remove the furnace condensate too. In most ba sement installations the furnace will be close to a drain. In new construction, adding a pump is less likely to be needed, because the builders generally plan in advance how to handle the condensate. Neutralizer filters are not that common any longer ; t h ey have problems with plugging up.

Condensate Freezup . Based on a review of Lennox and Carrier installation instructions, it is necessary to apply insulation and electric heat tapes to condensate traps, condensate pumps

, and drain lines in unconditioned spaces that may be subject to freezing in order to prevent condensate from freezing and potential nuisance shutdowns or breakage of plastic parts. The heat tape is to

be self

- regulating

— limit ing its own temperature by var ying resistance

— or its temperature must

be externally regulated with specific limits on watts per unit of drain area.8

- B

- 36 Whether or not to apply insulation and heat tape on units in unconditioned spaces is mostly based on the installers’ judgment. Personal experience with an attic installation that had

an insulated condensate line

, but no heat tape

, in Dallas indicates some freezing can be expected during night setback and when the ambient temperature is in the 10 °F

- 20 °F range. If this system had an exte rnal condensate trap, or condensate pump, it would need heat tape to prevent damage.

The majority of installations in unconditioned spaces that are subject to prolonged freezing temperatures should include insulating condensate handling parts and the app lication of a regulated heat tape. E xample s of such unconditioned spaces include unconditioned attics, crawl space s , and exterior closet s

.

8

-

B.6.1.2.6 Special considerations for manufactured home furnaces

Traditionally, furnaces installed in manufactured housing (mobile homes) have a special design

, such as a direct

- vent, downflow configuration unit of a natural draft design (sometimes

called a balanced flue) or more recently an induced draft, 75 %

- 80% AFUE direct

- vent furnace. Physical size and design are particu lar to a standard

- size closet with return air through the front of the cabinet. Two manufacturers, Coleman and Nordyne supply more than 90 % of the market. Standards for mobile homes construction and approvals are specified by HUD.

Replacements usually are the current version of the 75 %

- 80 % AFUE OEM mobile home furnace, although, where codes permit, traditional condensing furnaces from all manufacturers

have been installed in a direct

- vent configuration for increased energy savings. A quick search

does not indicate a condensing furnace option in new homes.

Modular homes, another subset of manufactured housing

, are commonly available with minimum efficiency furnaces or , as an upgrade option

, a condensing furnace. In a limited

number of homes observed in the Midwest, the furnace ha d been installed at the jobsite, usually

in a basement that was constructed as the foundation for the modular home.

8

- B.6.2 Furnace Installation Costs

There are nearly an infinite number of variables inherent in the installation or replacement of a furnace, thus making it impossible to estimate an average installation cost with any degree of certainty. Depending on the specific job, some or all of the basic tasks listed above are performed. The installer’s labor, material

, and over head costs also vary widely, compound ing the difficulty in estimating average installation costs. Some state requirements

, such as California’s Title 24, include duct and airflow performance measurements and minimum performance standards, again adding to t he variability of the cost. And how is the installation cost apportioned when both the furnace and air conditioner are installed or changed out? Or filtration and control upgrades such as night setback thermostats or zone controls are added? Also, how should the benefits of weatherization programs or rebate programs, such as federal tax

credits or state, municipal

, and utility rebates, be assigned ?8

- B

- 37 A study to estimate “typical” costs could be performed through surveys of installers in multiple geograp hic regions, or by specifying a limited set of “typical installations” and estimating their costs based on geographic differences in equipment requirements, labor

, and overhead. Such a study would be far larger than the scope of this project allows.

H owever, based on experience, some guidance can be provided on the range of costs today. A non

- weatherized furnace replacement could be expected to be in the range of $1

, 500 to $40

, 00 for basic 80 % or 90 % AFUE equipment depending on the degree of difficulty in the change

- out and local rates. Replacement of the air conditioning system at the same time as the furnace adds $2

, 000 to $5

, 000 for lower SEER equipment with standard controls. Top

- of

- the

line furnaces and air conditioners with advanced controls, enhanced filtration, and other features can top $10

, 000 per system.

New construction will also vary widely for the reasons mentioned previously, as well as geographic differences in construction

, such as location, rigid or flex duct, length of vents, ease of condensate disposal, high volume tract housing vs. a single custom home, and more

. Minimum efficiency systems could be expected to range from $5

, 000 to $8

, 000 per system.

8

- B.6.2.1 Additional Installati on Costs

The c ost of r elining a chimney in general is around $300

- $700. In about 10% of

installations that requir e chimney relining the cost could be as high as $1,000

- $1,200.

8

- B.6.3 Regional D ifferences

In addition to the regional items noted elsewhere in t his report , the following regional considerations may also affect the cost of furnace installations.

Predominantly Heating C limates (Northern)

This area tends to have a higher proportion of condensing furnace installations rather than

non

- condensing units. In replacement situations, this requires some additional installation work and cost. A new plastic vent (and perhaps air intake) and termina tion must be installed, along

with a means of condensate disposal. Because many of these homes originally had metal or masonry common vents for the furnace and water heater

, it is not uncommon for a new vent to
be required for the water heater to operate properly.

Supply and return ductwork tends to be in the basement, consisting of rigid metal with rigid takeoffs and

, in some cases

, a short flex duct run to the register boot. These systems generally require more labor than average for installation in n ew construction.

Predominantly Cooling C limates (Southern)8

- B

- 38 HVAC equipment and ductwork tend to be installed in the attic space, requiring additional secondary drain pans for condensing furnaces and air conditioner coils. Condensate is generally gravity piped to the home drainage system. In the portion of this area subject to freezing attic temperatures, heat tapes may be necessary to insure condensate drainage from condensing furnaces located in non

- conditioned locations.

Supply and return duc twork generally consists of rigid plenums with flex duct supply and return runs. Building cavities are often used as a part of the return air system.

8

- B.6.4 Furnace Installation Locations

The following table is an estimate of a snapshot of the currently install ed furnace population.

Table 8

- B.6.6 Estimated Furnace Installations, 2009

gas non

- weatherized,

80% interior

% % by closet exterior

Position basement attic except

basement crawlspace garage closet

I ndoor upflow 58 40 3 10 4 1

horizontal 35 24 11

downflow 7 3 4

gas non

- weatherized,

90% interior

closet exterior

basement attic except

basement crawlspace garage closet

I ndoor upflow 7 7 6 7 2 4 3 1

horizontal 16 6 10

downflow 7 5 2

oil non

- weatherized Garage or

basement crawlspace closet

I ndoor upflow 90 90

horizontal 5 5

downflow 5 5

gas weatherized sidewall

rooftop or on grade

outdoor horizontal 40 30 10

downflow 60 55 5

No definitive statistics are available regarding installations, and the following discussion will present some of the thought behind the estimates listed above. Furnaces are now commonly8

- B

- 39 built in horizontal upflow , horizontal downflow

, or true multi

- position configurations, thereby eliminating the information on configuration previously available in GAMA statistics.

Some clues to furnace type and location can be gleaned from foundation type. Residences with basements represe nt one of the largest segments of the existing foundation
types. According to Cens us statistics, currently about 3 0% of h omes are built with basements,

5 0% on slabs

, and 20% with crawlspace foundations. Thirty years ago, the equivalent statistics

were 4 0 % , 40 %

, and 20% respectively, showing the trend to a larger percentage of US

construction in the south and west.

The foundation type is important because, when a basement is present, generally an upflow furnace and basement or first

- floor ductwork are located therein. Two

- story homes with basements may be served by one furnace, or the second floor may be served by a second upflow furnace located in a closet on the second floor, or a horizontal in the attic. In a limited number of applications, a weathe rized unit may be mounted on or next to the foundation wall and connected to ductwork through this wall.

Basement construction tends to be standard in about two thirds of the U nited S tates

, primarily the Northeast and Midwest portions. States such as Washington, Oregon, California, Nevada, Arizona, New Mexico, Texas, Oklahoma, Arkansas, Louisiana, Mississippi, Alabama, Georgia, Florida, South and North Carolina

, and Hawaii are predominately slab or crawl space

construction.

Slab foundations generally have the furnace and duct system in the attic in primarily cooling climates. The use of a closet and an upflow furnace in the conditioned space is declining in single

- story slab homes. Homes in climates with significant heating demand may have the

duct s ystem buried in the slab foundation (Oklahoma

, for example). Two

- story slab homes generally have one or two furnaces with upper

- story ductwork and one or two furnaces located in

the attic.

Single

- story crawl space homes generally have a horizontal furnace and duct work located in the crawl space. Some have weatherized furnaces located next to the foundation. Parts of California and Arizona have concentrations of existing roof

- mounted non

- weatherized

furnaces and air conditioners on r esidences. Ten nessee and the surrounding states also make use

of non

- weatherized packages on grade in new and replacement for applications. Commercial applications of non

- weatherized furnaces are generally in basements or utility

closets or rooms, although some will als o be in attic spaces. The majority of weatherized units for this application will be roof mounted.

Condensing furnaces tend to be concentrated in states requiring the most heating, and

non

- condensing furnaces tend to be in those states with less heati ng and greater cooling needs. Oil furnaces are primarily found in the n ortheastern states, with a few in the Midwest and Northwest. Gas manufactured (mobile) home furnaces tend to have a special direct

- vent, downflow design that is suited to a standardize d closet

- size application.8

- B

- 40 8

- B.6.5 Fraction of Common Vents

There is no data available to reference for determining how many furnaces and water heaters are common vented. In the mid 1980s, as condensing furnace installations became more common, industry opinion held that a good estimate of common vents in all homes was in the

50 %

- 70% range, with more in the basement in heating climates. The growth of condensing furnace sales, code requirements that limit common venting with induced draft non

- condensing

furnaces , the issues with condensation in masonry chimneys

, and the shift of new construction to

the S outh and W est have caused a significant decline in the percentage of common vents. A reasonable estimate of today’s installed base might be in the 20 %

- 30% range.

8

- B.6.6 Additional Information about Weatherized Furnaces

Most states have some installations of weatherized furnaces i n residences. The largest

concentrations are found in three or four states . California and Arizona have a significant replacement market for ro of

- mounted units. Tennessee and the surrounding areas have many
units mounted on grade, in both the new construction and replacement market. Florida may also have a significant number of installations.

Commercial use of non

- weatherized units is universal in all states for small offices, retail,

and other uses . Most are mounted on the roof, although a small percentage are on exterior wall

supported platforms or on grade.

Residential use is probably driven by ease of replacement, freeing up floor or yard s pace
for other use s , cost effectiveness

, as well as some because “that’s the way we’ve always done it

around here”.

Air conditioning condensate is either piped into a drain, or dumped on the roof depending on local codes and conventions. Currently there are no, or very few, condensing heat sections in these units. Condensate disposal issues primarily associated with freeze

- up are the major impediment to the satisfactory mass application of condensing technology to condensing

furnaces.

8

- B.6.7 Appendix A: Example s of vent and chimney sizing based on the National Fuel

Gas Code table

I pulled down a copy of the GAMA venting tables that is probably close, if not identical to the current code tables and ran a couple examples similar to our conversation last night.

Let's assume a home originally had a 125Kbtuh furnace and 35 kbtuh water heater, both atmospheric, cat 1. Also assume the common vent is metal B vent and was 15 ft high, and the connectors for the two appliances were single wall. Connector length is 5 fe et with a one foot

rise.8

- B

- 41 Originally, the common vent would have been 6" dia B vent (or larger) at the installers option. For starters, let's assume 6".

Let's say the first replacement was a 125kbtuh fan assisted. The venting tables would say

the fan assist appliance must be 144k minimum and the installer would be faced with a choice of going to 5" common vent or double wall vent connector. Undoubtedly they would choose to use

the double wall vent connectors.

Next, let's assume the original equipmen t was oversized and the home had been weatherized, and a heat loss analysis yielded a 75kbtuh fan assist furnace as the replacement. As long as he uses a double wall vent connector, 4 or 5", the installation is ok. However, had the original common vent b een 7", it would need to be relined with 5 or 6".

Next, let's assume the furnace is removed from the common vent (condensing installed with separate vent system). The venting tables have no minimum for atmospheric, and allow the water heater with typic al 3 inch draft hood outlet on the 6" common vent. However to be compliant, it must meet the 7 times oversize rule. The 3" dia draft hood outlet is 7.1 square inches, and the 6 in common vent is 28 sq in, therefore it passes the 7* test. However, if the common vent were 8", it would not and the vent would have to be relined.

There are millions of combinations of variables making it difficult to generalize about when resizing is needed and when not. However, larger vents from older atmospheric

installa tions are more likely to require upgrading the vent connector and/or downsizing the

common vent.

A couple observations to remember on masonry common vent (chimney). First as I recall, the vent tables apply to internal, not external chimneys. External a utomatically need upgrading, at least in colder climates. Masonry were generally a minimum 8x8 or 8x12 tile (non tile lined, brick only, are not usable without lining) and as such are more apt to be oversized for both the change to a fan assist furnace, o r orphaned water heater.8

- B

- 42 REFERENCES

1. RS Means Company Inc., RS Means Residential Cost Data . 29th Annual Edition ed. 2010: Kingston, MA

2. U.S. Department of Energy

- Energy Efficiency & Renewable Energy, Technical Support

Document : Energy Efficiency Standards for Consumer Products: Residential Furnaces

and Boilers , 2007. Washington, DC.

3. RS Means Company

, Facilities Maintenance & Repair Cost Data 20 10 . Kingston, MA.

4. U.S. Department of Energy

- Energy Efficiency & Renewable Energy, Technical Support Document: Energy Efficiency Standards for Consumer Products: Residential Water

Heaters , 2001. Washington, DC.

5. Smith, D. C., Consultant Report

- Water Heater Installation Costs , 2008. Florence, SC.

6. RS Means Com pany Inc., 2010 Mechanical Cost Data . 2010 . Kingston, MA.

7. U.S. Department of Energy: Energy Information Administration, Residential Energy Consumption Survey: 2005 Public Use Data Files . 2008: Washington, DC. http://www.eia.doe.gov/emeu/recs/recspubuse05/pubuse05.html

8. Jakob, F. E., J. J. Crisafulli, J. R. Menkedick, R. D. Fischer, D. B. Philips, R. L. Osbone, J. C. Cross, G. R. Whitacre, J. G. Murray, W. J. Sheppard, D. W. DeW irth, and W. H. Thrasher, Assessment of Technology for Improving the Efficiency of Residential Gas Furnaces and Boilers, Volume I and II

- Appendices, September, 1994. Gas Research Institute. AGA Laboratories, Chicago, IL. Report No. GRI

- 94/0175.

9. D.D. Paul et al., Assessment of Technology for Improving the Efficiency of Residential
Gas Water Heaters, December, 1991. Battelle. Columbus. Report No. GRI

- 91/0298. GRI/GATC Water Heater NAECA Analysis.

10. National Fire Protection Association, National Fue l Gas Code

- 2002 Edition , 2002. 1 Batterymarch Park, P.O. Box 9101, Quincy MA.

11. Gas Appliance Manufacturers Association (GAMA), Updated Shipment Data for Residential Furnaces and Boilers, personal communication. April 25, 2005.

12. Air

- Conditioning Heating and Refrigeration Institute, AHRI Regional Furnace Shipments
Data, 2010. (Posted Submitted to DOE on July 20, 2010)

< http://www.ahrinet.org/Content/Furnaces_609.aspx >