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TECHNICAL SUPPORT DOCUMENT: 

RESIDENTIAL FURNACE AND BOILER ENERGY EFFICIENCY STANDARD

TABLE OF CONTENTS

CHAPTER 1. INTRODUCTION

1.1 PURPOSE OF DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 OVERVIEW OF APPLIANCE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 OVERVIEW OF RESIDENTIAL FURNACES AND BOILERS STANDARDS . . . . 1-2

1.3.1 Issues Related to Venting of Residential Furnaces and Boilers . . . . . . . . . . . . 1-6

1.3.1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.3.1.2 Summary of Stakeholder Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.3.1.3 Department of Energy Analysis Considerations . . . . . . . . . . . . . . . . . . 1-9

1.4 STRUCTURE OF THE DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

CHAPTER 2. ANALYTIC FRAMEWORK

2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3 MARKET AND TECHNOLOGY ASSESSMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3.1 Market Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3.2 Technology Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3.3 Product Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.4 SCREENING ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5 ENGINEERING ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5.1 Baseline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5.2 Manufacturing Cost Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5.3 Markup Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.5.4 Installation Cost Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.6 LIFE-CYCLE COST AND PAYBACK PERIOD ANALYSIS . . . . . . . . . . . . . . . . . . 2-8

2.7 NATIONAL IMPACTS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.7.1 Shipments Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.7.2 National Energy Savings Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.7.3 Net Present Value Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.8 LIFE-CYCLE COST SUBGROUP ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.9 MANUFACTURER IMPACT ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.9.1 Industry Characterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.9.2 Industry Cash Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.9.3 Manufacturer Sub-Group Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.9.4 Interview Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.9.5 Competitive Impact Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.10 UTILITY IMPACTS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.11 NET NATIONAL EMPLOYMENT IMPACT ANALYSIS . . . . . . . . . . . . . . . . . . . . 2-15
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2.12 ENVIRONMENTAL ASSESSMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.13 REGULATORY IMPACT ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

CHAPTER 3. MARKET AND TECHNOLOGY ASSESSMENT

3.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 TECHNOLOGY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.1 Furnace Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.1.1 Types of Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2.1.2 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.1.4 Mobile Home Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.2.1.5 Electric Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.2.1.6 Input Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.2.1.7 Electricity Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.2.2 Boiler Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.2.2.1 Types of Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.2.2.2 Boiler Input Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.2.2.3 Boiler Electricity Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.2.3 Combination Space- and Water-Heating Appliances . . . . . . . . . . . . . . . . . . . 3-15

3.3 EFFICIENCY CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.3.1 Efficiency Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.3.2 Furnace Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.3.3 Boiler Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.3.4 Combination Space- and Water-Heating Appliances . . . . . . . . . . . . . . . . . . . 3-21

3.4 MARKET FOR FURNACES AND BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.4.1 Shipments Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.4.2 Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.4.3 Distribution Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

CHAPTER 4. SCREENING ANALYSIS

4.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 DISCUSSION OF DESIGN OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1 Design Options that Passed Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1.1 Improved Heat Exchanger Effectiveness . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1.2 Modulating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2.1.3 Increased or Improved Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.2.1.4 Condensing Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.2.1.5 Electronic Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.2.1.6 Induced and Forced-Draft Combustion Systems . . . . . . . . . . . . . . . . 4-9

4.2.1.7 Infrared Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.2.1.8 Direct Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.2.1.9 Fuel Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
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4.2.1.10 Pulse Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.2.1.11 Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.2.1.12 Air-atomized Burner with Modulation . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.2.1.13 Delayed-Action Oil-Pump Solenoid Valve . . . . . . . . . . . . . . . . . . . 4-14

4.2.1.14 Increased Motor Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.2.1.15 Increased Blower Impeller Efficiency . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.2.2 Design Options Eliminated from Further Consideration . . . . . . . . . . . . . . . . . 4-15

4.2.2.1 Self-Generation of Electric Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.2.2.2 Fuel-Driven Heat Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.2.2.3 Flue-Gas Recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.2.2.4 Smart Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.3 SUMMARY OF SCREENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

CHAPTER 5. MARKUPS FOR EQUIPMENT PRICE DETERMINATION

5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 Baseline Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.1.2 Incremental Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2 MANUFACTURER MARKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.1 Estimation of Manufacturer Markup Probability Distribution . . . . . . . . . . . . . 5-5

5.3 WHOLESALE AND CONTRACTOR MARKUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3.1 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3.2 Estimation of Wholesaler Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.3.2.1 Estimation of Wholesaler Markup Probability Distribution . . . . . . . . . . . . . . . 5-8

5.3.3 Estimation of Contractor Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.3.3.1 Contractor Markups in the Replacement and New Construction 

Markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.3.3.2 Estimation of Contractor Markup Probability Distribution . . . . . . . . . 5-12

5.4 BUILDER MARKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.5 MARKUP FOR MOBILE HOME GAS FURNACES . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5.6 SALES TAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5.7 OVERALL MARKUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

CHAPTER 6. ENGINEERING ANALYSIS

6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 PRODUCT CLASSES CONSIDERED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 IDENTIFICATION OF BASELINE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.4 MANUFACTURING COST ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 Generation of Bills of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4.1.1 Teardown Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4.1.2 Modeling Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.4.2 Approach for Condensing Boilers and Mobile Home Furnaces . . . . . . . . . . . 6-11

6.4.3 Cost Model and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
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6.4.3.1 Outsourcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.4.3.2 Greenfield Facility Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.4.3.3 Production Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6.4.3.4 Generating Production-Cost Results . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.4.4 Sensitivity Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.4.5 Curves of Manufacturing Cost Versus Efficiency . . . . . . . . . . . . . . . . . . . . . . 6-20

6.5 INSTALLATION COSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6.5.1 Data Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6.5.1.1 Installation Model Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6.5.1.2 Installation Model Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.5.1.3 Model Results Compared to Other Data . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.5.2 Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

6.5.3 Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.5.4 Mobile Home Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6.5.5 Oil-Fired Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6.5.6 Hot-Water Gas Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6.5.7 Hot-Water Oil-fired Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

6.6 MAINTENANCE COST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

6.7 ENGINEERING ANALYSIS PAYBACK PERIODS . . . . . . . . . . . . . . . . . . . . . . . . 6-39

6.7.1 Calculation of Fuel Consumption for Each Design Option . . . . . . . . . . . . . . . 6-39

6.7.2 Calculation of Electricity Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6.7.3 Derivation of Fuel Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6.7.4 Rebuttable Payback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6.7.4.1 Rebuttable Payback Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6.8 ENGINEERING SPREADSHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

CHAPTER 7. ENERGY CONSUMPTION OF FURNACES AND BOILERS

7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 METHOD FOR NON-WEATHERIZED GAS FURNACES . . . . . . . . . . . . . . . . . . . . 7-1

7.3 VIRTUAL FURNACE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.3.1 Basic Actual Furnace Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3.2 Input Capacity and Maximum Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3.2.1 Non-weatherized gas furnaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3.2.2 Other Product Classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.3.3 Blower Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.3.4 Motor Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.3.5 Supply-Air Outlet Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.3.6 Power Consumption of Draft Inducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.3.7 Delay Times and Ignitor Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.4 ASSIGNING EXISTING EQUIPMENT TO SAMPLE HOUSES . . . . . . . . . . . . . . . 7-11

7.4.1 Furnace Input Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.4.2 Airflow Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.4.3 Efficiency Characteristics of Existing Equipment . . . . . . . . . . . . . . . . . . . . . . 7-13
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7.4.4 Electricity Consumption of the Existing Furnace Blower . . . . . . . . . . . . . . . . 7-14

7.5 CALCULATING FURNACE BLOWER ELECTRICITY CONSUMPTION . . . . . . 7-14

7.5.1 System Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7.5.2 Furnace Fan Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7.5.3 Overall Air-Moving Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7.5.4 Blower-Motor Electricity Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7.6 ANNUAL HEATING AND COOLING LOADS IN SAMPLE HOUSES . . . . . . . . . 7-21

7.6.1 Annual House-Heating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7.6.2 Annual House-Cooling Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7.7 FURNACE ENERGY CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7.7.1 Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7.7.2 Electricity Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7.8 BOILER ENERGY CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7.9 RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7.9.1 Non-Weatherized Gas Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7.9.2 Weatherized Gas Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7.9.3 Mobile Home Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7.9.4 Oil Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7.9.5 Gas Boiler Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7.9.6 Hot-Water Oil Boiler Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

CHAPTER 8. LIFE-CYCLE COST AND PAYBACK PERIOD ANALYSIS

8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1.1 General Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.2.1 Design Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.2.2 Data Set for Calculating LCCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.2.2.1 New Construction versus Replacement Installations . . . . . . . . . . . . . . 8-13

8.3 INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.3.1 First-Cost Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.3.1.1 Manufacturing Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8.3.1.2 Installation Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8.3.1.3 Finance Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.3.2 Operating-Cost Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.3.2.1 Energy Prices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8.3.2.2 Maintenance Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

8.3.3 Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8.3.4 Discount Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8.3.4.1 Approach for Estimating Discount Rates . . . . . . . . . . . . . . . . . . . . . . 8-22

8.3.4.2 Discount Rate Applied to New Housing Equipment . . . . . . . . . . . . . . 8-23

8.3.4.3 Discount Rate Applied to Replacement Equipment . . . . . . . . . . . . . . 8-23

8.3.4.4 Accounting for Variation in Discount Rates . . . . . . . . . . . . . . . . . . . . 8-24

8.3.5 Payback Period Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
1-vi

8.3.6 Summary of Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8.4 RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8.4.1 Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

8.4.2 Other Product Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

CHAPTER 9. SHIPMENTS

9.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 REPLACEMENTS AND CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2.1 Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.2.2 Replacement and Conversion Estimates for 2000 . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.3 SHIPMENTS TO NEW HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.3.1 Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.3.2 New Housing Projections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9.3.3 Heating Equipment Market Share in New Housing . . . . . . . . . . . . . . . . . . . . . 9-6

9.4 PROJECTED TOTAL SHIPMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

CHAPTER 10. NATIONAL IMPACT ANALYSIS

10.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2 NATIONAL ENERGY SAVINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.2.2 National Energy Savings Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10.2.2.1 Annual Energy Consumption per Unit . . . . . . . . . . . . . . . . . . . . . 10-3

10.2.2.2 Shipments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10.2.2.3 Equipment Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

10.2.2.4 National Annual Energy Consumption . . . . . . . . . . . . . . . . . . . . . 10-5

10.2.2.5 Site-to-Source Conversion Factor . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

10.2.2.6 Summary of Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10.3 CONSUMER IMPACTS: NET PRESENT VALUE . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.3.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.3.2 Net Present Value Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10.3.2.1 Total Annual Installed Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10.3.2.2 Total Annual Operating Cost Savings . . . . . . . . . . . . . . . . . . . . . . 10-8

10.3.2.3 Discount Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

10.3.3 Present Value of Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

10.3.4 Present Value of Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

10.4 NES AND NPV RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

10.4.2 Results Using Three Percent Discount Rate as a Sensitivity . . . . . . . . . . . . . 10-14

10.5 NES AND NPV SPREADSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

CHAPTER 11. LIFE-CYCLE COST SUB-GROUP ANALYSIS

11.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
1-vii

11.2 PURCHASE PRICE INCREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

CHAPTER 12. MANUFACTURER IMPACT ANALYSIS

12.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.2 METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.2.1 Phase 1: Industry Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.2.2 Phase 2: Industry Cash Flow Analysis and Interview Guide . . . . . . . . . . . . . . 12-2

12.2.2.1 Industry Cash Flow Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12.2.2.2 Interview Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12.2.3 Phase 3: Sub-Group Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12.2.3.1 Manufacturer Interviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12.2.3.2 Revised Industry Cash Flow Analysis . . . . . . . . . . . . . . . . . . . . . . 12-4

12.2.3.3 Manufacturer Sub-Group Analysis . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12.2.3.4 Competitive Impact Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12.2.3.5 Manufacturing Capacity Impact . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

12.2.3.6 Employment Impacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

12.2.3.7 Cumulative Regulatory Burden . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

12.3 RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12.3.1 Phase 1 – Industry Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12.3.2 Phase 2 – Industry Cash Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12.3.3 Phase 3 – Sub-Group Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

CHAPTER 13. UTILITY IMPACT ANALYSIS

13.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

13.2 METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

13.3 RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

CHAPTER 14. EMPLOYMENT IMPACTS ANALYSIS

14.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

14.2 ASSUMPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

14.3 METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

ENVIRONMENTAL ASSESSMENT

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EA-1

2.0 METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EA-1

3.0 RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EA-2

REGULATORY IMPACT ANALYSIS FOR RESIDENTIAL FURNACES AND

BOILERS
1-viii

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIA-1

2.0 METHODOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIA-1

APPENDIX 5.1. DETAILED DATA FOR EQUIPMENT PRICE MARKUPS

5.1.1 INTRODUCTION ................................................... 5.1-1

5.1.2 DETAILED WHOLESALER DATA .................................... 5.1-2

5.1.3 DETAILED BUILDER DATA ......................................... 5.1-3

5.1.4 DETAILED CONTRACTOR DATA .................................... 5.1-4

5.1.5 ESTIMATION OF MARKUP STANDARD DEVIATIONS .................. 5.1-5

5.1.6 ESTIMATION OF FRACTION OF GAS FURNACE SHIPMENTS TO NEW

CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-10

APPENDIX 6.1. TECHNICAL DESCRIPTION OF THE REVERSE ENGINEERING

COST ESTIMATION METHODOLOGY

6.1.1 INTRODUCTION .................................................. 6.1-1

6.1.2 TEAR-DOWNS .................................................... 6.1-1

6.1.2.1 General Tear-Down Practice ..................................... 6.1-1

6.1.2.2 Specific Product Class Features ................................... 6.1-2

6.1.2.3 Weight Confirmation of Tear-down Results ......................... 6.1-2

6.1.2.4 Final Confirmation of Tear-down Results .......................... 6.1-2

6.1.2.5 General Tear-down Practice of “Hypothetical” Units .................. 6.1-3

6.1.3 CREATING THE TEAR-DOWN BILL OF MATERIALS ................... 6.1-4

6.1.4 ADDITIONAL PRODUCTION COST DATA ............................. 6.1-5

6.1.4.1 Labor and Factory Overhead ..................................... 6.1-5

6.1.4.2 Depreciation .................................................. 6.1-5

6.1.4.3 Parts and Materials ............................................ 6.1-6

6.1.5 STRUCTURE OF THE COST MODELS ................................. 6.1-8

6.1.5.1 Main Cost Model ............................................. 6.1-8

6.1.6 SENSITIVITY ANALYSIS RESULTS ................................. 6.1-12

APPENDIX 6.2. INSTALLATION COST MODEL

6.2.1 INTRODUCTION ................................................... 6.2-1

6.2.2 DESCRIPTION OF VENTING OPTIONS AND CONFIGURATIONS ......... 6.2-2

6.2.2.1 Market ...................................................... 6.2-3

6.2.2.2 Furnace Category .............................................. 6.2-3

6.2.2.2.1 Non-Condensing ..................................... 6.2-4

6.2.2.2.2 Near-Condensing ..................................... 6.2-4
1-ix

6.2.2.2.3 Condensing ......................................... 6.2-4

6.2.2.3 Existing Vent Type ............................................ 6.2-5

6.2.2.3.1 Masonry Chimney .................................... 6.2-5

6.2.2.3.2 Type B Double Wall Metal ............................. 6.2-6

6.2.2.3.3 Plastic PVC ......................................... 6.2-7

6.2.2.4 Chimney Liner ................................................ 6.2-7

6.2.2.4.1 Exterior Chimneys .................................... 6.2-8

6.2.2.4.2 Interior Chimneys .................................... 6.2-8

6.2.2.5 Existing Vent Connector ........................................ 6.2-9

6.2.2.6 Venting Option Conclusion ..................................... 6.2-10

6.2.2.7 Vent Orientation ............................................. 6.2-11

6.2.2.8 Water Heater Venting ......................................... 6.2-11

 6.2.2.8.1 Orphaned Water Heaters .............................. 6.2-12

6.2.2.8.2 Unlined Masonry Chimney Vents ....................... 6.2-12

6.2.2.8.3 Type B Double Wall Metal Vent ........................ 6.2-13

6.2.2.8.4 Lined Masonry Chimney Vents ......................... 6.2-13

6.2.2.8.5 Orphaned Water Heater Summary ....................... 6.2-13

6.2.2.9 Venting Configurations Summary ................................ 6.2-14

6.2.3 MODEL APPROACH ............................................... 6.2-15

6.2.3.1 Candidate Standard Levels ..................................... 6.2-16

 6.2.3.1.1 80% AFUE Baseline Non-Condensing Trial Standard Level . . 6.2-16

6.2.3.1.2 81%A AFUE 2-Stage Modulation Near-Condensing Trial 

Standard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2-17

6.2.3.1.3 81%B, 82% AFUE Near-Condensing Trial Standard Levels . . 6.2-18

6.2.3.1.4 83% AFUE All Stainless Steel Near-Condensing Trial 

Standard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2-18

6.2.3.1.5 90%+ AFUE Condensing Trial Standard Level ............ 6.2-18

6.2.3.2 Bill of Material Calculations ................................... 6.2-20

6.2.3.2.1 Size-Related Parameter Calculation ..................... 6.2-20

6.2.3.2.2 Create Bill of Materials (BOM) ......................... 6.2-25

6.2.3.2.3 Labor and Material Costs for Each BOM Line Item ......... 6.2-27

6.2.4 MODEL ASSUMPTIONS SUMMARY ................................. 6.2-29

6.2.4.1 Venting Options .............................................. 6.2-29

6.2.4.2 Weighting .................................................. 6.2-30

6.2.4.3 Probabilities ................................................. 6.2-30

6.2.4.4 Size-Related Parameters ....................................... 6.2-30

6.2.4.5 Material .................................................... 6.2-31

6.2.4.6 Financial ................................................... 6.2-31

6.2.4.7 Gas Boiler Assumptions ....................................... 6.2-31

6.2.4.8 Oil Furnace Assumptions ...................................... 6.2-31

6.2.4.9 Oil Boiler Assumptions ........................................ 6.2-32

6.2.5 MODEL RESULTS ................................................. 6.2-32

6.2.5.1 81%A 2-stage Modulation Relative Cost Breakdown................. 6.2-33

6.2.5.2 83% All Stainless Steel Vent Relative Cost Breakdown .............. 6.2-34
1-x

6.2.5.3 90% Condensing Relative Cost Breakdown ........................ 6.2-35

6.2.5.4 Gas Boiler Model Results ...................................... 6.2-36

6.2.5.5 Oil Furnace Model Results ..................................... 6.2-36

6.2.5.6 Oil Boiler Model Results ....................................... 6.2-37

6.2.6 SENSITIVITY ANALYSIS .......................................... 6.2-37

6.2.6.1 Sensitivity Analysis Assumptions ................................ 6.2-38

6.2.6.2 Incremental Cost Result Ranges ................................. 6.2-39

6.2.6.3 Cost Result Sensitivity ........................................ 6.2-40

6.2.6.4 Weighting Sensitivity ......................................... 6.2-41

6.2.6.4.1 Regional Differences ................................. 6.2-41

6.2.6.4.2 Recent Trends ...................................... 6.2-42

6.2.7 INSTALLATION MODEL RESULTS COMPARED TO OTHER DATA ...... 6.2-43

6.2.7.1 Comparison of the Installation Model to 1994 GRI Data .............. 6.2-44

6.2.7.2 Comparison of the Installation Model to 1999 Canadian Data .......... 6.2-45

6.2.7.3 Comparison of the Installation Model to 1996 Wisconsin Data ......... 6.2-45

6.2.7.4 Comparison Summary ......................................... 6.2-46

6.2.8 WEIGHTING ESTIMATIONS FOR YEAR 2012 ......................... 6.2-46

6.2.8.1 Single : Double Wall Vent Connector Ratio ....................... 6.2-46

6.2.8.2 Masonry Chimney Linings ..................................... 6.2-47

6.2.9 ABSOLUTE COST BREAKDOWN .................................... 6.2-49

6.2.9.1 Non-Weatherized Gas Furnaces ................................. 6.2-49

6.2.9.2 Gas Boilers ................................................. 6.2-51

6.2.9.3 Oil Furnaces ................................................. 6.2-53

6.2.9.4 Oil Boilers .................................................. 6.2-54

6.2.10 VENTING GLOSSARY ............................................. 6.2-55

APPENDIX 6.3. DETERMINATION OF FURNACE AND BOILER ENERGY USE

6.3.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3.2 CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3.2.1 Determination of Average Annual Fuel Energy Consumption (EF) . . . . . . . . . 6-1

6.3.2.2 Determination of Average Annual Electrical Energy Consumption (EAE) . . . . 6-2

6.3.2.3 Determination of National Average Number of Burner Operating 

Hours (BOHSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3.2.4 Determination of National Average Number of Burner Operating Hours for 

Two-Stage and Step Modulating Furnaces and Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3.2.5 Determination of Heating Seasonal Efficiency (EffySS) . . . . . . . . . . . . . . . . . . 6-5

6.3.3 PARAMETERS TO DETERMINE THE ENERGY USE OF 

MODULATING FURNACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3.3.1 Parameters to Determine Average Annual Fuel Energy Consumption . . . . . . . 6-6

6.3.3.2 Parameters to Determine Annual Fuel Utilization Efficiency . . . . . . . . . . . . . . 6-7

6.3.3.3 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3.4 SUMMARY TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
1-xi

APPENDIX 6.4. ENGINEERING ANALYSIS COST AND EFFICIENCY TABLES

6.4.1 NOTE ............................................................. 6.4-1

APPENDIX 7.1. REDUCED SET OF FURNACE MODELS DATABASE

7.1.1 PURPOSE ......................................................... 7.1-1

7.1.2 DATABASE DEVELOPMENT ........................................ 7.1-1

7.1.2.1 Background .................................................. 7.1-1

7.1.2.2 Database Structure ............................................ 7.1-1

APPENDIX 7.2. DECODING OF MANUFACTURER MODEL NUMBERS

APPENDIX 7.3. DETERMINATION OF BASIC FURNACE MODELS

APPENDIX 7.4. FURNACE FAN CURVES

7.4.1 GENERAL AIR SPEED AND AIRFLOW RELATIONSHIP ................. 7.4-1

7.4.2 BLOWER FAN CURVES ............................................. 7.4-2

7.4.2.1 Fan Laws .................................................... 7.4-3

7.4.2.2 Motor Speed ................................................. 7.4-3

7.4.2.3 Shaft Power .................................................. 7.4-4

7.4.2.4 System Effect Factor ........................................... 7.4-4

7.4.3 FAN CURVES FOR GENERIC MODEL FURNACES ...................... 7.4-4

APPENDIX 7.5. BLOWER FAN CURVES

7.5.1 INTRODUCTION ................................................... 7.5-1

7.5.2 STATIC PRESSURE ................................................. 7.5-4

7.5.3 SHAFT POWER .................................................... 7.5-4

APPENDIX 7.6. OVERALL AIR-MOVING EFFICIENCY

7.6.1 INTRODUCTION ................................................... 7.6-1

7.6.2 RESULTS ......................................................... 7.6-5

APPENDIX 7.7. GAS AND ELECTRICITY USE FOR MODULATING FURNACES

7.7.1 INTRODUCTION ................................................... 7.7-1

7.7.2 SINGLE STAGE EQUIVALENT BURNER OPERATING HOURS ........... 7.7-1

7.7.2.1 Annual Average Heating Energy (EM) ............................. 7.7-2

7.7.3 BURNER OPERATING HOURS AT REDUCED AND HIGH FIRING MODES . 7.7-2
1-xii

7.7.3.1 Fraction of Heating Load ........................................ 7.7-3

7.7.3.2 Balance-Point Temperature (TC) .................................. 7.7-3

7.7.3.3 Oversize Factor (") ............................................ 7.7-3

7.7.3.4 Heating Capacity at Maximum Input Rate (QOUT) .................... 7.7-4

7.7.3.5 Reduced Fuel Input Rate Heating Capacity ......................... 7.7-5

7.7.3.6 Design Heating Requirement .................................... 7.7-5

7.7.4 FAN MOTOR ELECTRICITY CONSUMPTION .......................... 7.7-6

APPENDIX 8.1. GLOSSARY OF VARIABLES AND THEIR VALUES 

FROM EIA’S RECS97

APPENDIX 8.2. DISTRIBUTION FOR DISCOUNT RATES

8.2.1 DISTRIBUTION OF NEW INSTALLATION DISCOUNT RATES ............ 8.2-1

8.2.2 DISTRIBUTION OF REPLACEMENT DISCOUNT RATES ................. 8.2-1

APPENDIX 8.3. LCC AND PBP RESULTS USING ALTERNATIVE INSTALLATION

COST SCENARIOS

8.3.1 INTRODUCTION ................................................... 8.3-1

8.3.2 LCC AND PBP RESULTS FOR NON-WEATHERIZED GAS FURNACES 

USING ALTERNATIVE INSTALLATION COSTS ........................ 8.3-1

8.3.3 LCC AND PBP RESULTS FOR GAS BOILERS USING ALTERNATIVE 

INSTALLATION COSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3-7

APPENDIX 8.4. LCC AND PBP RESULTS USING ALTERNATIVE ENERGY 

PRICE SCENARIOS

8.4.1 INTRODUCTION ................................................... 8.4-1

8.4.2 LCC AND PBP RESULTS USING AEO 2003 HIGH GROWTH PRICE 

SCENARIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4-3

8.4.3 LCC AND PBP RESULTS USING AEO 2003 LOW GROWTH PRICE 

SCENARIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4-16

APPENDIX 8.5. ANALYSIS OF ELECTRICITY EFFICIENCY DESIGN OPTIONS 

FOR FURNACES AND BOILERS

8.5.1 INTRODUCTION ................................................... 8.5-1

8.5.2 ELECTRICITY EFFICIENCY OPTIONS THAT PASSED SCREENING ....... 8.5-1

8.5.3 MANUFACTURING COST .......................................... 8.5-2

8.5.4 CALCULATION OF FURNACE OR BOILER ELECTRICITY CONSUMPTION 

WITH DESIGN OPTIONS, USING DOE TEST PROCEDURE . . . . . . . . . . . . . . . 8.5-2

8.5.5 ELECTRICITY-EFFICIENCY DESIGN OPTIONS CONSIDERED IN THE 

LCC ANALYSIS FOR FURNACES .................................... 8.5-4
1-xiii

8.5.6 ELECTRICITY-EFFICIENCY DESIGN OPTIONS CONSIDERED IN THE 

LCC ANALYSIS FOR BOILERS AND OIL-FIRED EQUIPMENT ........... 8.5-5

8.5.7 RESULTS OF ENERGY CONSUMPTION CALCULATIONS ............... 8.5-6

8.5.8 LCC RESULTS INCLUDING ELECTRICITY-EFFICIENCY DESIGN 

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5-23

APPENDIX 8.7. POWER CONSUMPTION OF ECM BLOWER MOTORS

8.7.1 INTRODUCTION ................................................... 8.7-1

8.7.2 BLOWER SPEED AND SHAFT POWER ................................ 8.7-1

8.7.3 DEVELOPMENT OF EFFICIENCY EQUATION ......................... 8.7-3

8.7.4 BLOWER MOTOR POWER CONSUMPTION ........................... 8.7-10

APPENDIX 8.6. FURNACE AIRFLOW CAPACITY TESTING

8.6.1 SUMMARY ........................................................ 8.6-2

8.6.2 BACKGROUND .................................................... 8.6-2

8.6.3 INTRODUCTION ................................................... 8.6-3

8.6.3.1 Objectives of the Furnace and Blower Airflow Testing ............. 8.6-3

8.6.3.2 How is Airflow Tested Now .................................. 8.6-3

8.6.3.3 Who Did the Testing? ....................................... 8.6-3

8.6.3.4 Which Furnaces and Blowers were Tested? ...................... 8.6-3

8.6.3.5 What Data are Provided in the Carrier Furnace Literature for the 

Installer? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6-4

8.6.3.6 How was the Testing Conducted? .............................. 8.6-5

8.6.3.7 Basic Description of PSC and ECM Motors ...................... 8.6-5

8.6.3.8 Furnace Circulating-Air Blowers ............................... 8.6-5

8.6.3.9 Testing with AMCA 210 ..................................... 8.6-5

8.6.3.10 How did ESL do the testing? .................................. 8.6-5

8.6.3.11 Differences from a Typical Blower Curve Test by ESL ............. 8.6-6

8.6.3.12 Instrumentation and Test Setup ................................ 8.6-6

8.6.4 RESULTS ......................................................... 8.6-7

8.6.4.1 Should AMCA 210 be Used to Measure Airflow to More 

Accurately Measure Furnace Electrical Energy Use? ............... 8.6-8

8.6.4.2 Are There Energy Savings Benefits Possible for Furnace Blowers? . . . 8.6-10

8.6.5 BLOWER SPEED AND AIRFLOW .................................... 8.6-11

8.6.6 DISCUSSION OF RESULTS ......................................... 8.6-12

8.6.7 CONCLUSIONS ................................................... 8.6-12

APPENDIX 8.8. POWER CONSUMPTION OF BC/ECM+ BLOWER MOTORS

8.8.1 INTRODUCTION ................................................... 8.8-1

8.8.2 SHAFT POWER AND STATIC PRESSURE AT CONSTANT SPEED ......... 8.8-2

8.8.3 BLOWER AT OTHER SPEEDS AND AIRFLOWS ........................ 8.8-3
1-xiv

8.8.4 OTHER SIZE BLOWERS ............................................. 8.8-4

8.8.5 SYSTEM EFFECT FACTOR OF BLOWERS IN FURNACES ............... 8.8-5

8.8.6 BLOWER SPEED AND SHAFT POWER AS FUNCTION OF 

FURNACE STATIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8-7

8.8.7 ECM 4.0 MOTOR EFFICIENCY ....................................... 8.8-9

8.8.8 BC/ECM+ BLOWER MOTOR ELECTRICITY CONSUMPTION ........... 8.8-10

APPENDIX 8.9. AIR CONDITIONER OPERATING HOURS

8.9.1 INTRODUCTION ................................................... 8.9-1

8.9.2 ANNUAL HOUSE COOLING LOAD ................................... 8.9-1

8.9.3 ANNUAL AIR CONDITIONER OPERATING HOURS .................... 8.9-1

8.9.4 AIR CONDITIONER CAPACITY ...................................... 8.9-2

8.9.5 HEAT ADDED BY BLOWER AND BLOWER MOTOR .................... 8.9-2

8.9.6 IMPACT OF NEW BLOWER AND/OR BLOWER MOTOR 

DESIGN OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9-2

APPENDIX 10.1. NATIONAL ENERGY SAVINGS AND NET PRESENT VALUE

USING ALTERNATIVE INSTALLATION COSTS AND ENERGY PRICE SCENARIOS

10.1.1 INTRODUCTION .................................................. 10.1-1

10.1.2 RESULTS USING ALTERNATIVE INSTALLATION COSTS ............. 10.1-1

10.1.3 RESULTS USING ALTERNATIVE ENERGY PRICE SCENARIOS ......... 10.1-6

10.1.3.1 NES/NPV Results Using High Economic Growth Scenario ......... 10.1-6

10.1.3.2 NES/NPV Results Using Low Economic Growth Scenario ......... 10.1-9

10.1.4 RESULTS USING ALTERNATIVE ENERGY PRICE SCENARIOS– 

COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1-11

10.1.4.1 National Energy Savings (NES) ............................. 10.1-11

10.1.4.2 Net Present Value (NPV) ................................... 10.1-14

LIST OF TABLES

Table 1.3.1 History of Furnace and Boiler Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Table 1.3.2 Residential Furnace and Boiler Analyses Required by Process Rule . . . . . 1-4

Table 3.2.1 Median Capacity of Furnace Models in the GAMA Directory . . . . . . . . . . 3-8

Table 3.2.2 Median Annual Auxiliary Electricity Use of Furnace Models . . . . . . . . . 3-10

Table 3.3.1 Current Federal Residential Furnace and Boiler Minimum Efficiency

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Table 3.4.1 Market Statistics for Furnaces and Boilers by Product Class . . . . . . . . . . 3-23

Table 3.4.2 Manufacturer Market Shares for Non-Weatherized Gas Furnaces (%) . . . 3-26

Table 3.4.3 Approximate Manufacturer Market Shares for Blower Motors, 2002 (%) 3-28

Table 3.2.1 Median Capacity of Furnace Models in the GAMA Directory . . . . . . . . . . 3-8

Table 3.2.2 Median Annual Auxiliary Electricity Use of Furnace Models . . . . . . . . . 3-10
1-xv

Table 3.3.1 Current Federal Residential Furnace and Boiler Minimum Efficiency

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Table 3.4.1 Market Statistics for Furnaces and Boilers by Product Class . . . . . . . . . . 3-22

Table 3.4.2 Manufacturer Market Shares for Non-Weatherized Gas Furnaces (%) . . . 3-25

Table 3.4.3 Approximate Manufacturer Market Shares for Blower Motors, 2002 (%) 3-27

Table 4.3.1 Screening Results for Design Options by Product Class . . . . . . . . . . . . . . 4-19

Table 5.2.1 Manufacturer Gross Margins and Markups . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Table 5.2.2 Manufacturer Markups and Weights from Five Manufacturers . . . . . . . . . 5-5

Table 5.3.1 Wholesale Expenses and Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Table 5.3.2 Contractor Expenses and Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Table 5.3.3 Contractor Expenses and Baseline Markups by Market Type . . . . . . . . . . 5-11

Table 5.3.4 Incremental Markups by Contractor Size and Market Type . . . . . . . . . . . 5-12

Table 5.4.1 Builder Markups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Table 5.6.1 Distribution of Sales Tax Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Table 5.7.1 Summary of Markups on Residential Furnaces and Boilers . . . . . . . . . . . 5-17

Table 6.3.1 Features of Baseline Models by Product Class . . . . . . . . . . . . . . . . . . . . . . 6-3

Table 6.4.1 Gaps in Efficiency Levels of Units Selected for Teardown . . . . . . . . . . . . 6-7

Table 6.4.2 Ranking of Design Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Table 6.4.3 Cost Model Outsourcing Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Table 6.4.4 Cost Model Assumptions on Outsourced Components . . . . . . . . . . . . . . . 6-14

Table 6.4.5 Greenfield Facility Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Table 6.4.6 Greenfield Facility Production Cost Assumptions . . . . . . . . . . . . . . . . . . 6-15

Table 6.4.7 Annual Production Volume Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Table 6.4.8 Degree of Uncertainty for Main Variable Types . . . . . . . . . . . . . . . . . . . . 6-17

Table 6.4.9 Manufacturing Parameter Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Table 6.5.1 Fraction of Models Requiring a Category III Venting System . . . . . . . . . 6-25

Table 6.5.2 Installation Model, Non-Weatherized Gas Furnace 

Weighting Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Table 6.5.3 Master Bill of Materials for All Appliance Installation Configurations . . 6-28

Table 6.5.4 Material and Labor Cost Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Table 6.5.5 Non-Weatherized Gas Furnace, Installation Results . . . . . . . . . . . . . . . . . 6-30

Table 6.5.6 Comparison of Installation Model, GRI, NRCanada, and Wisconsin 

Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Table 6.5.7 Comparison of Incremental Installation Cost for 90 percent AFUE 

Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

Table 6.5.8 Installation Cost for Non-Weatherized Gas Furnaces ($) . . . . . . . . . . . . . 6-34

Table 6.5.9 Installation Cost for Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . 6-35

Table 6.5.10 Installation Cost for Oil-Fired Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

Table 6.5.11 Installation Cost for Hot-Water Gas Boilers . . . . . . . . . . . . . . . . . . . . . . . 6-37

Table 6.5.12 Installation Cost for Hot-Water Oil-fired Boilers . . . . . . . . . . . . . . . . . . . 6-37

Table 6.6.1 Annualized Maintenance Cost for Non-Weatherized Gas Furnaces . . . . . 6-38
1-xvi

Table 6.7.1 Fuel-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

Table 6.7.2 Efficiency Levels with Less Than 3-year Payback Period Using

 DOE Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Table 7.3.1 Characteristics of Basic Furnace Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Table 7.3.2 Virtual Model Furnaces: Capacity and Airflow . . . . . . . . . . . . . . . . . . . . . 7-4

Table 7.3.3 Relevant Sizes of Virtual Models for Non-Weatherized and 

Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Table 7.3.4 Relevant Sizes of Virtual Models for Mobile Home Furnaces . . . . . . . . . . 7-5

Table 7.3.5 Relevant Sizes of Virtual Models for Oil-Fired Furnaces . . . . . . . . . . . . . . 7-5

Table 7.3.6 Assigned Blower Size by Airflow Capacity . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Table 7.3.7 Assigned Motor Size by Airflow Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Table 7.3.8 Supply-Air Outlet Area (in Square Feet) for Virtual Non-Condensing 

Gas Furnace Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Table 7.3.9 Supply-Air Outlet Area (in Square Feet) for Virtual Condensing 

Gas Furnace Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Table 7.3.10 Values for Delay and Ignition Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Table 7.9.1 Non-Weatherized Gas Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . 7-26

Table 7.9.2 Weatherized Gas Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Table 7.9.3 Mobile Home Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Table 7.9.4 Oil Furnace Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Table 7.9.5 Hot-Water Gas Boiler Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Table 7.9.6 Oil Boiler Energy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Table 8.2.1 Criteria for Selection of RECS Household Data by Product Class . . . . . . 8-12

Table 8.2.2 New Construction Share by Product Class for Residential Furnaces and

Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Table 8.3.1 Manufacturing Cost Scalars for Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Table 8.3.2 Furnace and Boiler Lifetimes Used in the LCC Analysis (years) . . . . . . . 8-22

Table 8.3.3 After-Tax Real Interest or Return Rates for Household 

Debt and Equity Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Table 8.3.4 Summary of Inputs Used in the LCC and Payback Period Analysis . . . . . 8-26

Table 8.4.1 LCC and PBP Results for Non-Weatherized Gas Furnaces Using 

Installation Model Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Table 8.4.2 LCC and PBP Results for Weatherized Gas Furnaces . . . . . . . . . . . . . . . . 8-31

Table 8.4.3 LCC and PBP Results for Mobile Home Gas Furnaces . . . . . . . . . . . . . . 8-33

Table 8.4.4 LCC and PBP Results for Oil-Fired Furnaces . . . . . . . . . . . . . . . . . . . 8-35

Table 8.4.5 LCC and PBP Results for Hot-Water Gas Boilers . . . . . . . . . . . . . . . . . . . 8-37

Table 8.4.6 LCC and PBP Results for Hot-Water Oil-fired Boilers . . . . . . . . . . . . . . . 8-39

Table 9.2.1 Expected Equipment Lifetime (years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Table 9.2.2 Conversions to Natural Gas From Oil and Electric Heating . . . . . . . . . . . . 9-3

Table 9.2.3 Replacement and Conversion Estimates for 2000 . . . . . . . . . . . . . . . . . . . . 9-5
1-xvii

Table 9.3.1 Change in Energy and Equipment Price Indices and Gas Furnace Market

Share in New Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Table 9.3.2 Estimated Elasticity of Gas Furnace Market Share in New Housing in

Response to Change in Fuel and Equipment Price Indices . . . . . . . . . . . . . 9-9

Table 9.3.3 Shipments of Non-Weatherized and Weatherized Gas Furnaces to New

Housing for Different Efficiency Levels . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Table 9.3.4 Shipments of Mobile Home Gas Furnaces for Different Efficiency Levels 9-10

Table 9.3.5 Projected Shipments to New Housing in Other Product Classes (million) 9-11

Table 9.4.1 Total Shipments of Non-Weatherized Gas Furnaces for Different 

Efficiency Levels (million per year) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Table 9.4.2 Total Shipments in Other Product Classes (million per year) . . . . . . . . . . 9-12

Table 10.2.1 Trend of the Market Share of Condensing Furnaces in Total Shipments of 

Non-Weatherized Gas Furnaces ( percent) . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Table 10.2.2 Base Case Forecast AFUE of Other Product Classes . . . . . . . . . . . . . . . . 10-4

Table 10.2.3 NES and NPV Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

Table 10.4.1 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Gas Furnaces Using 7% Discount Rate . . . 10-12

Table 10.4.2 Cumulative National Energy Savings and Consumer Net Present 

Value for Weatherized Gas Furnaces Using 7% Discount Rate . . . . . . . 10-13

Table 10.4.3 Cumulative National Energy Savings and Consumer Net Present 

Value for Mobile Home Gas Furnaces Using 7% Discount Rate . . . . . . 10-13

Table 10.4.4 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Oil-Fired Furnaces Using 7% 

Discount Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

Table 10.4.5 Cumulative National Energy Savings and Consumer Net Present 

Value for Hot Water Gas Boilers Using 7% Discount Rate . . . . . . . . . . 10-14

Table 10.4.6 Cumulative National Energy Savings and Consumer Net Present 

Value for Oil-Fired Boilers Using 7% Discount Rate . . . . . . . . . . . . . . . 10-14

Table 10.4.7 Cumulative Consumer Net Present Value for Non-Weatherized 

Gas Furnaces Using 3% Discount Rate . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Table 10.4.8 Cumulative Consumer Net Present Value for Weatherized Gas 

Furnaces Using 3% Discount Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Table 10.4.9 Cumulative Consumer Net Present Value for Mobile Home Gas 

Furnaces Using 3% Discount Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Table 10.4.10 Cumulative Consumer Net Present Value for Non-Weatherized 

Oil-fired Furnaces Using 3% Discount Rate . . . . . . . . . . . . . . . . . . . . . . 10-16

Table 10.4.11 Cumulative Consumer Net Present Value for Hot-Water Gas Boilers 

Using 3% Discount Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Table 10.4.12 Cumulative Consumer Net Present Value for Hot-Water Oil-fired 

Boilers Using 3% Discount Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
1-xviii

Table 1.1 Non-regulatory Alternatives to Standards . . . . . . . . . . . . . . . . . . . . . . . RIA-1

Table 5.1.2.1 Disaggregated Costs and Expenses for Wholesalers ................. 5.1-2

Table 5.1.3.1 Disaggregated Costs and Expenses for Builders .................... 5.1-3

Table 5.1.4.1 Disaggregated Costs and Expenses for Contractors .................. 5.1-4

Table 5.1.5.1 Wholesale Baseline Markups by State ............................ 5.1-6

Table 5.1.5.2 Builder Baseline Markups by State .............................. 5.1-7

Table 5.1.5.3 Contractor Baseline Markups by State ............................ 5.1-9

Table 5.1.6.1 Fraction of Gas Furnace Shipments to New Construction ............ 5.1-10

Table 6.1.2.1 Specific Features for Each Product Class ........................ 6.1-2

Table 6.2.2.1 Six Common Vent and Vent Connector Configurations ............... 6.2-10

Table 6.2.2.2 Orphaned Water Heater Consumer Options (Unlined Masonry Vents) . . . 6.2-13

Table 6.2.2.3 Orphaned Water Heater Cost Adder Summary ...................... 6.2-13

Table 6.2.2.4 Results Table Format (Baseline Example) ......................... 6.2-14

Table 6.2.3.1 Original Results Summary ..................................... 6.2-15

Table 6.2.3.2 Format of 80% AFUE Baseline Trial Standard Level Results .......... 6.2-17

Table 6.2.3.3 Format of 81%A AFUE 2-stage Mod. Trial Standard Level Results ..... 6.2-17

Table 6.2.3.4 Format of 83% AFUE Stainless Steel Trial Standard Level Results ..... 6.2-18

Table 6.2.3.5 Format of 90%+ AFUE Condensing Trial Standard Level Results ...... 6.2-19

Table 6.2.3.6 Common Vent Diameters Calculated Using the NFGC ............... 6.2-20

Table 6.2.3.7 Nominal Tees and Elbows ...................................... 6.2-21

Table 6.2.3.8 Assumed Living Area Square Feet Ranges (NWGF) ................. 6.2-24

Table 6.2.3.9 Master BOM: Includes All Installation Configurations ............... 6.2-26

Table 6.2.3.10 2003 RS Means Crew Labor Rates ............................... 6.2-28

Table 6.2.3.11 RS Means Substitutions ........................................ 6.2-29

Table 6.2.5.1 Overall Results for the Non-Weatherized Gas Furnace Class ........... 6.2-33

Table 6.2.5.2 Overall Results for the Gas Boiler Class ........................... 6.2-36

Table 6.2.5.3 Overall Results for the Oil Furnace Class .......................... 6.2-36

Table 6.2.5.4 Overall Results for the Oil Boiler Class ........................... 6.2-37

Table 6.2.6.1 Sensitivity Analysis Assumption Ranges .......................... 6.2-38

Table 6.2.7.1 Installation Data Comparison: GRI, Canadian, and WI ............... 6.2-44

Table 6.2.7.2 Incremental Installation Cost Data Comparison ..................... 6.2-45

Table 6.2.8.1 Year 2012 Chimney Relining Projections .......................... 6.2-48

Table 6.2.9.1 80% AFUE Baseline Installation Cost (NWGF) ..................... 6.2-49

Table 6.2.9.2 81%A AFUE 2-Stage Modulation Installation Cost (NWGF) .......... 6.2-49

Table 6.2.9.3 83% AFUE All Stainless Vent Installation Cost (NWGF) ............. 6.2-50

Table 6.2.9.4 90% AFUE Condensing Installation Cost (NWGF) .................. 6.2-50

Table 6.2.9.5 80% AFUE Baseline Installation Cost (Gas Boiler) .................. 6.2-51

Table 6.2.9.6 85% AFUE All Stainless Vent Installation Cost (Gas Boiler) .......... 6.2-51

Table 6.2.9.7 90% AFUE Condensing Installation Cost (Gas Boiler) ............... 6.2-52

Table 6.2.9.8 80% AFUE Baseline Installation Cost (Oil Furnace) ................. 6.2-53
1-xix

Table 6.2.9.9 85% AFUE All Stainless Vent Installation Cost (Oil Furnace) ......... 6.2-53

Table 6.2.9.10 80% AFUE Baseline Installation Cost (Oil Boiler) .................. 6.2-54

Table 6.2.9.11 87% AFUE All Stainless Vent Installation Cost (Oil Boiler) ........... 6.2-54

Table 6.3.3.1 AFUE for Similar Single-Stage and Two-Stage Furnace Models Series . . 6-8

Table 6.3.4.1 Single-Stage Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . 6-9

Table 6.3.4.2 Single-Stage Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Table 6.3.4.3 Single-Stage Mobile Home Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Table 6.3.4.4 Single-Stage Oil-Fired Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Table 6.3.4.5 Single-Stage Hot-Water Gas Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Table 6.3.4.6 Single-Stage Hot-Water Oil Boilers . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Table 6.3.4.7 Two-Stage Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . 6-13

Table 6.3.4.8 Two-Stage Mobile Home Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Table 6.3.4.9 Two-Stage Hot-Water Oil Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Table 6.3.4.10 Two-Stage Hot-Water Gas Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Table 6.3.4.11 Two-Stage Hot-Water Oil Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Table 6.4.1.1 Cost Table for Non-Weatherized Gas Furnaces (Installation Model) .... 6.4-2

Table 6.4.1.2 Energy and Economics Table for Non-Weatherized Gas Furnaces 

(Installation Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4-6

Table 6.4.1.3 Summary Results for Non-Weatherized Gas Furnaces (NRCan) ...... 6.4-10

Table 6.4.1.4 Summary Results for Non-Weatherized Gas Furnaces (GRI) ......... 6.4-14

Table 6.4.1.5 Cost Table for Weatherized Gas Furnaces ........................ 6.4-18

Table 6.4.1.6 Energy and Economics Table for Weatherized Gas Furnaces ......... 6.4-19

Table 6.4.1.7 Cost Table for Mobile Home Gas Furnaces ....................... 6.4-20

Table 6.4.1.8 Energy and Economics Table for Mobile Home Gas Furnaces ........ 6.4-21

Table 6.4.1.9 Cost Table for Oil-fired Furnaces ............................... 6.4-22

Table 6.4.1.10 Energy and Economics Table for Oil-fired Furnaces ................ 6.4-23

Table 6.4.1.11 Cost Table for Gas Boilers (Installation Model Data) ............... 6.4-24

Table 6.4.1.12 Energy and Economics Table for Gas Boilers (Installation Model Data) 6.4-25

Table 6.4.1.13 Cost Table for Gas Boilers (GRI Data) .......................... 6.4-26

Table 6.4.1.14 Energy and Economics Table for Gas Boilers (GRI Data) ............ 6.4-27

Table 6.4.1.15 Cost Table for Oil-fired Boilers ................................ 6.4-28

Table 6.4.1.16 Energy and Economics Table for Oil-fired Boilers ................. 6.4-29

Table 7.1.1 Furnace Data Table Field Names and Definitions ................... 7.1-5

Table 7.1.2 Pressure Table Field Names and Definitions ....................... 7.1-6

Table 7.1.3 Power Table Field Names and Definitions ......................... 7.1-7

Table 7.1.4 Series Table Field Names and Definitions ......................... 7.1-7

Table 7.1.5 Delay Times Table Field Names and Definitions .................... 7.1-7

Table 7.2.1 Amana Furnace Model Number Description ....................... 7.2-1

Table 7.2.2 Carrier Model Number Description .............................. 7.2-1

Table 7.2.3 ICP Model Number Description ................................. 7.2-2
1-xx

Table 7.2.4 Goodman Model Number Description ............................ 7.2-2

Table 7.2.5 Lennox Model Number Description .............................. 7.2-2

Table 7.2.6 Armstrong Model Number Description ........................... 7.2-2

Table 7.2.7 Trane/American Standard Model Number Description ............... 7.2-3

Table 7.2.8 Rheem Non-Condensing Model Number Description ................ 7.2-3

Table 7.2.9 Rheem Condensing Model Number Description .................... 7.2-3

Table 7.2.10 York Furnace Model Number Description ......................... 7.2-4

Table 7.2.11 Nordyne Model Number Description ............................. 7.2-4

Table 7.3A.1 Models and Manufacturers of Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-3

Table 7.3A.2 Values of Input Capacity (kBtu/h) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-4

Table 7.3A.3 Values of Output (kBtu/h) Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-5

Table 7.3A.4 Values of Maximum CFM @ 0.5 in w.c. for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-6

Table 7.3A.5 Values of Low CFM @ 0.5 in w.c. for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-7

Table 7.3A.6 Values of Blower Size (diam X width) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-8

Table 7.3A.7 Values of Motor Size (HP) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-9

Table 7.3A.8 Number of Speed Taps for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-10

Table 7.3A.9 Values of Supply Air Outlet Area (sq.ft.) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-11

Table 7.3A.10 Values of AFUE for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-12

Table 7.3A.11 Values for Eae (kWh/y) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-13

Table 7.3A.12 Values of PE (W) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-14

Table 7.3A.13 Values of On-Delay (secs) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-15

Table 7.3A.14 Values of Off-Delay Time (secs) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-16

Table 7.3A.15 Values of Pre-Purge Time (secs) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-17

Table 7.3A.16 Values of Post-Purge Time (secs) for Non-Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-18

Table 7.3B.1 Models and Manufacturers of Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-19

Table 7.3B.2 Values of Input Capacity (kBtu/h) for Condensing Basic Model 
1-xxi

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-20

Table 7.3B.3 Values of Output (kBtu/h) Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-21

Table 7.3B.4 Values of Maximum CFM @ 0.5 in w.c. for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-22

Table 7.3B.5 Values of Low CFM @ 0.5 in w.c. for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-23

Table 7.3B.6 Values of Blower Size (diam X width) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-24

Table 7.3B.7 Values of Motor Size (HP) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-25

Table 7.3B.8 Number of Speed Taps for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-26

Table 7.3B.9 Values of Supply Air Outlet Area (sq.ft.) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-27

Table 7.3B.10 Values of AFUE for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-28

Table 7.3B.11 Values for Eae (kWh/y) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-29

Table 7.3B.12 Values of PE (W) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-30

Table 7.3B.13 Values of On-Delay (secs) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-31

Table 7.3B.14 Values of Off-Delay Time (secs) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-32

Table 7.3B.15 Values of Pre-Purge Time (secs) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-33

Table 7.3B.16 Values of Post-Purge Time (secs) for Condensing Basic Model 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3-34

Table 7.4.1 Coefficients for Static Pressure as a Function of Airflow .............. 7.4-6

Table 7.5.1.1 Models Used For Virtual Furnace Blowers ......................... 7.5-1

Table 7.5.2.1 Coefficients to Calculate Pressure for Different Blower Sizes ........... 7.5-4

Table 7.5.3.1 Coefficients to Calculate Shaft Power for Different Blower Sizes ........ 7.5-5

Table 7.6.2.2 Coefficients for Overall Air-Moving Efficiency of Condensing 

Generic Model Furnaces ........................................ 7.7-6

Table 7.7.3.1 QOUT and Corresponding DHR values .............................. 7.7-5

Table 8.3.2.1 LCC and PBP Results for Non-Weatherized Gas Furnaces Using GRI 

Installation Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3-1
1-xxii

Table 8.3.2.2 LCC and PBP Results for Non-Weatherized Gas Furnaces Using NRCan

Installation Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3-4

Table 8.3.3.1 LCC and PBP Results for Hot-Water Gas Boilers Using GRI 

Installation Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3-7

Table 8.4.2.1 LCC and PBP Results for Non-Weatherized Gas Furnaces (High Growth) . 8.4-3

Table 8.4.2.2 LCC and PBP Results for Weatherized Gas Furnaces (High Growth) ..... 8.4-6

Table 8.4.2.3 LCC and PBP Results for Mobile Home Furnaces (High Growth) ........ 8.4-8

Table 8.4.2.4 LCC and PBP Results for Oil Furnaces (High Growth) ............... 8.4-10

Table 8.4.2.5 LCC and PBP Results for Gas Boilers (High Growth) ................ 8.4-12

Table 8.4.2.6 LCC and PBP Results for Oil Boilers (High Growth) ................. 8.4-14

Table 8.4.3.1 LCC and PBP Results for Non-Weatherized Gas Furnaces (Low Growth) 8.4-16

Table 8.4.3.2 LCC and PBP for Weatherized Furnaces (Low Growth) .............. 8.4-19

Table 8.4.3.3 LCC and PBP Results for Mobile Home Furnaces (Low Growth) ...... 8.4-21

Table 8.4.3.4 LCC and PBP Results for Oil Furnaces (Low Growth) ............... 8.4-23

Table 8.4.3.5 LCC and PBP Results for Oil Boilers (Low Growth) ................. 8.4-25

Table 8.5.3.1 Incremental Manufacturing Cost of Electricity-Efficiency 

Design Options for Furnaces ..................................... 8.5-2

Table 8.5.3.2 Incremental Manufacturing Cost of Electricity-Efficiency 

Design Options for Hot-Water Boilers and Oil Equipment . . . . . . . . . . . . . . 8.5-2

Table 8.5.4.1 Electricity-Efficiency Design Options for Gas Furnaces ............... 8.5-3

Table 8.5.4.2 Electricity-Efficiency Design Options for Oil-Fired Furnaces and 

Hot-Water Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5-3

Table 8.5.7.1 Non-Weatherized Gas Furnace Energy Use ......................... 8.5-6

Table 8.5.7.2 Mobile Home Furnace Energy Use ............................... 8.5-10

Table 8.5.7.3 Weatherized Furnaces Energy Use ............................... 8.5-13

Table 8.5.7.4 Oil-Furnace Energy Use ....................................... 8.5-16

Table 8.5.7.5 Gas Boiler Energy Use ........................................ 8.5-19

Table 8.5.7.6 Oil Boiler Energy Use ......................................... 8.5-21

Table 8.5.8.1 LCC and PBP Results for Non-Weatherized Gas Furnaces, 

Including Electricity-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . 8.5-23

Table 8.5.8.2 LCC and PBP Results for Weatherized Gas Furnaces, 

Including Electricity-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . 8.5-26

Table 8.5.8.3 LCC and PBP Results for Mobile Home Gas Furnaces, 

Including Electricity-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . 8.5-28

Table 8.5.8.4 LCC and PBP Results for Oil-Fired Furnaces, 

Including Electricity-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . 8.5-30

Table 8.5.8.5 LCC and PBP Results for Hot-Water Gas Boilers, 

Including Electricity-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . 8.5-32

Table 8.5.8.6 LCC and PBP Results for Hot-Water Oil-fired Boilers, 

Including Electricity-Efficiency Design Options . . . . . . . . . . . . . . . . . . . . 8.5-34

Table 8.7.2.1 Coefficients for Blower Speed Equation ............................ 8.7-2
1-xxiii

Table 8.7.2.2 Coefficients for Blower Shaft Power Equation ....................... 8.7-3

Table 8.7.3.1 Coefficients for Equation of Y at 76% Efficiency as a Function of X ..... 8.7-7

Table 8.7.3.2 Coefficients for Equation of Logistic Transform of Motor Efficiency .... 8.7-10

Table 8.8.2.1 Coefficients for Shaft Power and Static Pressure at Constant Speed ...... 8.8-3

Table 8.8.4.1 Scalars for Airflow and Shaft Power for the Backward-Inclined Blowers . . 8.8-4

Table 8.8.5.1 SEF for BC/ECM+ Blowers in Virtual Model Furnaces ................ 8.8-6

Table 8.8.6.1 Coefficients for Blower Speed Equation ............................ 8.8-8

Table 8.8.6.2 Coefficients for Blower Shaft Power Equation ....................... 8.8-9

Table 10.1.2.1 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Gas Furnaces (GRI Installation Costs) 10.1-2

Table 10.1.2.2 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Gas Furnaces 

(NRCan Installation Costs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1-3

Table 10.1.2.3 Cumulative National Energy Savings and Consumer Net Present 

Value for Gas Boilers (GRI Installation Costs) . . . . . . . . . . . . . . . . 10.1-5

Table 10.1.3.1 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Gas Furnaces (High Growth) ....... 10.1-6

Table 10.1.3.2 Cumulative National Energy Savings and Consumer Net Present 

Value for Weatherized Gas Furnaces (High Growth) ........... 10.1-6

Table 10.1.3.3 Cumulative National Energy Savings and Consumer Net Present 

Value for Mobile Home Gas Furnaces (High Growth) .......... 10.1-7

Table 10.1.3.4 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Oil-Fired Furnaces (High Growth) . . . 10.1-7

Table 10.1.3.5 Cumulative National Energy Savings and Consumer Net Present 

Value for Hot Water Gas Boilers (High Growth) . . . . . . . . . . . . . . 10.1-8

Table 10.1.3.6 Cumulative National Energy Savings and Consumer Net Present 

Value for Oil-Fired Boilers (High Growth) . . . . . . . . . . . . . . . . . . . 10.1-8

Table 10.1.3.7 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Gas Furnaces (Low Growth) ....... 10.1-9

Table 10.1.3.8 Cumulative National Energy Savings and Consumer Net Present 

Value for Weatherized Gas Furnaces (Low Growth) ........... 10.1-9

Table 10.1.3.9 Cumulative National Energy Savings and Consumer Net Present 

Value for Mobile Home Gas Furnaces (Low Growth) .......... 10.1-9

Table 10.1.3.10 Cumulative National Energy Savings and Consumer Net Present 

Value for Non-Weatherized Oil-Fired Furnaces (Low Growth) . . 10.1-10

Table 10.1.3.11 Cumulative National Energy Savings and Consumer Net Present 

Value for Hot Water Gas Boilers (Low Growth) . . . . . . . . . . . . . . 10.1-10

Table 10.1.3.12 Cumulative National Energy Savings and Consumer Net Present 

Value for Oil-Fired Boilers (Low Growth) . . . . . . . . . . . . . . . . . . 10.1-10
1-xxiv

LIST OF FIGURES

Figure 2.1.1 Analytic Framework for Residential and Boilers Rulemaking . . . . . . . . . . . . . 2-3

Figure 3.1.1 Saturation of Space Heating Equipment in U.S. Housing . . . . . . . . . . . . . . . . . 3-1

Figure 3.2.1 Distribution of Non-Weatherized, Gas Furnace Models by Input Capacity . . . 3-9

Figure 3.2.2 Distribution of Weatherized, Gas Furnace Models by Input Capacity . . . . . . . 3-9

Figure 3.2.3 Distribution of Non-Weatherized, Oil-Fired Furnace Models by 

Input Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure 3.2.4 Distribution of Electricity Consumption Values for Non-Weatherized, 

Gas Furnace Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3.2.5 Number of Hot-Water Oil and Gas Boiler Models by Input Capacity . . . . . . 3-14

Figure 3.2.6 Distribution of Electricity Consumption Values for HotWater Boiler Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Figure 3.3.1 Distribution of Non-Weatherized Gas Furnace Models by Efficiency . . . . . . 3-18

Figure 3.3.2 Distribution of Weatherized Gas Furnace Models by Efficiency . . . . . . . . . . 3-18

Figure 3.3.3 Distribution of Oil-Fired Furnace Models by Efficiency . . . . . . . . . . . . . . . . 3-19

Figure 3.3.4 Distribution of Mobile Home Furnace Models by Efficiency . . . . . . . . . . . . . 3-19

Figure 3.3.5 Distribution of Efficiency Values for Hot-Water Boiler Models . . . . . . . . . . 3-20

Figure 3.3.6 Distribution of Efficiency Values for Steam Boiler Models . . . . . . . . . . . . . . 3-20

Figure 3.4.1 Total Gas Furnace Shipments, 1975-2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Figure 3.4.2 Estimated Furnace Shipment to Mobile Homes . . . . . . . . . . . . . . . . . . . . . . . 3-24

Figure 3.4.3 Shipments of Oil-Fired Furnaces, 1975-2000 . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Figure 3.4.4 Shipments of Residential Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Figure 5.1.1 Distribution Channel for Residential Furnaces and Boilers . . . . . . . . . . . . . . . 5-1

Figure 5.1.2 Distribution Channel for Mobile Home Gas Furnaces . . . . . . . . . . . . . . . . . . . 5-2

Figure 5.3.1 Wholesaler Baseline Markup Probability Distribution . . . . . . . . . . . . . . . . . . . 5-9

Figure 5.3.2 Wholesaler Incremental Markup Probability Distribution . . . . . . . . . . . . . . . . 5-9

Figure 5.3.3 Contractor Baseline Prob. Distribution, New Constr.Market . . . . . . . . . . . . . 5-13

Figure 5.3.4 Contractor Incremental Markup Prob. Distribution, New Constr. Market . . . 5-13

Figure 5.4.1 Builder Baseline Markup Probability Distribution . . . . . . . . . . . . . . . . . . . . . 5-14

Figure 5.4.2 Builder Incremental Markup Probability Distribution . . . . . . . . . . . . . . . . . . 5-14

Figure 6.4.1 Probability Distribution for the Production Cost of an Equipment Sample . . 6-19

Figure 6.4.2 Importance of Input Parameters for Production Costs for

 Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Figure 6.4.3 Incremental Manufacturing Costs for Non-Weatherized Gas Furnaces . . . . . 6-20

Figure 6.4.4 Incremental Manufacturing Costs of Weatherized Gas Furnaces . . . . . . . . . . 6-21

Figure 6.4.5 Incremental Manufacturing Costs for Oil-Fired Furnaces . . . . . . . . . . . . . . . . 6-21

Figure 6.4.6 Incremental Manufacturing Costs for Gas-Fired Boilers . . . . . . . . . . . . . . . . 6-22

Figure 6.4.7 Incremental Manufacturing Costs for Oil-Fired Boilers . . . . . . . . . . . . . . . . . 6-22

Figure 6.4.8 Incremental Manufacturing Costs of Mobile Home Gas Furnaces . . . . . . . . . 6-23

Figure 6.4.1 Probability Distribution for the Production Cost of an Equipment Sample . . 6-21
1-xxv

Figure 6.4.2 Importance of Input Parameters for Production Costs for 

Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Figure 6.4.3 Incremental Manufacturing Costs for Non-Weatherized Gas Furnaces . . . . . 6-22

Figure 6.4.4 Incremental Manufacturing Costs of Weatherized Gas Furnaces . . . . . . . . . . 6-23

Figure 6.4.5 Incremental Manufacturing Costs for Oil-Fired Furnaces . . . . . . . . . . . . . . . . 6-23

Figure 6.4.6 Incremental Manufacturing Costs for Gas-Fired Boilers . . . . . . . . . . . . . . . . 6-24

Figure 6.4.7 Incremental Manufacturing Costs for Oil-Fired Boilers . . . . . . . . . . . . . . . . . 6-24

Figure 6.4.8 Incremental Manufacturing Costs of Mobile Home Gas Furnaces . . . . . . . . . 6-25

Figure 7.3.1 Number of GAMA Listed Furnace Models by Input Capacity . . . . . . . . . . . . . 7-3

Figure 7.3.2 Supply-Air Outlet Area for Non-Condensing Natural Gas Furnaces . . . . . . . . 7-8

Figure 7.3.3 Supply-Air Outlet Area for Condensing Natural Gas Furnaces . . . . . . . . . . . . 7-9

Figure 7.4.1 Percent of Existing Furnaces by Input Capacity . . . . . . . . . . . . . . . . . . . . . . . 7-12

Figure 7.5.1 Sample of System Curves with a Typical Fan Curve . . . . . . . . . . . . . . . . . . . 7-16

Figure 7.5.2 Fan Curves for 800 cfm Virtual Furnace Model . . . . . . . . . . . . . . . . . . . . . . . 7-17

Figure 7.5.3 Fan Curves for 1200 cfm Virtual Furnace Model . . . . . . . . . . . . . . . . . . . . . . 7-17

Figure 7.5.4 Fan Curves for 1600 cfm Virtual Furnace Model . . . . . . . . . . . . . . . . . . . . . . 7-17

Figure 7.5.5 Fan Curves for 2000 cfm Virtual Furnace Model . . . . . . . . . . . . . . . . . . . . . . 7-17

Figure 7.5.6 Overall Air-Moving Efficiency of Existing Furnaces . . . . . . . . . . . . . . . . . . . 7-19

Figure 7.5.7 Overall Air-Moving Efficiency of Non-Condensing Virtual Furnace Models 7-20

Figure 7.5.8 Overall Air-Moving Efficiency of Condensing Virtual Furnace Models . . . . 7-20

Figure 7.9.1 Range of Annual Gas Use, Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . 7-26

Figure 7.9.2 Range of Annual Gas Usage by Region, 90 percent AFUE, 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Figure 7.9.3 Range of Winter Electricity Use, Non-Weatherized Gas Furnaces . . . . . . . . . 7-27

Figure 7.9.4 Annual Gas Use, Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Figure 7.9.5 Winter Electricity Use, Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . 7-29

Figure 7.9.6 Annual Gas Use, Mobile Home Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Figure 7.9.7 Winter Electricity Use, Mobile Home Furnaces . . . . . . . . . . . . . . . . . . . . . . . 7-31

Figure 7.9.8 Range of Annual Oil Use, Oil Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Figure 7.9.9 Range of Winter Electricity Use, Oil Furnaces . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Figure 7.9.10 Range of Annual Gas Use, Hot-Water Gas Boilers . . . . . . . . . . . . . . . . . . . . . 7-35

Figure 7.9.11 Range of Winter Electricity Use, Hot-Water Gas Boilers . . . . . . . . . . 7-35

Figure 7.9.12 Range of Annual Oil Use, Hot-Water Oil Boilers . . . . . . . . . . . . . . . . 7-37

Figure 7.9.13 Range of Winter Electricity Use, Hot-Water Oil Boilers . . . . . . . . . . . . . . . . 7-37

Figure 8.2.1 Non-Weatherized Gas Furnace LCC Analysis–Efficiency Levels and 

Design Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Figure 8.2.2 Weatherized Gas Furnace LCC Analysis– Efficiency 

Levels and Design Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Figure 8.2.3 Mobile Home Gas Furnace LCC Analysis–Efficiency 

Levels and Design Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Figure 8.2.4 Oil Furnace LCC Analysis–Efficiency Levels and Design Options . . . . . . . . . 8-8

Figure 8.2.5 Hot-Water Oil Boiler LCC Analysis–Efficiency Levels and Design Options . 8-9
1-xxvi

Figure 8.2.6 Hot-Water Gas Boiler LCC Analysis–Efficiency Levels and Design Options 8-10

Figure 8.3.1 First Cost for Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Figure 8.3.2 Manufacturing Costs ($) for Baseline Model Non-Weatherized Furnaces by 

Input Capacity and Airflow Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Figure 8.3.3 Example RECS97 Household: Billing Data . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Figure 8.3.4 Example RECS97 Household: Regression Lines, Slopes . . . . . . . . . . . . . . . . 8-20

Figure 8.4.1 Range of LCC Savings for Non-Weatherized Gas Furnaces . . . . . . . . . . . . . . 8-29

Figure 8.4.2 LCC Savings for Each Census Division for the 90 percent AFUE 

Condensing Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Figure 8.4.3 LCC Savings Ranges by Design Option for Weatherized Gas Furnaces . . . . 8-32

Figure 8.4.4 LCC Savings Ranges by Design Option for Mobile Home Furnace . . . . . . . . 8-34

Figure 8.4.5 LCC Savings Ranges by Design Option for Oil-Fired Furnaces . . . . . . . . . . . 8-36

Figure 8.4.6 LCC Savings Ranges by Design Option for Hot-Water Gas Boilers . . . . . . . 8-38

Figure 8.4.7 LCC Savings Ranges by Design Options for Hot-Water Oil-Fired Boilers . . 8-40

Figure 10.2.1 NES and NPV Process and Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Figure 10.3.1 Non-discounted Annual Installed Cost Increases and Annual Operating 

Cost Savings at the National Level for the 81 percent AFUE 

Non-Weatherized Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

Figure 6.1.3.1 Bill of Materials Sample ........................................ 6.6-5

Figure 6.1.5.1 Cost Model Structure ........................................... 6.6-8

Figure 6.1.5.2 Sample of Global Controls Sheet .................................. 6.6-9

Figure 6.1.5.3 Subassembly Breakdown ........................................ 6.6-9

Figure 6.1.5.4 Site Table Spreadsheet ......................................... 6.6-10

Figure 6.1.5.5 Components Sheet ............................................ 6.6-10

Figure 6.1.5.6 In-house Fabrication Process .................................... 6.6-11

Figure 6.1.5.7 Raw Materials Sheet .......................................... 6.6-11

Figure 6.1.6.1 Standard Deviations of Manufacturing Costs ....................... 6.6-13

Figure 6.2.2.1 Common Venting Options for a Typical U.S. Single Family Home ....... 6.2-2

Figure 6.2.2.2 Year 2003 Furnace Category Distribution ........................... 6.2-3

Figure 6.2.2.3 Illustration of Lined Masonry Chimney Vented Installations ............ 6.2-6

Figure 6.2.2.4 Illustration of Type B Double Wall Metal Vented Installations .......... 6.2-6

Figure 6.2.2.5 Illustration of Horizontal Sidewall Plastic Vented Installations .......... 6.2-7

Figure 6.2.2.6 Approximate Chimney Size Distribution: Existing Housing Stock ....... 6.2-9

Figure 6.2.3.1 Model Structure Overview (Illustration Only) ...................... 6.2-16

Figure 6.2.3.2 Furnace Size Distribution ...................................... 6.2-21

Figure 6.2.3.3 Average Ceiling Height ........................................ 6.2-22

Figure 6.2.3.4 Number of Floor in a Dwelling .................................. 6.2-23

Figure 6.2.3.5 Basement Types .............................................. 6.2-23

Figure 6.2.3.6 NWGF, 1-Floor Living Area (LCC 1997 RECS) .................... 6.2-25

Figure 6.2.3.1 81% AFUE: Breakdown of Installation Cost Deltas (81%-80%) ........ 6.2-33

Figure 6.2.5.2 83% AFUE: Breakdown of Installation Cost Deltas (83%-80%) ........ 6.2-34
1-xxvii

Figure 6.2.5.3 90% AFUE: Breakdown of Installation Cost Deltas (90%-80%) ........ 6.2-35

Figure 6.2.6.1 81%A AFUE Two-stage Modulation Incremental Cost Distributions .... 6.2-39

Figure 6.2.6.2 83% AFUE All Stainless Incremental Cost Distributions .............. 6.2-39

Figure 6.2.6.3 90% AFUE Condensing Incremental Cost Distributions .............. 6.2-40

Figure 6.2.6.4 Baseline, 81%A, 83%, and 90% Tornado Charts .................... 6.2-41

Figure 6.2.6.5 Regional Variation Effects on Incremental Costs .................... 6.2-42

Figure 6.2.6.6 Masonry Relining Effects on Incremental Costs ..................... 6.2-43

Figure 7.1.1 Map Showing Relationship Between the Furnace Data Table, 

Pressure Table, and Power Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1-3

Figure 7.1.2 Map Showing Relationship Between the Furnace Data Table, 

Series Table, and Delay Times Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1-3

Figure 7.1.3 Map Showing Relationship Between the GAMA Directory April 2002 

Table Model Translation Table, and the Furnace Data Table ............ 7.1-4

Figure 7.1.4 Map Showing Relationship Between the Series Table, References 

Table, and Bibliographies Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1-4

Figure 7.3.1 Number of Non-Weatherized Furnace Models by Input Capacity ........ 7.3-2

Figure 7.5.1.1 Blower Fan Curves for Lau #DD9-8A ......................... 7.5-2

Figure 7.5.1.2 Blower Fan Curves for Lau #DD10-8A ........................ 7.5-2

Figure 7.5.1.3 Blower Fan Curves for Lau #DD10-10A ....................... 7.5-3

Figure 7.5.1.4 Blower Fan Curves for Lau #DD11-10AT ...................... 7.5-3

Figure 7.6.1.1 Overall Air-Moving Efficiency (non-condensing, cooling mode) ........ 7.6-2

Figure 7.6.1.2 Overall Air-Moving Efficiency (non-condensing, low-fire mode) ........ 7.6-2

Figure 7.6.1.3 Overall Air Moving Efficiency (non-condensing, heating mode) ......... 7.6-3

Figure 7.6.1.4 Overall Air-Moving Efficiency (condensing, cooling mode) ............ 7.6-3

Figure 7.6.1.5 Overall Air Moving Efficiency (condensing, heating mode) ............ 7.6-4

Figure 7.6.1.6 Overall Air-Moving Efficiency (condensing, low-fire mode) ............ 7.6-4

Figure 7.7.3.1 XR and XH versus Balance-Point Temperature for Modulating Furnaces 

and Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7-4

Figure 8.2.1.1 Distribution of New Home Mortgage Nominal Interest Rates ........... 8.2-1

Figure 8.2.2.1 Distribution of Second Mortgage Nominal Interest Rates ............... 8.2-2

Figure 8.2.2.2 Distribution of Credit Card Nominal Interest Rates ................... 8.2-3

Figure 8.2.2.3 Distribution of CD’s Nominal Interest Rates ........................ 8.2-3

Figure 8.2.2.4 Distribution of T-Bill Nominal Interest Rates ........................ 8.2-4

Figure 8.2.2.5 Distribution of Corporate Bond Nominal Interest Rates ................ 8.2-4

Figure 8.2.2.6 Distribution of S&P 500 Nominal Return Rates ...................... 8.2-5

Figure 8.3.2.1 National LCC Savings for Non-Weatherized Gas Furnaces, Using GRI Data 8.3-3

Figure 8.3.2.2 National LCC Savings for Non-Weatherized Gas Furnaces, 
1-xxviii

Using NRCan Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3-6

Figure 8.3.3.1 National LCC Savings for Gas Boilers, Using GRI Data ............... 8.3-8

Figure 8.4.1.1 Residential Natural Gas Price Forecast (AEO 2003) ................. 8.4-1

Figure 8.4.1.2 Residential Electricity Price Forecast (AEO 2003) .................. 8.4-2

Figure 8.4.1.3 Residential Oil Fuel Price Forecast (AEO 2003) .................... 8.4-2

Figure 8.4.2.1 National LCC Savings Results for Non-Weatherized Gas Furnaces 

(High Growth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4-5

Figure 8.4.2.2 National LCC Savings Results for Weatherized Furnaces (High Growth) 8.4-7

Figure 8.4.2.3 National LCC Savings Results for Mobile Home Furnaces (High Growth) 8.4-9

Figure 8.4.2.4 National LCC Savings Results for Oil Furnaces (High Growth) ....... 8.4-11

Figure 8.4.2.5 National LCC Savings Results for Gas Boilers (High Growth) ........ 8.4-13

Figure 8.4.2.6 National LCC Savings Results for Oil Boilers (High Growth) ........ 8.4-15

Figure 8.4.3.1 National LCC Savings Results for Non-Weatherized Gas Furnaces 

(Low Growth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4-18

Figure 8.4.3.2 National LCC Savings Results for Weatherized Furnaces (Low Growth) 8.4-20

Figure 8.4.3.3 National LCC Savings Results for Mobile Home Furnaces (Low Growth) 8.4-22

Figure 8.4.3.4 National LCC Savings Results for Oil Furnaces (Low Growth) ....... 8.4-24

Figure 8.4.3.5 National LCC Savings Result for Oil Boilers (Low Growth) ......... 8.4-26

Figure 8.4.3.6 National LCC Savings Results for Gas Boilers (Low Growth) ........ 8.4-28

Figure 8.5.7.1 Range of Annual Gas Use, Non-Weatherized Gas Furnaces ........... 8.5-8

Figure 8.5.7.2 Range of Winter Electricity Use, Non-Weatherized Gas Furnaces ...... 8.5-8

Figure 8.5.7.3 Range of Summer Electricity Use, Non-Weatherized Gas Furnaces ..... 8.5-9

Figure 8.5.7.4 Range of Annual Gas Use, Mobile Home Furnaces ................. 8.5-11

Figure 8.5.7.5 Range of Winter Electricity Use, Mobile Home Furnaces ............ 8.5-11

Figure 8.5.7.6 Range of Summer Electricity Use, Mobile Home Furnaces ........... 8.5-12

Figure 8.5.7.7 Range of Gas Use, Weatherized Gas Furnaces ..................... 8.5-14

Figure 8.5.7.8 Range of Winter Electricity Use, Weatherized Gas Furnaces ......... 8.5-14

Figure 8.5.7.9 Range of Summer Electricity Use, Weatherized Furnaces ............ 8.5-15

Figure 8.5.7.10 Range of Oil Use, Oil-Fired Furnaces ........................... 8.5-17

Figure 8.5.7.11 Range of Winter Electricity Use, Oil-Fired Furnaces ................ 8.5-17

Figure 8.5.7.12 Range of Summer Electricity Use, Oil-Fired Furnaces .............. 8.5-18

Figure 8.5.7.13 Range of Gas Use, Hot Water Gas Boilers ........................ 8.5-20

Figure 8.5.7.14 Range of Winter Electricity Use, Hot Water Gas Boilers ............ 8.5-20

Figure 8.5.7.15 Range of Annual Oil Use, Hot-Water Oil Boilers .................. 8.5-22

Figure 8.5.7.16 Range of Winter Electricity Use, Hot-Water Oil Boilers ............. 8.5-22

Figure 8.5.8.1 Range of LCC Savings by Design Option for Non-Weatherized 

Gas Furnaces ............................................... 8.5-25

Figure 8.5.8.2 Range of LCC Savings by Design Option for Weatherized Gas Furnaces 8.5-27

Figure 8.5.8.3 Range of LCC Savings by Design Option for Mobile Home Gas Furnaces 8.5-29

Figure 8.5.8.4 Range of LCC Savings by Design Option for Oil-Fired Furnaces ...... 8.5-31

Figure 8.5.8.5 Range of LCC Savings by Design Option for Hot-Water Gas Boilers . . . 8.5-33

Figure 8.5.8.6 Range of LCC Savings by Design Option for Hot-Water Oil-Fired Boilers8.5-35
1-xxix

Figure 8.6.3.1 Schematic of Airflow Apparatus – from Figure 12 of AMCA 210 ........ 8.6-6

Figure 8.6.3.2 Airflow Measurement Apparatus at Energy System Laboratory ......... 8.6-7

Figure 8.6.4.1 Airflow versus Static Pressure for Three Motor/Blower Combinations at 

Highest Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6-9

Figure 8.6.4.2 Comparison with Manufacturer's Reported Airflow versus Static Pressure 

Data at the Highest Blower Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6-10

Figure 8.6.4.3 Airflow Efficiency versus Static Pressure at Highest Blower Speed Setting 8.6-11

Figure 8.6.5.1 Blower Speed versus Airflow ................................... 8.6-12

Figure 8.7.3.1 Iso-Efficiency Lines for GE ECM 2.3 ............................ 8.7-4

Figure 8.7.3.2 Plot of Iso-Efficiency Lines Against Speed and Shaft Power .......... 8.7-5

Figure 8.7.3.3 Plot of Rotated Iso-Efficiency Lines ............................. 8.7-6

Figure 8.7.3.4 Residuals of Y After Subtracting Predicted 76% Efficiency Y Values . . . 8.7-8

Figure 8.7.3.5 Fit of Transformed Efficiency to Difference between Y and 76% 

Efficiency Y Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7-9

Figure 8.7.4.1 Comparison of Reported to Estimated Blower Motor Input Power ..... 8.7-11

Figure 8.8.2.1 Pressure and Shaft Power versus Airflow at Constant Speed ............ 8.8-2

Figure 8.8.5.1 SEF Versus Nominal Airflow for Virtual Model Furnaces ............. 8.8-6

Figure 8.8.7.1 Efficiencies and Operating Range of Prototype Motor ................ 8.8-10

Figure 10.1.2.1 Non-Weatherized Gas Furnaces Installation Cost Scenarios (Quads) . . 10.1-2

Figure 10.1.2.2 Non-Weatherized Gas Furnaces Installation Cost Scenarios (NPV) . . . 10.1-3

Figure 10.1.2.3 Gas Boiler Installation Cost Scenarios (Quads) .................. 10.1-4

Figure 10.1.2.4 Gas Boiler Installation Cost Scenarios (NPV) .................... 10.1-5

Figure 10.1.4.1 Weatherized Gas Furnace Energy Price Scenarios (Quads) ........ 10.1-11

Figure 10.1.4.2 Non-Weatherized Gas Furnaces Energy Price Scenarios (Quads) . . . 10.1-12

Figure 10.1.4.3 Mobile Home Furnace Energy Price Scenarios (Quads) .......... 10.1-12

Figure 10.1.4.4 Oil Furnace Energy Price Scenarios (Quads) ................... 10.1-13

Figure 10.1.4.5 Oil Boiler Energy Price Scenarios (Quads) ..................... 10.1-13

Figure 10.1.4.6 Gas Boiler Energy Price Scenarios (Quads) .................... 10.1-14

Figure 10.1.4.7 Non-Weatherized Gas Furnace Energy Price Scenarios (NPV) ..... 10.1-14

Figure 10.1.4.8 Weatherized Gas Furnace Energy Price Scenarios (NPV) ......... 10.1-15

Figure 10.1.4.9 Mobile Home Energy Price Scenarios (NPV) ................... 10.1-15

Figure 10.1.4.10 Oil Furnace Energy Price Scenarios (NPV) .................... 10.1-16

Figure 10.1.4.11 Gas Boiler Energy Price Scenarios (NPV) ..................... 10.1-16

Figure 10.1.4.12 Oil Boiler Energy Price Scenarios (NPV) ...................... 10.1-17