MAINTENANCE AND REPA IR COST DETERMINATIO N FOR APPENDIX 8

- E.

COMMERCIAL PACKAGED BOILERS

TABLE OF CO NTENTS

8

- E.1 INTRODUCTION

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

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- 1
8

- E.2 MAINTENANCE COST FOR COMMERCIAL PACKAGED BOILERS

.......... 8

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- 1
8

- E.3 REPAIR COST FOR COMM ERCIAL PACKAGED BOIL ERS

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

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8

- E.4 REGIONAL MATERIAL AN D LABOR COSTS

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

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- 5

LIST OF TABLES

Table 8

- E.1.1 Example Cost Table

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

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- 1
Table 8

- E.2.1 Example Maintenance Tasks and Costs of 120

- 500 kBtu/h Hot Water
Boiler Based on 2013 RS Means Data

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

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- 3
Table 8

- E.2.2 Annualized Maintenance Costs Based on 2013 RS Means Data

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

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- 4
Table 8

- E.3.1 Boiler Repair Rates

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

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- 5
Table 8

- E.3.2 Boiler Repair Costs and Labor Hours

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

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- 5
Table 8

- E.4.1 RS Means 2013 National Average Labor Costs by Crew

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

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Table 8

- E.4.2 RS Means Labor Costs Markups by Trade

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

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- iMAINTENANCE AND REPA IR COST DETERMINATIO N FOR APPENDIX 8

- E.

COMMERCIAL PACKAGED BOILERS

8

- E.1 INTRODUCTION

This appendix provides further details about the derivation of maintenance and repair costs for commercial packaged boilers.

The U.S. Department of Energy (DOE) estimate s maintenance and repair costs for boilers based on RS Means, a construction estimation database that is used by professional estimator s for up to date labor, materials and overhead costs for specific project types and locations

, as well

as manufacturer literature and info rmation from expert consultants. Table 8

- E.1.1 offers an example of the cost calculation method using RS Means data

. The cost calculation consists of first estimating the material and labor costs, and then applying appropriate markups and summing the two quantitie s to get a final cost value. All labor costs are derived using the latest

commercial 201 3 RS Means labor costs by crew type. 1 Maintenance and repair cost tables sometimes include a trip charge, which is often charged by contractors and estimated to be eq ual to one half hour of labor per crew. Labor hours (or person

- hours) are based on RS Means data, expert consultant information, or engineering judgment. Bare costs include all costs without any markups. Material costs are based on RS Means data, expert da ta, or other sources. The subtotal column is the sum of the material and labor costs without markups. The final total column includes overhead and profit (O&P). To clarify, the labor costs shown in the tables in this appendix are the national average valu es, in its analysis, DOE use s regional labor and material markups to more accurately estimate installation costs by region. Section 8

- D. 3 describes the derivation of regional labor costs. DOE then applie s the appropriate regional labor cost to each Commercial Building Energy Consumption Survey ( CBECS ) sample building.

Table 8

- E.1.1 Example Cost Table

Description Crew Labor

Hours Unit Bare Costs ( 2012$ ) Quantity Total
incl.

O&P Material Labor Subt otal

Trip Charge CREW1 0.5

- 0.00 23.00 23.00 1 35.00
Description of Installation Item CREW1 0.5 Ea. 15.00 23.00 48.00 1 51.50

Total 1.0 15.00 46.00 71.00 86.50

8

- E.2 MAINTENANCE COST FOR COMMERCIAL PACKAGED BOILERS

The maintenance cost is the routine cost to the commercial consumer of general
maintenance for equipment operation . DOE estimate s the labor hours and costs for each

maintenance task from 2013 RS Means Facilities Maintenance and Repair Cost Data

. 1 The maintenance cost depends on boiler capacity and heating medium (hot water or steam). Within

8

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- 1an equipment class, DOE assume s that the maintenance cost is the same at all non

- condensing efficiency levels, and that the maintenance cost at condensing efficiency levels is slightly higher

, due to an added cost for a condensate neutralizer

. Table 8

- E.2.1 presents an example of the
considered maintenance costs for a 120

- 500 k B tu/h h ot w ater boiler

. Each maintenance task has

a n associated crew type

, number of labor hours , and frequency of occurrence

. RS Means does
not itemize m aterial co sts by task

, but presents them as a total annualized value. 8

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- 4

8

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- 2Table 8

- E.2.1 Example Maintenance Tasks and Costs of 120

- 500 k B tu/h H ot W ater

B oiler Based on 2013 RS Means Data

Task

ID Task Description Labor

H ou rs Material
Cost Freq uency (times per year)

1 Check combustion chamber for air or gas leaks. 0.077

- 1

2 Inspect and clean oil burner gun and ignition assembly where applicable. 0.835

- 1

3 Inspect fuel system for leaks and change fuel filter element, where applicable. 0.125

- 1

4 Check fuel lines and connections for damage. 0.023

- 12

5 Check for proper operational response of burner to
thermostat controls. 0.169

- 4

6 Check and lubricate burner and blower motors. 0.099

- 4

7 Check main flame failure protection and main flame detection scanner on boiler equipped with spark ignition (oil burner). 0.155

- 12

8 Check electrical wiring to burner controls and
blower. 0.100

- 1

9 Clean firebox (sweep and vacuum). 0.793

- 1

10 Check operation of mercury control switches (i.e., steam pressure, hot water temperature limit, atomizing or combustion air proving, etc.). 0.185

- 12

11 Check operation and condition of safety pressure
relief valve. 0.038

- 12

12 Check operation of boiler low water cut off devices. 0.070

- 12

13 Check hot water pressure gauges. 0.073

- 12

14 Inspect and clean water column sight glass (or replace). 0.160

- 12

15 Clean fire side of water jacket. 0.433

- 1

16 Check condition of flue pipe, damper and exhaust
stack. 0.183

- 4

17 Check boiler operation through complete cycle, up
to 30 minutes. 0.806

- 1

18 Check fuel level with gauge pole, add as required. 0.046

- 12

19 Clean area around boiler. 0.137

- 12

20 Fill out maintenance checklist and report deficiencies. 0.022

- 12

Total 15.881 $101
Reference: 2013 RS Means Maintenance and Repair Cost Data , Page 413, D3025 130 2950

.

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- 3Table 8

- E.2.2 shows the annualized maintenance costs for representative commercial packaged boilers.

Table 8

- E.2.2 Annualized Maintenance Costs Based on 2013 RS Means Data

Description Crew Labor Hours Material Cost

Steam H ot W ater Steam H ot W ater
Maintenance (Small boilers) 1 STPI 20.7 0 17.38 $196 $108
Maintenance (Large boilers) 1 STPI 27.72 26.66 $332 $164

DOE assume s that all steam boilers and oil

- fired boilers are maintained regularly by on

site maintenance staff, and that the maintenance tasks occur at the frequency specified in RS

Means. DOE assume s that gas

- fired hot water boilers may or may not be maintained regularly.
The CBECS and Residential Energy Consumption Survey ( RECS ) survey data provide s informa tion on whether building owners maintain their equipment regularly. For gas

- fired hot water boilers, if the building owner reported that the site maintenance staff did not maintain the building’s equipment regularly, then DOE assume s maintenance occurred o ne third as often as specified in RS Means. If the building owner reported regular equipment maintenance , then DOE

assume s maintenance occurred at the frequency specified in RS Means.

DOE investigated the effec ts of recent low

- sulfur fuel oil requirements on oil boiler
maintenance. DOE assumed that all fuel oil boilers, regardless of fuel oil sulfur content , will be maintained with the same frequency. Therefore

, the maintenance costs between boilers using regular and low

- sulfur fuel oil are assumed to be the same.

8

- E.3 REPAIR COST FOR COMM ERCIAL PACKAGED BOIL ERS

The repair cost is the cost to the commercial consumer for replacing or repairing components in the boiler that have failed. DOE estimate s repair costs at each considered
ef

ficiency level using a variety of sources, including 201 3 RS Means Facility Maintenance and Repair Cost Data

, 1 manufacturer literatur e, and information from expert consultants. Heat exchanger replacement costs are assumed to be 1/3 of the total boiler replacement cost. DOE

account s for regional differences in labor costs , as is discussed in appendix 8

- D

.

Table 8

- E.3.1 and Table 8

- E.3.2 show repair rate and cost assumptions used in the analysis. The failu re year distribution is assumed to be a Weibull function for each component. The mean failure years for the ignition, controls, mechanical vent damper, and power vent were based on RS Means. The heat exchanger mean failure year i s based on a report from th e Gas Research Institute (GRI)

. 2 DOE assume s that all boilers have a one

- year warranty for parts and
labor and a ten

- year warranty on the heat exchanger. If any component of a boiler fail s in one year or less, then the cost of the repair i s presumed free for the owner. If the heat exchanger fail s be tween 1 and 10 years, it i s pre sumed that there is no material cost to the owner, but there i s still
a labor cost.

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- 4Table 8

- E.3.1 Boiler Repair Rates Repair Description Mean Failure Year Repair Rate Ignition, Controls 7.0 50% Mechanical Vent Damper or Power Vent Blower 15.0 35% Heat Exchanger 20 .0 17%

Table 8

- E.3.2 Boiler Repair Costs and Labor Hours

Repair Description Bare Material Cost (2013$)* Total Labor Hours

Gas Oil Gas Oil Large Small Large Small Large Small Large Small Ignition, Controls, Gas Valve, Automatic Means (Baseline) $4072 $1668 $395 $389 15 6 4 4

Ignition, Controls, Gas Valve, Automatic Means (Condensing) $4072 $1668 $395 $389 15 6 4 4

Mechanical Vent Damper $59 $56 $59 $56 7 7 7 7

Power Vent Blower $236 $223 $236 $223 7 7 7 7

*Does not include sales tax or markups.

8

- E.4 REGIONAL MATERIAL AN D LABOR COSTS

DOE use s regional material and labor costs to more accurately estimate installation, maintenance, and repair costs by region. RS Means provides average national labor costs for different trade groups as shown in Table 8

- E.4.1

. Bare costs are given in RS Means, while labor costs including O&P are the bare costs multiplied by the RS Means markups by trade shown i n Table 8

- E.4.2

.

Table 8

- E.4.1 RS Means 2013 National Average Labor Costs by Crew

Crew

No. Crew Description No. of

Laborers Cost per Labor

- Hour

Bare Costs Incl. O&P
Q1 1 Plumber, 1 Plumber Apprentice 2 50.23 $78.15

1 STPI 1 Steamfitter or Pipefitter 1 56.65 $88.15

Q5 1 Steamfitter, 1 Steamfitter Apprentice 2 50.98 $79.32

Q7 1 Steamfitter Foreman, 2 Steamfitters, 1 Steamfitter Apprentice 4 53.94 $83.93

* O& P includes markups in Table 8

- E.4.2

8

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- 5Table 8

- E.4.2 RS Means Labor Costs Markups by Trade

Trade Workers Comp. Aver age Fixed
Overhead Overhead Profit Total

Plumber , Steamfitter, and Pipefitter (Repair/ Remodel) 6.7 % 17.9% 16 .0% 15 .0% 55.6 %

RS Means also provides material and labor cost factors for 295 cities and towns in the U.S. To derive average labor cost values by state, DOE weight s the price factors by city or town population size using 2012 census data. DOE use s the material and labor cost factors for cost associated with fire suppression, p lumbing , and heating, ventilating, and air conditioning . See appendix 8

- D for more details.

8

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- 6REFERENCES

1. RS Means Company Inc., RS Means Facilities Maintenance & Repair Cost Data . 2013. Kingston, MA.

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

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

- 94/0175.

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