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From the installation instructions from the water heater manufacturer our Florida homeowner has in his home: “If this water heater is installed in a closed water supply system, such as the one having a back-flow preventer in the cold-water supply, provisions shall be made to control thermal expansion. DO NOT operate this water heater in a closed system without provisions for controlling thermal expansion. Your water supplier or local plumbing inspector should be contacted on how to control this situation.”

I wonder too about the wisdom of locating the secondary pressure relief valve outdoors. The potable water that wastes, the potential for contamination (think flooding during hurricanes or heavy rains that potentially submerge the relief valve), and eventual fowling or failing partially open, which may well go unnoticed for an extended period of time. Bugs no doubt will appreciate the source of water! Discharge from the water heater’s T&P relief valve must terminate with an air gap and these secondary relief valves also must also terminate with an air gap.

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Words have an impact, and from this master plumber’s perspective, it begs the question: are we controlling or limiting thermal expansion? We do control thermal expansion when a properly sized TXT is installed on a closed potable water system. If, on the other hand, we are installing a secondary pressure relief valve that limits system pressure to 125 PSI, that is a pressure-limiting device and we are not actually controlling thermal expansion.

If a potable water system has a backflow device, pressure-reducing valve or check valve where it enters the building, it is a closed system. Long ago, we had open systems where thermal expansion simply pushed water back into the municipal water system and we were blissfully unaware of thermal expansion pressure issues. Pressure-reducing valves had an internal bypass relief that allowed increased pressure caused by thermal expansion to push through the internal relief and move back into the service line.

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Clearly, the homeowner has done his research and makes valid points regarding the conflicts within the Uniform Plumbing Code that was adopted by his local Authority Having Jurisdiction. My reply:

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It appears Collier County has allowed the use of installing a secondary Pressure Relief Valve outdoors to replace the required installation of a Thermal Expansion Tank indoors.

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The question, it seems, is if utilizing a secondary relief valve set to 125-PSI constitutes uncontrolled thermal expansion and that repeated cycles between 80 PSI to 125-PSI will have an adverse impact on the plumbing system’s components.

Some of the secondary pressure relief valve manufacturers have disparaging content regarding TXTs that doesn’t hold up to my decades of TXT experience. It is common for properly sized TXTs to last the lifetime of the tank-style water heater and when a new water heater was installed, the TXT was also replaced.

There's that word "control" again. The IPC (commentary edition) uses the same word in 607.3 and goes further regarding thermal expansion in 607.3.1 when discussing pressure-reducing valves by stating the PRVs with pressure bypass can no longer be used as a means to relieve thermal expansion, and the downstream pressure cannot exceed the reduced pressure setting due to thermal expansion. That's not realistic, even with a properly sized thermal expansion tank as there will certainly be a small rise in a closed system’s pressure. PRVs with internal bypass are mostly a moot point anyway due to municipal water companies installing dual-check valves or testable BFPs where more than a few apartments (two in our case) exist connected to the same water service. Interesting to see the code touch upon why the repeated opening/closing of the T&P valve raises a safety concern. In 607.3 the code book commentary does note a thermal expansion tank is typically installed to control thermal expansion.

Semantics! Where a properly sized thermal expansion tank does control thermal expansion, a secondary relief valve, even if its specific purpose is to relieve excessive pressure, does not (in my opinion) control thermal expansion — it relieves excessive pressure. While the two are related, they are not the same.

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The builder stock has advised me that Collier County approved the method of not installing any Thermal Expansion Tank on closed loop water heater systems, and substituted a small Boiler Relief Pressure Valve mounted outdoors.

If the AHJ allows pressure relief valves or TXTs, then it’s your call as to which one you believe best serves your customer’s needs. Even better, educate the homeowner(s) and let them decide.

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When our local water company began installing dual-check backflow preventers, we suddenly found gas-fired water heaters developed collapsed flue tubes, which caused the byproducts of combustion to spew forth from their access doors. The hot and cold water lines were cocked at odd angles, too, looking like a bowlegged cowboy! Customers were less than thrilled when told they needed a new water heater.

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Lots of confusion reigned supreme regarding how to deal with the thermal expansion-generated increased pressure. At that time, in the early 1980s, available potable water thermal expansion tanks were not rated to 150 PSI, so a secondary relief valve had to be installed. In addition to TXTs (thermal expansion tanks), there was a ballcock valve that would relieve pressures in excess of 80 PSI and they are still available. Eventually, potable water TXTs became widely available with a 150 PSI rating. Unfortunately, very little information was available, with much of it misleading in regards to properly sizing the TXTs.

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I found your contact on PM site and wanted to reach out to see if you could assist me in direction concerning our county in Florida allowing the elimination of expansion tanks on closed loop systems and replace it with another pressure relief valve mounted outdoors.

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As pros, we must design for worst-case conditions. No matter where you live, you will see 40° F incoming cold water from municipal systems during winter months. Although tank-style water heaters come with a theoretical 120° F thermostat setting, ASSE codes recognize thermal stacking happens where layers of water as much as 30° F above the thermostat setting can occur, which makes the upper limit of 150° F code compliant. Then, along come homeowners who jack up the thermostat setting because they run out of hot water! Plumbing codes limit water pressure to 80-PSI before a pressure-reducing valve is required. In theory, we should be sizing our thermal expansion tanks for a 110° F temperature rise and thermal expansion charts provide a multiplier of .01787, which for a 50-gallon water heater equals .89, or 9/10ths of 1-gallon.

I have always purchased commentary editions for plumbing and mechanical code books because each code rule is followed with commentary on how to interpret the code. For example, following the IPC 607.3 Thermal Expansion Control code passage, the commentary addresses uncontrolled pressure increases due to thermal expansion and states that elevated pressure above 80 PSI causes faucets and other system components to have shorter than normal lifespans. Also addressed are the stresses placed on water heater tanks due to frequent pressure fluctuations caused by uncontrolled thermal expansion.

There are three methods to control tank pressure and one method to control thermal expansion. Emergency Pressure Relief, Emergency Temperature Relief, combo T&P Emergency Relief, and Regulate/Control Thermal Expansion in a contained environment using an Expansion Tank. All of these are required by the manufacturer of the Heater Tank. Relief valves do not balance the pressure on a continuous cycle as an expansion tank performs.

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I have always purchased commentary editions for plumbing and mechanical code books because each code rule is followed with commentary on how to interpret the code. For example, following the IPC 607.3 Thermal Expansion Control code passage, the commentary addresses uncontrolled pressure increases due to thermal expansion and states that elevated pressure above 80 PSI causes faucets and other system components to have shorter than normal lifespans. Also addressed are the stresses placed on water heater tanks due to frequent pressure fluctuations caused by uncontrolled thermal expansion.

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Dave Yates began his career in the PHCP-PVF trades in 1972 with F. W. Behler, a third-generation plumbing/ HVAC firm he purchased in 1985. Besides running F.W. Behler, writing articles for industry trade publications and speaking at events, Yates also is an experienced teacher in the hydronics industry, serving as an adjunct professor and on the Technical Advisory Board for the Thaddeus Stevens College of Technology. He can be reached at dyates@consultyates.com.