Unit 3 - Hot Water Supply

UNIT III: HOT WATER SUPPLY
Syllabus content
3.1 Systems of hot water supply using conventional and non-conventional energy sources. -
Instantaneous and Centralized - Direct system and In-Direct system - Components and Equipment
used for the same.
3.2 Piping Insulation, safety and special considerations in piping network.
3.3 Failures, precautions, and safety measures
3.4 Information on other Circulation systems i.e. ring system, up-feed/ down-feed systems, etc. and
its application.
Hot water is needed for bathing and washing in domestic use. It is used in kitchens and bathrooms in
residential areas. It is also required for laundries and industrial kitchens and in buildings like hotels,
hospitals, schools, hostels industrial canteens etc. Hot water is also required as a heating medium for
space heating and air conditioning.
Fuels used for hot water supply-
1.Wood- wood is now restricted to small boilers used in the small scale industry other fuels such as
rice husk bagasse are extensively used in specific areas where they are available as byproducts of
Agricultural and manufacturing processes
2.Coal- use of coal in boilers is confined to industrial applications only. It is cheaper than liquid or
gas fuels. It requires large area for storage and is difficult to handle besides polluting the environment.
Coal fired boilers are also larger than boilers using other fuels because they have a greater furnace
heating surface area due to the low calorific value of coal. Additional space is also required for storing
the coal.
3. Liquid fuels- they are petroleum products and are fired into the boiler furnace sprayed by suitable
oil firing equipment. They take less space and are easier to handle. Depending on local climatic
conditions they need preheating at different stages of storage and use. Liquid fuels if badly handled
can be a serious fire hazard and must be transported stored and used in a manner established by
known safety procedures.
4. Gases- they are clean and efficient form of fuel for boilers. The source gas is usually piped city -
gas from which a connection is obtained. Liquefied Petroleum gas (LPG) may be supplied from gas
stored in high pressure tanks known as bullets or cylinder banks. All fuel gases are convenient and
easy to store they do not require much storage space.
5. Electricity it is the most efficient form of energy for heating water. It is clean, requires no storage
and is less hazardous than other fuels. Electric boilers are compact and modern.
6. Solar energy- A wide variety of solar heating systems are now in use. Solar heating systems were
initially used as a supplementary hot water source to main hot water boiler but recent advances have
made such systems more efficient and reliable thus making them a primary source of hot water
supplemented by other conventional sources.
Unit III: BS I: Notes compiled by Ar. Rajashri Deshpande, ASAD, Pune & Ar. Vaishali Muneshwar, Allana COA, Pune 1
Buildings such as hotels, hospitals and manufacturing industries requiring hot water can fully utilise
solar hot water heating systems to save conventional fuels. Solar energy is in exhaustible, clean and
safe.
Gas water heaters -They can be of two types-instantaneous or storage type. The instantaneous type
may be multi-point supplying to more than one outlet or single-point supplying to one outlet only.
The multi-point type may be connected to all hot water taps. When a tap is turned on the flow of
water opens the gas valve and the gas is ignited by the pilot flames. The cold water flowing through
the appliance is heated immediately and the flow of hot water will continue as long as it is required.
When the tap is turned off, the gas is extinguished except for the pilot jet. The quantity and
temperature of water delivered per minute depends on the rate of flow of gas and its thermal
properties and the rate of flow of water. A single point instantaneous heater is controlled by a water
tap on the inlet and the hot water outlet shall have an unobstructed discharge into the bath basin, sink,
etc. The domestic storage type water heaters for use with LPG are governed by IS : 5115-1969.
In the storage type, water is heated and flows into the cylinder or tank until all the water is raised to
a temperature between 60 and 65°C whereupon the gas rate is automatically reduced by a thermostat
to that required to maintain the water at that temperature. When hot water is drawn from the cylinder
or the tank, the thermostat valve opens and the full gas rate is resorted to until the incoming cold
water has been heated. Heaters of either type have an automatic water operated gas valve interlocking
the gas and water tap.
T
h
Figure 1: Instant gas geyser
Electric heaters-
Hot water distribution methods
The distribution and supply of hot water in a building is made by two methods. In one method water
heaters or geysers are used for the hot water supply. This is called instantaneous/Individual method
while the second method is called as centralized hot water system.
Types of Hot
Water Supply
System
Individual Centralised Others
Instant type Direct Solar heating
Storage type Indirect
Figure 2: Types of hot water supply system
I) Individual method- In this method water heaters or geysers are used for the hot water supply.
Water heaters or geysers are of two types-
a) Instant water heaters-
This water heater has a small size and narrow cylindrical shape. The outer cover is made of chromium
plated (C.P.) brass or PVC. Inside this body is provided electric heating coils. The geyser is provided
with a cold water inlet at the bottom. The cold water thus enters through the bottom and is heated
when it comes in contact with the hot electrical coils and rises naturally and is taken out from the
outlet provided at the top of the geyser. The outlet has spout like shape hence hot water falls
downward which is needed to be collected in a bucket or any other similar container. Since the heater
has no storage capacity one has to ensure a continuous water flow through the geyser especially when
in use. The major shortcoming of this type of heater is that it cannot be connected through a pipe line
to supply hot water to wash basins , washing taps or to showers but can only be collected in a bucket
or similar container. Hence it's use has limitations and is invariably located especially provided in
bathing spaces only.
Figure 3: Instant type Electric geyser
b) Storage type water heaters-

This type of geyser has a long wide cylindrical shape resembling a drum and is bigger in size than
instant geysers. This type of geyser is available in different storage capacities ranging from 15 litres
to 90 litres. The outer part of the geyser is normally made out of mild steel and is thoroughly and
properly painted in different colours. The inner layer is made of thick copper sheet and between the
two metal sheets is firmly placed a thick layer of good insulating material mostly glass wool or
thermocol. Within the space of the inner cover of copper are located electrical heating coils. The
surface area of these heating coils depends upon the quantity of water to be heated and stored this
geyser is provided with thermostat control which automatically cuts off the electrical supply when
water is heated to predetermined temperature and similarly automatically puts on the electric supply
when the temperature of the water inside the geyser drops to a pre-programmed level. The geysers
are also provided with pilot lights which indicates whether the geyser is in on mode or off mode.
They are available in two varieties one which is aligned and fixed vertically and the other horizontally.
Cold water inlet pipe to geyser is usually branched from its distribution pipeline and the geyser is
connected to this pipeline through a stop cock with a flexible connecting piece usually made of PVC
door CP copper pipe.
Similarly the hot water outlet point of geyser is connected with flexible connecting pipe to hot water
distribution pipeline mostly made up of G.I. or CPVC. This pipeline can be connected to various
sanitary and bedding outlet such as wash basin taps showers etc. The outlet of hot water to such
sanitary fittings is through a mixer unit or simple bib tap or pillar cocks.
At the bottom of these geysers is provided a drain outlet which is kept close with a threaded brass
plug which can be opened whenever draining of geyser is required and the plug re-fixed after the use.
It is recommended to provide cold water connection to the geyser from overhead water storage tank
for better water pressure. They operate with the help of electricity and therefore while fixing their
position especially within wedding or our areas the electrical outlets and switches should not be e
within the position where the water reading from showers may come in contact with them hence it is
recommended to locate the geysers in a safe corner of the building areas. The bottom part of the
desert should also be so placed that it leaves sufficient headroom below it.
Figure 4: Storage type geyser
Geysers are available in the following types

1. Pressure type geysers
2. Non Pressure Type Geysers
3.Cistern type
4.Dual heater type
Pressure type Geysers:
These geysers are kept under pressure of water mains supply or an overhead tank. The
pressure allows hot water to be distributed to a number of points, generates good flow in taps and
showers, and permits mixing of hot and cold supply through a mixing fitting.
A cold- water inlet is placed at the bottom of the geyser and an outlet at the top. Whenever hot
water is drawn into the system, an equivalent amount of cold water enters displacing the hot water
used. This keeps the geyser always filled up with water, thus eliminating the danger of the geyser
emptying and the heating elements burning out.
Storage-type geysers permit a longer time for heating up the water before period of non-use. An
electric heating element of lower capacity can thus be used.
The vessel must be so constructed as to withstand the pressure it is subjected to.
Figure 5: Pressure type geyser
Non-Pressure type geyser:

Similar to pressure type except that it has a single outlet which displaces hot water
when the valve on the cold water is opened. The geyser remains full of water and is provided with
a thermostat. It can be installed on many water supply system, (e.g. overhead, direct supply etc.)
and does not require vent pipe or vacuum breaker.
Figure 6: Non Pressure type
Cistern type: geyser
The shape of the storage heater is normal is cylindrical or rectangular in shape it incorporates a feed
tank with Ball valve arranged for direct connection to the water main an overflow arrangement is
also provided
Dual heater type:

This type is a displacement water heater having two heating units one towards the top and the other
near the bottom unit being independently controlled the unit is provided with two heaters each
controlled by a thermostat one place near the top of the tank is of low rating to provide sufficient hot
water for ordinary domestic use the main heater of higher rating is place near the bottom of the tank
and can be manually switched on before a bath is required. The complete unit as manufactured
comprises a thermally insulated cylinder, electric heating element ,thermostats and pipe connections.
Individual geysers
• Individual geysers prove useful in small installations, e.g. in houses and hostels.
• When the supply points are many and the demand constant, a large number of individual
geysers present serious limitations in usage and require more power load and maintenance.
• They are useful when a building is used occasionally e.g. on weekends, or when it has a
variable occupancy, needing hot water only for a short while when the building is in use.
Safety features.
Dangers of Expansion
• Water when heated expands at 65 to 70 degree Celsius. The expansion is about 3 to 5% of its
original volume at ambient temperature. The increased volume increases the pressure within the fixed
volume of the Geyser straining it structurally.
• The boiling point of water increases with pressure.
• All pressure type geysers are controlled by an automatic thermostatic switch which cuts on and off
at preset temperatures.
• If the thermostat fails to cut off it will continue to heat the water up to its boiling point at the given
pressure.
• During the period of this overheating if the pressure drops due to water supply failure the water will
become flash steam and expand very rapidly within a few seconds.
• The limited volume of the geyser will not be able to accommodate the steam so generated if
adequate safety provisions are absent.
• The vessel may start leaking or explode with considerable force similar to a bomb blast causing
heavy damage to life and property.
Vacuum formation
Hot water geysers installed on a common cold water main in a vertical down take/riser may cause
negative pressure in some sections if the cold feed is submerged in water in the overhead tank. In
case the main cold feed valve is closed and hot water is drawn from geysers in lower floors when all
taps on the upper floors are shut, it will draw water from geysers in upper level geysers and the
vacuum will cause inward collapse of the geysers if they are not constructed strongly. Access to
atmospheric air through vent/expansion pipe, eliminates negative pressure. A check valve and
vacuum breaker installed on the inlet also eliminates the problem.
Figure 7: Explosion in geysers Figure 8: Collapse of geysers
Expansion pipe:
The expansion of hot water is overcome by providing a pipe from the top of the geyser and extending
above the water level in overhead tank the pipe acts as a vent and expansion pipe the pipe also allows
the exit of any steam formed due to overheating. The cold feed of the geyser and the vent pipe act as
a ‘U’ tube, providing hydraulic balance in the system. The expansion pipe has to be separate and
independent for each geyser. Should not have any kind of valve on it. Most geysers are also
provided with a fusable link similar to the one provided in domestic pressure cookers. Individual
expansion or vent pipes are difficult to provide in tall buildings and one has to depend on the safety
devices mentioned below in addition to the strength of the geyser.
Safety devices
All pressure type geysers should be constructed from sheets suitable for sustaining high pressure
encountered.
Each geyser must have an approved temperature and pressure relief valve set to release at preset
settings. This should be in addition to the fusible link.
A vacuum breaker must be provided on all geysers to present negative pressure.
Safety Devices
Temperature and pressure relief valve set to release at preset settings.
Vacuum breaker
Vent/expansion pipe
Figure 9: Application of Expansion Pipe
II. Centralized hot water system

Individual geysers prove useful in small installations. When the supply points are many and the
demand constant, a large number of individual geysers present serious limitations in usage and
require more power load and maintenance. In such cases centralized hot water system is more
beneficial and economical.
Main features
Centralized system has the following advantages:
1.supplies enough hot water on demand at any point of use.
2. eliminates individual geysers avoiding replacement of heating elements and overloading of power
supply system
3.It is able to meet the peak hot water demand and use the diversity of demand at different points
efficiently.
4. can prove economical in terms of capital, maintenance and fuel cost depending on equipment and
fuel used.
Thermosiphon action
Circulation of hot water from the main pipe connected to the boiler and return line can occur without
the aid of a pump by thermosiphon action which takes place due to the difference in the density of
water at different temperatures.
Thermosiphon action will take place only when the boiler is below the point of supply so that the
hottest water from the boiler rises in the main line to the top of the system. Hot water in the rest of
the system has a lower temperature and being heavy settles at the bottom of the system through the
return pipe the boiler reheated rises again to generate convection current which is known as
thermosiphon action.
The overhead tank maintenance pressure in the system through a cold feed. The hot water pipe is
extended as an expansion pipe above the overhead tank.
Figure 10: Thermosiphon action
Circulation by natural thermosiphon action is successful only in smaller installations, where the boiler
is installed in basements below the supply-line and the usage is uniform. When larger flow is required,
the limited circulating pressure makes the pipe sizes very large and uneconomical.
Forced circulation
Due to limitation of thermosiphon circulating pressure, it becomes necessary to generate additional
pressure within the system to force the circulation by means of a pump. This enables the reduction
of pipe sizes and allows hot water to circulate in all parts of the system for quick draw off.
Temperature of hot water -The design of hot water supply system and its appliance shall be based
upon the following temperatures in accordance with IS 7558 – 1974.
Scalding -65 degree Celsius
supply to sink -60 degree Celsius
supply to washbasin- 55 degree Celsius
supply to hot bath 43 degrees celsius as run and for use at 41 degrees celsius
supply for warm bath 37 degree Celsius
Hot water storage temperature 60 degree Celsius.
This may be increased to 65 degree Celsius when soft water is used.
The temperature of the supply to wash basins and for baths including supply to bath tubs and for
showers is preferably controlled by the use of a mixing valve.
The efficiency in a water heating system depends upon the measures taken to minimise heat losses
which occur from the storage vessel and from the distributing pipework and associated accessories.
Hot water storage capacity-The size of the storage vessel is governed by the maximum short time
demand of the domestic or industrial premises depending on local conditions this shall be 50 to 75
litres at 60 degrees celsius in a dwelling with a bathtub and 25 litres at 60 degree Celsius for a shower
or at tap.
The capacity of the storage vessel shall not be less than 20% in excess of the required maximum short
time demand.
Location of storage vessel -The loss of heat increases in proportion to the length of pipe between
the storage vessel and the hot water tap since each time water is drawn the pipe is filled with hot
water which then cools. The storage vessel shall therefore be so placed that the pipe runs to the most
frequently used outlets are as short as possible.
Distribution system-Special Features
Hot water generated in a central boiler must be supplied to points of use efficiently without excessive
loss of temperature and pressure. If the length of the pipe from the boiler to the point of supply is
long, the heat in the water will dissipate even when the pipes are insulated. On opening a tap hot
water will come out of it only after delivering the cold water in it taking a time of 1 to 5 minutes. The
user will waste about 8 to 50 litres of water before getting the hot water.
Recirculation
To overcome this wastage of heat, a return pipe is installed from the remotest section of the hot water
main which is connected back to the vessel supplying hot water to the building. In case there are a
number of risers, each one is provided with a return line, connected to a common return header to the
boiler.
System components- The system broadly comprises of-

a. A set of distributary piping system with a return pipe to the boiler to keep the water circulating
and keeping it hot for immediate use.
b. Hot water boilers using electricity or any other fuel such as wood, kerosene, LPG etc.to
produce hot water or steam.
c. Hot water storage tanks, caloriefiers or hot water generators.
d. Primary hot water recirculating pumps for circulation between boilers and tanks and secondary for
circulation between calorifiers and the distribution system.
e. Fuel storage handling and feeding system when solid or liquid fuels are used.
f. Boiler chimney for all boilers except those using electricity or solar energy.
g. Temperature and pressure safety devices.
Figure 11: Hot water cylinders or calorifiers
Single Feed Double Feed Combination
Figure 12: Different types of storage cisterns
Figure 13: Immersion heaters
Indirect cylinder or calorifier
Indirect cylinders in a standard system will only

be fitted with one coil, which is heated by the
boiler. If the hot water system is changed to
incorporate a renewable or alternative heat
source, additional coils in the cylinder are
required.
Figure 14: Indirect Cylinders or calorifiers
Thermostat (Temperature safety device)
The boiler has a thermostat that regulates the primary water temperature, which flows to the coil.
When the primaries are up to temperature, the boiler will cut out until the temperature reduces.
Temperature control
A blending valve is now required to restrict the hot water being discharged above 48°C in a bath. In
public areas 43°C is commonly used for most appliances.
Generally, factory set,

but sometimes
adjustable
Hot water from Cold water from

cylinder supply
Blended (mixed) water

to appliance
Figure 15: Blending valve
Figure 16: Shower mixer Figure 17: Tap stat

valve
Cold Water Supply to Heaters
A storage water heater (pressure type) shall be fed from a cold water storage tank and under no
circumstances connected directly to the water main, except the type which incorporates a feed
tank with ball valves and overflow pipe arrangement (cistern type heaters) or non-pressure type
heaters.
Storage cisterns
The storage capacity of a cold water tank shall be at least twice the capacity of the hot water
heater. The capacity of the storage tank may, however, be 1.5 common tank exceeds 10. The
storage tank for supply of cold water to hot water heaters shall be
separate, if practicable. In the case of a common tank which also supplies cold water to the fixtures,
this cold water supply connection shall be so arranged that 50 percent of the net capacity, shall
be available for supply to the hot water heaters. In the case of multistoried buildings where a
common overhead tank over the stair/lift well
is generally installed, it is advisable to have one or more local tanks for supply to the hot water
heaters or a compartment in the tank with required storage always available for hot water heater.
In tall multistoried buildings where the static pressure increases with the height, the total static
pressure on the hot water heaters on the lowest floor shall not exceed the rated working pressure
of the hot water heater installed. Should the height of the building so require, additional tanks
shall be provided on the intermediate floors to restrict the static head to permissible limits or the
pressure shall be reduced to
working pressure by providing pressure reducing valves. As an alternative to the arrangements
stated an individual storage tank in each flat may be provided for supply to hot water heaters.
Cold Water Feed
The feed pipe connecting cold water tank with the hot water heater shall not be of less than 20
mm bore and it shall leave the cold water tank at a point not less than 50 mm above the bottom
of the tank and shall connect into the hot water heater near its bottom. The feed pipe shall not
deliver cold water to any other connection, but into the hot water cylinders only. In the case of
multistoried buildings, a common cold water feed pipe may be installed, but each hot water heater
shall be provided with a check valve (horizontal type check valve shall be preferred to vertical
type for easy maintenance). Care shall be taken in installing the piping to prevent air locks in the
piping and negative pressure in the hot water heater. Cold water feed pipe shall not be cross-
connected with any other source of supply under pressure.
Hot water heaters
The common hot water delivery pipe shall leave the hot water heater near its top and shall be of
not less than 20 mm bore generally, not less than 25 mm bore if hot water taps are installed on
the same floor as that on which the hot water heater is situated.
Hot water taps shall be of such design as would cause the minimum friction. Alternatively,
oversized tap may be provided, such as a 20 mm tap on a 15 mm pipe.
The hot water distributing system shall be so designed as to ensure that the time lag between
opening of the draw-off taps and discharge of hot water is reduced to the minimum to avoid
wastage of an undue amount of water which may have cooled while standing in the pipes when
the taps are closed. With this end in view, a
secondary circulation system with flow and return pipes from the hot water tank shall be used
where justified. Whether such a system is used or not, the length of pipe to a hot water draw-off
tap, measured along the pipe from the tap to the hot water tank or the secondary circulation pipe,
shall not exceed the lengths given in Table 5.
Wherever mixing of hot and cold water is done by a mixing fitting, that is, hot and cold stop-
cocks deliver to a common outlet of mixed water (that is, showers, basin or bath supply fittings),
the pressure in the cold and hot water systems shall be equal. This can be achieved by connecting
the cold water supply from an overhead tank at the same static height as the overhead tank
supplying cold water to the hot water heaters. In case this is not possible, hot and cold water
should be supplied to the
fixtures by separate supply taps. The hot and cold water thermostatic mixers/diverters/
faucets for public use should have ‘hot’ and ‘cold’ clearly marked in the form of colour coding
and tactile information. The functioning of hot and cold water from the thermostatic
mixer/diverter/faucet should be consistent, for example, a clockwise turn should result in
discharge of hot water and counter clockwise for cold. It is recommended that a thermostat be
installed to limit the temperature of the hot water to a maximum of 40°C in order to prevent
scalding.
Hot water generation
1) Direct system of hot water supply
 Direct systems are ideal for small installations.

 Hot water generated by a boiler can be tapped directly from the boiler for use. If hot
water holding capacity of the boiler is small a storage tank is installed so that peak demand which
may be in in excess of generation capacity can be drawn from the tank. The supply temperature
is normally 55-65°C.
 If the water has a pH lower than 7, its corrosive effects increase with rise in temperature
and corrodes the boiler. This system is not suited to hard waters, typical of those extracted from
boreholes into Chalk or limestone strata. When heated the calcium precipitates to line the boiler
and primary pipework eventually furring up the system to render it ineffective and dangerous.
 When drawn off directly, the cold water entering the boiler near the bottom comes in
contact with the boiler furnace, which is at a higher temperature. The contact generates a thermal
imbalance, which may strain the body of the boiler and develop cracks on the surface sheet of
the furnace.
 Boiler nozzle must be large enough to match the rate of flow generated by the
recirculating water in the distribution system.
 The storage cylinder and associated pipe work should be well insulated to reduce energy
losses.
It is possible to heat the water in the
storage vessel (cylinder) by using
only an immersion heater
This immersion heater is normally

inserted vertically into the top of the
cylinder therefore heating the water
Directly:
Figure 18: Direct system of hot water supply
2) Indirect system of hot water supply

This system is used in hard water areas to prevent scaling of the boiler and primary pipe work.
Unlike the direct system, water in the boiler and primary circuit is not drawn off through the tap.
The same water circulates continuously throughout the boiler, primary circuit and heat exchange
coil inside the storage cylinder. Freshwater cannot gain access to the higher temperature areas
where precipitation of calcium will occur. The system is also used in combination with Central
heating with flow and return pipes to radiators connected to the boiler. Boiler water temperature
maybe set buy thermostat at about 80 degree Celsius.
Figure 19: Indirect system of hot water supply
Sealed Indirect Hot Water System for a High Rise Building

For convenience and to reduce wear on fittings, the maximum head of water above taps and the
outlets is 30 m. This is achieved by using intermediate or break pressure cisterns for each sub-
circuit. Head tanks are provided to ensure sufficient volume of stored hot water and adequate
delivery to the upper floors. Compared with conventional installations a considerable amount of
pipework and fitting time can be saved by using an expansion vessel to absorb expansion of water
in the primary circuit. However, the boiler and calorifiers must be specified to a high quality
standard to withstand the water pressure. All pipework and equipment must be well insulated.
Figure 20: Sealed Indirect system of hot water supply for high rise building
Solar water heaters

Heat radiated by the sun is effectively trapped by solar collectors to heat water. For domestic
application the collector should be 4 to 6 square meter in area secured at an angle of 40 Degrees
to the horizontal and facing South. The solar cylinder capacity of about 200 litres is heated to
60ƒC. The cylinder and associated pipework must be very well insulated and the solar part of the
system should contain a blend of water and non-toxic anti-freeze. The pump is switched on when
the temperature of water at point X exceeds that at point Y by 2 to 3ƒC. The solar cylinder and
the conventional cylinder may be fitted on the same level, or to save space a combined
solar/conventional cylinder can be obtained from specialist suppliers.
Figure 21: Exploratory sketches of solar water heater system
For hot water system in buildings the flat collectors are most commonly used, because they are
simple in design, require very little maintenance and do not have moving parts, are also cost
effective and can be used in all kinds of applications where temperature required ranges between
40°C-90°C.
Figure 22: Flat plate solar collectors
Figure 23: Evacuated tube solar collector
Figure 24: Solar water heating process
Piping layouts
Hot water piping layout must follow some basic principles for efficient, effective and economical
design. Piping layouts are also to be decided on the basis of architectural and structural
considerations. There are two basic types of layouts.
Up feed system
In this system, the main flow (1) and return (4) pipes run at the ceiling level of the lowest level.
Vertical flow (2) and return lines (3) supply the water to the rooms above. Circulation will occur
due to thermosiphon action or by forced circulation
Figure 25: Up feed system

Downfeed system
The system requires the main hot water pipes (1) to run to the top floor where the distribution
main(2) runs. Single pipes (3) are dropped in each shaft to join a common return line (4) at the
lowest level, which is then connected to the boiler or calorifier. For efficient operation, the flow
pipe on the top floor must run at the same level. A change in direction in the vertical plane is
best avoided to prevent air traps. Accessible space is necessary on the top floor to run the main
HW pipe.
Figure 26: Down feed system
Reverse circulation system
Reverse circulation is similar to the up feed system, except that the return flow occurs in the same
direction as that of the main flow pipe (1) till the end of the remotest circuit from where it returns
to the calorifier through a separate reverse line (2).
This system is suitable where the circuits are long and where it is a likelihood of least favorably
placed fixtures not receiving adequate flow of pressure.
A reverse return line enables closer balancing of pressure in the system
Electrical switch gear enable shutting off of power supply in case of electrical leakage within
the system. Electrical boilers have a heating efficiency of 95 to 98%.
Figure 27: Reverse Circulation system
Other systems
Without losing sight of the basic principles of hot water circulation and thermosiphon
action, distribution systems of types other than described earlier can be planned to suit the
building layout.
Many a time the main hot water flow and return lines are laid on the terrace of the building
and supply pipes dropped to lower floors in pipe shafts. The hot water and the air
released within the piping system, being the lightest remain on the top of the system. It is
important to remove the air by means of air vents or expansion tanks to eliminate air
locking in the piping system and ensure continued flow. Additional pumping energy is
required to keep hot water under circulation and ensure correct temperature at supply
points.
Expansion loops
All metal expands when heated. Pipes commonly used in hot water system are made of copper,
mild steel and cast iron.
When carrying hot water or steam, the pipes expand, generate tension, which may distort or break
the joints, resulting in leakages. It is therefore important to provide arrangement for the
expansion of the pipes.
Expansion loops fabricated from pipes and provided in the main lines absorb the expansion. One
end of the loop is anchored to permit the rest of pipe to transfer the expansion to the loop.
Mechanical expansion joints and bellows are also used in place of loops.
When pipes pass through walls, they must have a sleeve around it to permit movement due to
expansion.
Figure 28: Expansion Loops
Air locks
When water is heated, it releases air dissolved in it and finds its way into the highest points in the
system. As air is lighter than water it floats on the water. This causes air lock in the pipe and
flow in the pipe will cease when the line has an air at top.
Air locks are best avoided by designing a piping lay-out in which the hot water taps are located
above the supply pipe. When taps are opened, the tap will discharge the entrapped air.
In case air-locks cannot be avoided automatic air valves, manual air purging valves or expansion
tanks are provided to let the air escape at points.
Figure 29: Air locks
Pipe slope
In large distribution system, the hot water pipe mains should slope towards its origin of supply,
with the highest points terminating in a usable hot water tap.
Slope assists in draining out the system.
A slope of 0.5-0.2 percent is reasonable.
Isolation valves
All sections of the distribution system should be provided with isolation valves which allow
shutting off a portion of the circuit without affecting the flow to the other areas for maintenance
and repairs.
No valve to be provided on vent/expansion line r pressure relief valves.
Valves on boilers, heat exchangers and mainlines should be full way gate valves and used only
for shut-off duty.
Valves at individual connections, sometimes on risers, should be globe type, which allow
regulation of flow rates enabling balancing the flow in each circuit.
Balancing valves, calibrated and locked for a fixed rate flow, are also used in large installations.
Check valves
Check valves, also known as non-return valves, are used to prevent backflow of water.
Drain valves
Drain valves should be provided for boilers, heat exchangers and storage tanks, as well as for the
lowest points in the system and horizontal mains as required.
Drain valves should be discharged over a drain with an air gap and a visible flow. They should
not be connected to a drain.
The air gap also prevents back-flow.
Make up line
A makeup line is the pipe which feeds cold water to the system from an overhead tank or other
direct supply or pressurised systems.
The diameter of the makeup line must be calculated taking into account the pressure losses in the
distribution system from boiler or heat exchanger to the remotest hot water tap in the system and
adding the pressure loss of the cold feed from the overhead tank to the boiler or heat exchanger.
Insulation for hot water supply systems
Need for insulation-

Boilers, storage tanks,
calorifier, chimneys and hot water pipes lose their heat when exposed to outside air hence they
should be insulated.
Insulation material-
The insulation material should be non-corrosive, nontoxic, moisture resistant, rot and vermin
proof ,fire resistant, light, easy to apply, anti-weathering durable and in addition possess good
insulation properties and low thermal conductivity. Properties of insulation of a material are
defined by its density expressed in in KG per cubic metre and its thermal conductivity denoted
by letter 'K '
and is expressed as heat loss in kilo calories per thickness per hour per difference of temperature
in degree centigrade (kcal/m/ h/ degree centigrade)
 Mineral wool: Mineral wool is fibres spun from selected rocks melted and blended to
an adjustable composition. The fibres are very thin and manufactured in the form of loose
wool or in resin-bonded mats and pipe sections of different thickness.
 Glass wool: fibre glass is manufactured from pure silica and is available in the same forms
as mineral wool.
 Polyurethane: are foams manufactured from resins of polyesters or polyether based

polyol. They can be formed as rigid slabs and performed pipe sections of different thickness.
 Thermocole: thermocole is more suitable for carrying cold water up to 20°C and used
extensively in chilled water systems and not suitable for hot water.
References-
1.Plumbing (Design and practice)by S.G. Deolalikar
2.Building services Handbook by Fred Hall and Roger Greeno
3.Handbook on Water supply and Drainage, Bureau of Indian standards
4.Building services and equipments by Prof.Ashok Chhatre
5.National Building Code, 2016

Unit 3 - Hot Water Supply

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Unit 3 - Hot Water Supply

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UNIT III: HOT WATER SUPPLY

Figure 1: Instant gas geyser

Individual Centralised Others

Instant type Direct Solar heating

Storage type Indirect

Figure 2: Types of hot water supply system

b) Storage type water heaters-

Figure 4: Storage type geyser

Geysers are available in the following types

Pressure type Geysers:

Figure 5: Pressure type geyser

Non-Pressure type geyser:

Dual heater type:

Figure 9: Application of Expansion Pipe

II. Centralized hot water system

Figure 10: Thermosiphon action

supply to sink -60 degree Celsius

supply to washbasin- 55 degree Celsius

supply for warm bath 37 degree Celsius

Hot water storage temperature 60 degree Celsius.

This may be increased to 65 degree Celsius when soft water is used.

System components- The system broadly comprises of-

c. Hot water storage tanks, caloriefiers or hot water generators.

g. Temperature and pressure safety devices.

Single Feed Double Feed Combination

Figure 12: Different types of storage cisterns

Indirect cylinder or calorifier

Indirect cylinders in a standard system will only

Figure 14: Indirect Cylinders or calorifiers

Generally, factory set,

Hot water from Cold water from

Blended (mixed) water

Figure 16: Shower mixer Figure 17: Tap stat

1) Direct system of hot water supply

 Direct systems are ideal for small installations.

This immersion heater is normally

Figure 18: Direct system of hot water supply

2) Indirect system of hot water supply

Sealed Indirect Hot Water System for a High Rise Building

Solar water heaters

Figure 22: Flat plate solar collectors

Figure 23: Evacuated tube solar collector

Figure 24: Solar water heating process

Figure 25: Up feed system

Reverse circulation system

Figure 28: Expansion Loops

Insulation for hot water supply systems

Need for insulation-

 Polyurethane: are foams manufactured from resins of polyesters or polyether based

1.Plumbing (Design and practice)by S.G. Deolalikar

2.Building services Handbook by Fred Hall and Roger Greeno

3.Handbook on Water supply and Drainage, Bureau of Indian standards

4.Building services and equipments by Prof.Ashok Chhatre

5.National Building Code, 2016

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