Hot Water Return Systems and Applications

8/22/22
Hot Water Return

Distances and
Applications
Presented by: James Dipping, PE, CPD, GPD, LEED AP BD+C,
ARCSA AP
Director of Plumbing Engineering
Environmental Systems Design, Inc.
Chicago, IL
Copyright 2022 American Society of Plumbing Engineers
Today’s Objective
• Overview Of Hot Water Return Systems
• Codes That Affect Hot Water Return System Design
• Standards That Affect Hot Water Return System Design
• Effects Of HWR Systems On Fixture Performance
• Effects Of Stagnation On Water Quality
• Recommended Approach To Maximum Uncirculated Distances
In HWR Systems
What is a Hot Water Return System?

• Per The American Society Of Plumbing
Engineers, Domestic Hot Water
Recirculation Systems Maintain Domestic
Hot Water Supply Temperature By Using A
Pump To Continuously Pass Hot Water
Through The System And Return It To The
Heating Source To Be Reheated.
• Intended To Provide Readily Available Hot
Water Near The Fixtures For Delivery.
• The Supply And Return System Can Be
Thought Of As An Extension Of The Water
Heater.
1
8/22/22
Components of a Hot Water Return System

Hot Water Return Pump
• The Necessary Flow Through The
System Is A Function Of The Heat Loss
Over Time And The Acceptable
Temperature Drop Across The Entire
System.
• If Flow Is Increased, The Temperature
Drop Will Decrease.
• Take Precautions When Using Safety
Factors, Especially If Thermostatic
Balancing Valves Are Used.

Hot Water Return Pump
• If A Mechanical Thermostatic Mixing Valve
Is Used, The Pump Should Discharge The
Flow Into Both The Water Heater And The
Mixing Valve.
• This Allows A Portion Of The Water To Be
Exchanged In The Water Heater And Then
Mixed With The Lower Temperature Water
From The Return, Providing The Design
Temperature To Be Re-circulated Back To
The Fixtures.
• This Is More Complicated Than It May
Appear, As This Assumes A Constant
Cold-Water Temperature, Which
Fluctuates Seasonally.
Balancing Valves
• The Flow Through Each Segment Is A
Set Percentage Of The Total System
Flow And Is Regulated By The
Balancing Valves.
• A Properly Balanced Recirculation
System Will Result In The Same
Temperature Drop At Each Balancing
Valve.
• Balancing Valves Can Be Adjusted By
Manual Or Fixed Calibration, Or
Thermostatic Means.
2
8/22/22
Balancing Valves
• Thermostatic Balancing Valves Will Adjust
Their Opening Depending On The
Temperature Of The Water Entering The
Return System.
• This Theoretically Provides An Equal
Temperature Drop At Each Valve Without
Calibration.
• Special Pump Controls Must Be Employed
To Provide Constant Pressure Differential
With Varying Flow Conditions.
Balancing Valves
• Digital Options Are Emerging, With The
Capability To Control Based On
Temperature
• Valves Are Daisy Chained And Self Balance
At The Touch Of A Button.
• Valves Will Monitor Temperature And Log
Data
• Special Pump Controls Must Be Employed
To Provide Constant Pressure Differential
With Varying
Copyright 2022 Flow
American Society of Conditions.
Plumbing Engineers
Water Heater
• As the system recirculates, heat is lost
through the piping and insulation.
• To maintain the system temperature, the
heat loss needs to be in equilibrium with
the heat gained from the water heater.
• The demand that this equilibrium imposes
on the water heater is dependent on the
heat loss from the supply and return
piping.
3
8/22/22
Thermostatic Mixing Valve

• In Systems Where The Domestic Hot Water
Temperature Is To Be Lower Than The
Temperature Stored In The Water Heater, A
Thermostatic Mixing Valve (TMV) Should Be
Used For Tempering.
• A TMV Performs Best When Mixing Water Of
Two Extreme Temperatures To Create
Tempered Water For Supplying Fixtures.
• If The Temperature Of The Cold-water Inlet Is
Too Close To The Set Temperature (As Is The
Case When Being Recirculated), The TMV Will
Temper Inaccurately (Temperature Creep, A
Scalding Issue).
10
Design of a Hot Water Return System

Determining Flow
• The Total Flow Through The System Is Selected Based On The
Heat Loss From The Supply System When Fixtures Are Not In Use.
11

Determining Heat Loss
• Determine total heat loss per foot, per pipe size. Automation
Tool, Anyone?
12
4
8/22/22

Flow at Each Balancing Valve
• The Flow At Each Balancing Valve
Requires Calculations To Be Made For
Each Division Of Flow (Node) In The
Recirculated Supply Piping.
• Each Node Represents A Division Of
Flow Direction Or A Connection To The
Return System.
• Since The Piping Closer To The Water
Heater Will Be Carrying The Flow Of
More Balancing Valves, The
Compensation For The Heat Loss Will
Be Distributed Among The Balancing
Valves Being Supplied.
13

Flow at Each Balancing Valve
• As A Guide To Sizing Circulation Piping
And Circulation Pumps, The Following
Empirical Methods Are Given:
• An Allowance Of 0.5 GPM Is Assigned
For Each Small Hot Water Riser (1/2–1
Inch).
• 1 GPM For Each Medium-size Hot Water
Riser (1¼–1½ Inches).
• 2 GPM For Each Large Hot Water Riser
(2 Inches And Larger).
• 1 GPM Is Assigned For Each Group Of
20 Hot Water-supplied Fixtures.
14
Codes that Affect Hot Water Design

• International Energy
Conservation Code
• ASHRAE 90.1
• OSHA (Guideline)
• CDC
15
5
8/22/22

IECC
• Insulation
Requirements
• Maximum Piping
Length
• Maximum Piping
Method
16

IECC
• Insulation Requirements
17

IECC
• Maximum Pipe Length Per Chart Below
• Volume 1.3-3 (1/2” or 3/4”) Ounces Max Public Lavatory
• Volume 27-62 (1/2” or 3/4”) Ounces All Other Fixtures
18
6
8/22/22

ASHRAE 90.1
19

ASHRAE 90.1 - 2019
20

ASHRAE 90.1 - 2019
21
7
8/22/22

ASHRAE 90.1 - 2019
22

OSHA
23

OSHA
24
8
8/22/22

CDC
CDC
• CDC: Store Hot Water At Temperatures Above 140°F (60°C)
And Ensure Hot Water In Circulation Does Not Fall Below
120°F (49°C). Recirculate Hot Water Continuously, If
Possible.
• Water Systems In Health Care Facilities, Section 3b: “To
Minimize The Growth And Persistence Of Gram-negative
Waterborne Bacteria (E.G., Thermophilic NTM And
Legionella Spp.),627, 703–709 Cold Water In Health-care
Facilities Should Be Stored And Distributed At
Temperatures Below 68°F (20°C); Hot Water Should Be
Stored Above 140°F (60°C) And Circulated With A Minimum
Return Temperature Of 124°F (51°C),661 Or The Highest
Temperature Specified In State Regulations And Building
Codes.
• (https://www.cdc.gov/infectioncontrol/pdf/guidelines/enviro
nmental-guidelines-P.pdf)
25
Effects of These Codes / Standards
• More Piping
• More Insulation
• More Balancing Valves
• Larger Pumps (Maybe?)
• Still Must Design For
Approximately 5F To 10F Degree
Drop In Hot Water Return System –
Hard To Avoid.
• Must Take This Into Account To
Maintain Supply And Return
Temperatures Of 120F To 124F.
26
Effects of a HWR System on

Fixture Performance
• W ith The Ever-decreasing Flow Rates Of
Lavatories, Sinks, Showers, Etc. It Is
Imperative To Provide A Hot Water
Return System W ith Appropriate
Distances Of Uncirculated Hot Water
Supply To Meet Energy Codes, Reduce
Stagnant Lines, And Delivery Hot Water
Quickly.
• Every 1’-0” Of ¾” Copper Tube Holds
0.025 Gallons Of Hot Water. Thus Every
10 Feet Of Supply Pipe Is 0.25 Gallons Of
Water. This Equates A Vertical Drop In A
Wall.
• Any Fixture W ith A 0.5 GPM Aerator
Using 100% Hot Water W ill Take 30
Seconds To Flush Out That 10 Feet Of
Hot Water Supply Pipe.
27
9
8/22/22
Effects of a HWR System on Fixture

Performance
28
Effects of Stagnation on Water Quality

• Stagnant Or Standing Water In A
Plumbing System Can Increase The Risk
For Growth And Spread Of Legionella
And Other Biofilm-associated Bacteria.
When Water Is Stagnant, Hot Water
Temperatures Can Decrease To The
Legionella Growth Range (77°–113°F,
25°–42°C).
• Stagnant Water Can Also Lead To Low
Or Undetectable Levels Of Disinfectant,
Such As Chlorine. Ensure That Your
Water System Is Safe To Use After A
Prolonged Shutdown To Minimize The
Risk Of Legionnaires’ Disease And Other
Diseases Associated With Water.
29

Performance
• Metals Can Be Released To Water From
The Corrosion Of Pipes And Plumbing
Components In The Distribution And
Building Water Systems.
• Metals May Also Be Deposited In Building
Water Systems Scales And Sediments.
• Stagnation Provides The Time And, In
Some Cases The Water Quality
Conditions, That Allow Scales To
Destabilize Or Concentrations Of Metals
In The Water To Rise To Levels That Can
Cause Health Effects And/Or Aesthetic
Concerns.
• When Water Use Is Resumed, Water May
Contain Elevated Levels Of Metals.
30
10
8/22/22

Performance
• During Stagnation Hot Water
Temperatures Cool To Ambient
Temperatures At Point Of Use Outlets.
• Water Use After Periods Of Stagnation
Can Release Opportunistic Pathogens
That Have Grown Or Become Detached
From The Biofilm.
• When Stagnant Water Conditions Worsen
Water Quality Issues Caused By
Engineering, Mechanical, Or Operational
Deficiencies, Conditions That Allow
Opportunistic Pathogens To Proliferate
Increase .
• Once Problematic Conditions Have Been
Established In A Portion Of A Building
Water Systems, Interventions Beyond
Flushing May Be Necessary.
31
Recommended Approach To Maximum

Uncirculated Distances In HWR Systems
Prior To Modern Energy

Codes, The Maximum With The Increased
Distance Any Individual Enforcement Of Energy
Or Fixture Group Hot Codes, Distances Of
Water Supply May Be Run Uncirculated Lines Have
From A Main Or Hot Dropped Significantly, In
Water Source Is Typically Come Applications Down
100 Feet (30 Meters) Per To Inches Instead Of Feet.
Most Plumbing Codes.
32
Recommended Approach To Maximum

Uncirculated Distances In HWR Systems
• We Must Learn To Balance Of Energy Code

Requirements, Appropriate Wait Times For Hot Water
Delivery, And The Reduction Of Stagnant Lines To Prevent
Water Born Pathogen Growth W ith Project Costs. In
Today’s Environment However, We Must Design HW R
Systems To Provide Individual Fixture Circulation More
Than Ever Before.
33
11
8/22/22
Recommended* Approach To Distribution in

Domestic Hot Water Supply and Return
Systems
Distribution - Commercial Office
• Water Generated/Stored At 140F.
• Water Distribution From Source At 140F. No Master Mixing
Valve.
• Point Of Use Mixing At All Required Outlets.
• Asse 1070 At All Public Handwashing Applications, Max
110F.
• Asse 1070 At Pantry Sink Applications, Max 120F.
*each building is different, don’t forget you’re an engineer!!
34

Systems
Distribution - Commercial Residential
• Water D istribution From Source A t 135F.
• Asse 1017 Master Mixing Valve (Digital Recirculating Valve
Recommended).
• Point O f U se M ixing A t A ll Required O utlets:
• A sse 1070 A t A ll Public H andw ashing A pplications.
• A sse 1016 A t A ll Public A nd Private Show ering A pplications.
35

Systems
Distribution - Health Care
• Water Distribution From Source At 140F.
• A sse 1017 M aster M ixing Valve (D igital Recirculating Valve
Recom m ended).
• Point Of Use Mixing At All Required Outlets:
• A sse 1070 A t A ll Public H andw ashing A pplications, M ax 110F.
• A sse 1070 A t A ll Patient H andw ashing A pplications, M ax 110F.
• A sse 1070 A t A ll Exam Room A pplications, M ax 120F.
• A sse 1016 A t A ll Public A nd Private Show ering A pplications, M ax
110F
• C oordinate A ny Specialty A pplications A s N eeded, Such A s M edical
Equipm ent.
36
12
8/22/22

Systems
Distribution - Commercial Data / Industrial
Applications
• Water generated/stored at 140F.
• Water distribution from source at 140F. No master
mixing valve.
• Point of use mixing at all required outlets.
• ASSE 1070 at all public handwashing
applications, max 110F.
• ASSE 1070 at pantry sink applications, max 120F.
*each building is different, don’t forget you’re an

engineer!!
37

Systems
Velocity
• Most Codes Allow For A Maximum Velocity Of 8 Fps, However,
Pipe Material Manufacturers And The Copper Development
Association Recommends A Maximum Velocity For Hot Water
Piping Of 5 Fps For Systems Below 140F, And 3 Fps For
Systems Above 140F And The Hot Water Return Piping To 4
Fps.
Flow
• Flow Rates Of Less Than 0.5 GPM Are Difficult To Control As
Calibrated Balancing Valves Do Not Accurately Function
Below 0.5 GPM. Therefore, If The Calculated Flow Rate For
Any One Branch Or Riser Is Less Than 0.5 GPM, A Flow Rate
Of 0.5 GPM Should Be Used.
Minimum Piping Sizes
• A Minimum Hot Water Return Piping Size Of 1/2" Should Be
Provided; However, Larger Pipe Sizes Should Be Provided If
Required Per The Design.
38
Recommended*
Approach To
Distribution in
Domestic Hot
Water Supply and
Return Systems
39
13
8/22/22

Systems
Self-Regulating Heat Trace Systems
• This Type Of System Utilizes Self-regulating Electrical

Cable Installed On The Hot Water Supply Pipes
Underneath The Standard Pipe Insulation.
• The Cable Adjusts Its Power Output To Compensate For
Variations In Water And Ambient Temperatures. It
Produces More Heat If The Temperature Drops And Less
Heat If The Temperature Rises.
• The Heating Cable Replaces Supply Pipe Heat Losses At
The Point Where Heat Loss Occurs, Thereby Providing
Continuous Hot Water Temperature Maintenance And
Eliminating The Need For A Recirculating System.
• Heat Trace Systems Are Practical For Small Systems,
Systems Where Added Flexibility Of Terminal Runs Is
Needed, Or Situations Where Recirculation Piping Is
Impractical.
40
14

Hot Water Return Systems and Applications

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hot Water Return Systems and Applications

Uploaded by

Copyright:

Available Formats

8/22/22

Hot Water Return

Copyright 2022 American Society of Plumbing Engineers

Copyright 2022 American Society of Plumbing Engineers

What is a Hot Water Return System?

Copyright 2022 American Society of Plumbing Engineers

Components of a Hot Water Return System

Components of a Hot Water Return System

Copyright 2022 American Society of Plumbing Engineers

Components of a Hot Water Return System

Components of a Hot Water Return System

Components of a Hot Water Return System

Components of a Hot Water Return System

Components of a Hot Water Return System

Thermostatic Mixing Valve

Design of a Hot Water Return System

Copyright 2022 American Society of Plumbing Engineers

Design of a Hot Water Return System

Copyright 2022 American Society of Plumbing Engineers

Design of a Hot Water Return System

Design of a Hot Water Return System

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Codes that Affect Hot Water Design

Copyright 2022 American Society of Plumbing Engineers

Effects of These Codes / Standards

Effects of a HWR System on

Effects of a HWR System on Fixture

Copyright 2022 American Society of Plumbing Engineers

Effects of Stagnation on Water Quality

Copyright 2022 American Society of Plumbing Engineers

Effects of a HWR System on Fixture

Copyright 2022 American Society of Plumbing Engineers

Effects of a HWR System on Fixture

Recommended Approach To Maximum

Prior To Modern Energy

Copyright 2022 American Society of Plumbing Engineers

Recommended Approach To Maximum

• We Must Learn To Balance Of Energy Code

Copyright 2022 American Society of Plumbing Engineers

Recommended* Approach To Distribution in

*each building is different, don’t forget you’re an engineer!!

Copyright 2022 American Society of Plumbing Engineers