WATER SYSTEMS

Abstract

A circulating hot water system has a hot water flow circuit defined by pipework leading out from and back to an in-line heater, and including a pump to drive circulation of the hot water. Each of multiple user points has an outflow branch conduit and a return flow branch conduit with a common wall for heat exchange, as does the main flow circuit: the outflow conduit surrounds the return conduit. Water is fed into the system from a pressurized cold water supply main through a check valve. Sensors are used to monitor water temperatures and flow conditions around the system. A programmed control processor can control heating and pumping rates in various regimes, e.g. to maintain system temperature above a predetermined threshold. An isolation valve adapted for concentric double pipes is also described.

Claims

1. A circulating hot water system with a hot water flow circuit defined by pipework leading out from and back to a heater, and including a pump to drive circulation of the hot water; the system comprising multiple user points on the flow circuit, at least some of the user points being outlet user points where an outlet can be opened to take hot water out of the system and the system having a branch from the flow circuit leading to a said outlet user point; and wherein the branch comprises an outflow branch conduit and a return flow branch conduit, and branch circulation is provided by communication, adjacent to the outlet user point, between the outflow branch conduit and a return flow branch conduit, the branch return flow conduit returning to the main flow circuit.

2. Water system according to claim 1 wherein the outflow and return branch conduits have a common wall for heat exchange.

3. Water system according to claim 2 wherein the outflow branch conduit surrounds the return flow branch conduit.

4. Water system according to claim 1 wherein the hot water flow circuit comprises an outflow conduit and a return conduit making up the hot water flow circuit, and the outflow conduit and return conduit have a common wall.

5. Water system according to claim 4 wherein the outflow conduit surrounds the return conduit.

6. Water system according to claim 4 wherein the pump is provided in the return conduit, at a position separate from any contact or shared wall of the return conduit with the outflow conduit.

7. Water system according to claim 1 wherein the pump has a controllably variable pumping rate.

8. Water system according to claim 1 comprising a heater acting on said flow circuit to heat water flowing therein.

9. Water system according to claim 8 in which the heat output of said heater is controllably variable.

10. Water system according to claim 8 in which the heater is an electrically-powered or combustion fuel instant (non-storage) heater.

11. Water system according to claim 1 comprising a pressurised supply to feed water into the flow circuit to compensate for water taken at user points.

12. Water system according to claim 11 in which the pressurised supply is directly into the flow circuit from a pressurised cold water main.

13. Water system according to claim 11 which the pressurised supply feeds into a return flow conduit of the flow circuit.

14. Water system according to claim 11 in which the pressurised supply feeds water into the flow circuit downstream of the pump and/or upstream of a heater to heat the water.

15. Water system according to claim 11 in which the pressurised supply feeds water into the flow circuit through a check valve.

16. Water system according to claim 1 comprising a sensor to detect when water below the predetermined circulation temperature is being fed into the flow circuit, and connected to a control system to adjust the output of a heater of the system.

17. Water system according to claim 1 comprising a shut-off or flow restrictor for a return conduit of the flow circuit, operable to stop or restrict return flow when hot water is taken out at one or more outlets.

18. Water system according to claim 17 comprising one or more sensors to detect opening of an outlet, flow at an outlet, or flow in the flow circuit above a certain threshold level, and a control system connected to said one or more sensors and operable to actuate said shut-off or flow restrictor in response to said detection.

19. Water system according to claim 18 in which the control system is operable to stop or slow the pump in response to said detection.

20. Water system according to claim 1 comprising a control system including a programmed control processor, operable according to any one or more of the following modes: to adjust the operation of any or all of the pump, a heater and a flow restrictor or closure valve in dependence on the output from one or more temperature sensors comprised in the system; to respond to consumption of hot water from the system, detected as flow at or near an outlet user point or with reference to the external supply, by actuating a shut-off valve or flow restrictor for the return conduit; to increase the power output of a heater of the system in dependence on a detected increased flow rate in the flow circuit and/or in an external supply conduit e.g. above predetermined threshold values or on a continuously variable basis; to switch between a stasis mode, corresponding to circulation of heated water through the flow circuit without consumption at the outlets, and a dynamic mode when hot water is consumed at one or more outlets, the stasis mode operating to maintain a predetermined flow rate and a predetermined operating temperature in the flow circuit, and the dynamic mode operating to stop or slow the pump and/or shut off or restrict circulating flow and/or increase heater output; to operate in an exceptional pasteurisation mode in which flow rate and/or heater output are adjusted to achieve an exceptional raised minimum temperature of at least 60 C., 65 C. or 70 C. to decontaminate the system; to operate in a dormant mode in which the pump is turned off and/or flow is shut off with no circulation, and/or in which heating is turned off or reduced to a reduced predetermined level corresponding to a dormant temperature below a predetermined operating temperature.

21. Water system according to claim 1 comprising an isolation valve having concentric conduits and comprising a movable closure element and a fixed structure; the movable closure element comprising an outer tube with an external spherical surface portion and an inward surface defining an outer conduit, and an inner tube coaxial with the outer and supported inside it by a support structure such as plural circumferentially-spaced struts, fins or axially-extending walls to define an inner conduit, and the fixed structure having first and second sealing portions to seal against and around respective oppositely-directed ends of the moveable closure element.

22. Isolation valve for a fluid flow system having concentric conduits and comprising a movable closure element and a fixed structure; the movable closure element comprising an outer tube with an external spherical surface portion and an inward surface defining an outer conduit, and an inner tube coaxial with the outer and supported inside it by a support structure such as plural circumferentially-spaced struts, fins or axially-extending walls to define an inner conduit, and the fixed structure having first and second sealing portions to seal against and around respective oppositely-directed ends of the moveable closure element.

23. Isolation valve of claim 22 in which the movable closure element is a ball element.

24. Isolation valve of claim 22 which is a discrete unit to be coupled into adjacent lengths of conduit having concentric inner and outer pipes, and having inner connector or union portions to slide into or around the inner pipes of the conduit, and outer tubular unions to slide into or around the outer pipes of the conduit, these coupling structures being comprised in a valve housing which also carries an external operating member by which the moveable closure element can be turned between open and closed positions.

25. A method comprising operating a hot water system according to claim 1.

26. A circulating water system with a water flow circuit defined by pipework leading out from and back to a pump to drive circulation of the water, the water flow circuit comprising an outflow conduit and a return conduit and the outflow conduit and return conduit having a common wall; the system comprising multiple user points on the flow circuit, at least some of the user points being outlet user points where an outlet can be opened to take water out of the system; comprising a control system including a programmed control processor, operable according to any one or more of the following modes: to adjust the operation of any or all of the pump, a heater and a flow restrictor or closure valve in dependence on the output from one or more temperature sensors comprised in the system; to respond to consumption of hot water from the system, detected as flow at or near an outlet user point or with reference to the external supply, by actuating a shut-off valve or flow restrictor for the return conduit; to increase the power output of a heater of the system in dependence on a detected increased flow rate in the flow circuit and/or in an external supply conduit e.g. above predetermined threshold values or on a continuously variable basis; to switch between a stasis mode, corresponding to circulation of heated water through the flow circuit without consumption at the outlets, and a dynamic mode when hot water is consumed at one or more outlets, the stasis mode operating to maintain a predetermined flow rate and a predetermined operating temperature in the flow circuit, and the dynamic mode operating to stop or slow the pump and/or shut off or restrict circulating flow and/or increase heater output; to operate in an exceptional pasteurisation mode in which flow rate and/or heater output are adjusted to achieve an exceptional raised minimum temperature of at least 60 C., 65 C. or 70 C. to decontaminate the system; to operate in a dormant mode in which the pump is turned off and/or flow is shut off with no circulation, and/or in which heating is turned off or reduced to a reduced predetermined level corresponding to a dormant temperature below a predetermined operating temperature.

Description

DESCRIPTION OF EMBODIMENTS

[0040] Examples of the invention are now described, with reference to the accompanying drawings in which

[0041] FIG. 1 is a schematic diagram of a conventional circulating hot water system as already described;

[0042] FIG. 2 is a corresponding schematic diagram of a first hot water system embodying our proposals, operating in a stasis mode;

[0043] FIG. 3 shows the FIG. 2 system operating in a dynamic mode;

[0044] FIGS. 4 and 5 show a second embodiment of hot water system, in stasis mode and dynamic mode respectively;

[0045] FIGS. 6 and 7 are schematic sections showing alternative dispositions of concentric flow conduits;

[0046] FIGS. 8 and 9 show open and operational configurations of a spacer clip for mounting an inner conduit in an outer conduit;

[0047] FIGS. 10 and 11 are respectively longitudinal and transverse cross-section through a slide coupling;

[0048] FIGS. 12 and 13 are respectively longitudinal and transverse sections through a first embodiment of isolator valve;

[0049] FIG. 14 is an exploded view of the isolator valve,

[0050] FIGS. 15(a), 15(b) and 15(c) are respectively a top view, end view and side view of a rotary component of the valve;

[0051] FIGS. 16(a) and 16(b) are longitudinal sections through a second embodiment of isolator valve in closed and open positions, and

[0052] FIG. 17 shows schematically a possible disposition of isolator valves in a water system serving multiple floors in a building.

DETAILED DESCRIPTION

[0053] Referring firstly to FIGS. 2 and 3 showing the first embodiment, a hot water system comprises a circulation system 1, a heater 20 and a programmed control 7.

[0054] The main elements of the circulation system 1 are an outflow pipe 11 for outward flow of heated water from a heater 20 (or multiple heaters, if needed for higher power output), along an outflow channel 21, and a return pipe 12 of substantially smaller diameter extending concentrically along inside the outflow pipe 11 and defining a central return channel 22. Preferably these pipes are of copper or stainless steel. They are of generally circular cross-section, and the return pipe 12 is mounted concentrically inside the outflow pipe 11 by means of suitable support structures, not shown, examples of which are described later. An insulative jacket or lagging is provided around the hot water circulation system 1 to reduce losses; again this is not shown.

[0055] At the most distant point from the heater 20, the inner return pipe 12 finishes short of a terminus of the outer pipe 11 so that the two communicate via a main return opening 23. This terminus may be a blank terminus or may have an outlet or other user point. A series of outlet user points 4 such as taps is provided on respective pipe branches 14 from the main circulation system 1. At each branch point 13 both the inner return conduit 12 and the outer flow conduit 11 have a branch or T-piece, and the branch 14 to the outlet 4 then has an outer branch outflow conduit 141 and an inner concentric branch return conduit 142. The inner return portion 142 terminates short of the outlet 4, providing a branch return opening 143 where the flows of the inner and outer tubes and the outlet all communicate without dead space.

[0056] Near the heater 20, the return pipe 12 emerges through an elbow of the outer pipe 11. The exposed return pipe there has an electrically-driven pump 8 for driving the circulating flow, a control valve 3 and a return temperature sensor 9 before re-entering the heater 20.

[0057] The heater is a continuous or in-line type instant heater which heats the water flow conduit directly before it emerges as the outflow conduit 11. For example, a gas-fuelled condensing (exhaust pre-heating) heater with adjustable and switchable output is suitable.

[0058] A sentinel temperature sensor 5 detects the circulating water temperature at the turnaround point 23 between the outflow and return conduits at the most distant point 40 of the circulatory system, and feeds this information to the control processor 7 (e.g. a programmable logic controller) via a transducer 6. The temperature sensed by the return sensor 9 shortly before the return flow re-enters the heater 20 is also fed to the control processor 7. The control processor 7 is connected and programmed to control the adjustable output of the heater 20, and also to control the pump 8 by turning it on or off and/or by modulating its pumping rate. A pump with variable rate, controllable e.g. via a built-in VSD (inverter) is suitable.

[0059] An external cold water supply conduit 100, in this case a pressurised mains water supply, enters the return pipe 12 at a junction 15 shortly before it re-enters the heater 20. A check valve 110 permitting only forward flow is provided in the supply conduit 100, and a flow sensor 111 immediately downstream of this detects when there is flow from the supply 100 into the circulation system. The flow sensor 111 is connected to the control processor 7.

[0060] In the stasis mode shown, all of the outlets 4 (taps etc.) are closed and the control processor 7 is programmed to maintain the temperatures (as assessed at the sentinel sensor 5, the return sensor 9 or other strategically located sensor) within predetermined acceptable ranges, such as a minimum of 50 C. and a maximum of 60 C. For a pasteurisation mode, the temperature may be controlled at 70 C. or above. The processor 7 controls the heater output and/or pump rate with appropriate feedback to maintain the temperature accordingly. The system is full of water at full pressure, so no water enters through the external supply conduit 100 from the mains, the check valve 110 remaining closed and the flow sensor 111 detecting no flow.

[0061] In the stasis mode heated water flows in a generally laminar flow out along the annular cross-section outflow channel 21. This includes flowing out along the outflow tube of each branch 14, and back along the return conduit 12 with flow along the subsidiary return branch conduit portions 142 of each of the branches 14, since flow pressure differences prevail at each of the branches as they do at the terminal point 40. Because the return pipe is surrounded or jacketed by the outflow pipe, heat losses are reduced and may be further reduced by appropriate lagging or other insulation of the pipe system including its branches. Laminar flow in the stasis mode reduces vibration, other noise and wear in the pipes. It can be provided by programming to adjust the pump rate down (adjusting the heating rate up if necessary) to below a predetermined flow rate limit, when the desired temperature is achieved for the stasis mode. In dynamic mode the flow rate may be higher according to demand.

[0062] Each outlet 4 is provided with an appropriate mixer tap, such as an automatic (thermostatic) mixing device to prevent inadvertent scalding by mixing with cold water from the cold water supply (which is not shown, and may be a conventional supply direct from a pressurised main).

[0063] FIG. 3 shows the FIG. 2 system when two of the outlets (taps) 4 have been opened and hot water is flowing out. Because water leaves the system the pressure drops and water flows in through the supply main 100, opening the check valve 110 and activating the flow sensor 111. The control processor 7 responds by stopping the pump 8 and closing the shut-off valve 3 immediately downstream of the pump, thereby closing off the return flow. The flow is then a direct flow of cold supply water under mains pressure into the heater 20 where it is heated and passes into the outflow conduit 11 and to the open outlets 4, for as long as needed. There is no return flow, so the energy from the heater is devoted to the active outlets. When use is finished and all outlets are closed, the pressure in the circulation system 1 returns to mains pressure, the check valve 110 closes and the flow sensor 111 is deactivated causing the control processor to revert to the stasis mode, opening the return shut-off valve 3 and turning on the pump 8.

[0064] The system controller (in this example and in general) may be programmed to provide a limited use reservation, whereby when an outlet is opened the system remains in the stasis mode unless and until water use exceeds a preset threshold parameter of flow rate, time and/or volume e.g. as detected using the flow sensor. This can avoid unnecessary powering-up of the heater and/or interruption of the pump in the event of minimal uses. Such a system desirably uses a positively actuated (rather than passive, flow/pressure-actuated) shut-off valve 3 to control its operation in tandem with the pump 8.

[0065] FIGS. 4 and 5 show respectively the stasis and dynamic modes of a second embodiment. Most components of the system correspond to those of the first embodiment and have the same reference numerals.

[0066] An additional feature in the second embodiment is a heat source thermostat 208 detecting the water temperature in the heater 20, and connected to the control processor 7. [In this embodiment the sensors are matched to appropriate input transducers comprised in the control processor 7 so no separate transducer is shown.] The temperature sensor 208 (thermostat) in the heater 20 takes the place (functionally speaking) of the return temperature sensor 9 of the first embodiment. Immediately downstream of the pump 8 a passive mechanical check valve 30 is provided (instead of the positively controlled shut-off valve 3 of the first embodiment).

[0067] In the stasis mode of FIG. 4 the outlets 4 are all closed, the pump 8 circulates liquid and the process control 7 determines whether the water temperatures measured by the sentinel temperature sensor 5 and the heat source thermostat temperature 208 are within the set parameters. If they are not, the controller modulates the power output of the heat source 20 to bring the temperature within the set parameters. This is similar to the first embodiment, except for the disposition of the temperature sensor 208. When one or more outlet user points (taps) 4 are opened, as shown in FIG. 5, as in the first embodiment the circulation system pressure drops and cold water under mains pressure enters along the external supply conduit 100 through the check valve 110 and past the flow sensor 111 which is duly activated. Detection of flow sensor activation switches the control processor 7 to the dynamic mode and it stops the pump 8. In this second embodiment the return flow substantially ceases (because the pump stops) and any reverse flowwhich would obviously be undesirableis prevented by the passive check valve 30 in the return conduit, without use of a positively controlled shut-off seen in the first embodiment. The substantial result is the same, namely a direct supply from the external main via the heater 20. However a positively controlled valve 3 as in the first embodiment may have some advantages, such as less flow obstruction in the open position and the ability to react to parameters or signals other than flow.

[0068] FIG. 6 is a schematic cross section showing concentric inner and outer pipes 12,11 defining the cylindrical return channel 22 surrounded by the annular-section outflow channel 21. Radial supports 16 extend between the inner and outer pipes to maintain their relative positions. FIG. 7 shows a convenient manner of implementing support without complicated manufacture or assembly, by providing integral opposed lobes or flanges 126 on the inner tube 12 which match the inner diameter of the outer tube 11, so that the inner tube 12 is held substantially in the middle of the outer. These lobes or fins 126 may be vertically oriented to maximise the support. Other means of providing nested or concentric pipes may be used.

[0069] FIGS. 8 and 9 show a further option, in the form of a discrete spacer clip 130. The main part of the clip is a part-cylindrical metal strap dimensioned to grip resiliently around the inner pipe (not shown) with some deformation, as in FIG. 9 indicating a base hinge portion 131 slightly forced open. The opposed ends of the strap have projecting flanges 136 whose extremities, with the bottom of the projecting hinge portion 131, abut against the interior of the outer pipe to keep the inner pipe at a suitable spacing. A series of these spacer clips 130 is provided at intervals along the pipes.

[0070] FIGS. 10 and 11 show a convenient coupling 220 for connecting adjacent lengths of the concentric (coaxial) double pipe 11,12. The coupling 220 is a one-piece unit with an outer tube 222 connected to a coaxial inner tube 225 by a pair of opposed internal support struts 223. Each of the inner and outer tubes 222, 225 presents oppositely-directed open ends, to receive slidingly the ends of respective sections of outer (outflow) pipe 11 and inner (return) pipe 12. The outer tube 222 has external threads 227 at each end for clamp rings, not shown but of known type and which include compressible external seals, to grip and seal the assembly. The outer tube also carries an exterior central tool surface 229, such as a polygonal nut form to help tighten the clamp rings. The inner tube 225 has, half-way along its interior, an inward annular projection 226 which functions as a pipe stop. In use, the respective pipes 11,12 to be joined can quickly be slid into engagement with the respective inner and outer tubes of the coupling 220 which is then tightened into sealing engagement with the outer pipe. No special sealing is required for the inner pipe, because the pressure difference between the two conduits is modest and slight leakage is of no consequence.

[0071] FIGS. 12 to 15 show details of a ball valve 250 which can be used as an isolator valve for temporarily separating or isolating different sections of the concentric (coaxial) flow conduits from one another, e.g. for maintenance or repair. In particular we envisage that one of these valves 250 may be provided on each branch leading to a user point.

[0072] The isolator valve 250 is a quarter-turn ball valve consisting essentially of a body or housing 270 and a rotatable closure member 260. The body 270 consists of a main body portion 271 and a retainer body portion 272. Each body portion 271, 272 comprises a tubular outer union 273 sized to receive slidingly an end of a respective outer pipe 11, with an external thread for the sealed securing of the outer pipe. The main body portion 271 defines an interior cavity for the ball 261 of the closure member 260, and the bonnet 274 of the valve which includes a packing seal 275 and retaining nut 276 for the actuating spindle 262 of the closure member 260. Actuation may be manual, or automated e.g. by any conventional drive. The body retainer portion 272 screws into the main body portion 271 to enclose the valve mechanism and hold the components in place. An opposed pair of seat union components 280 are retained in this cavity, held between the body portions by external flanges 285, and these provide both peripheral seals (seats) 281 for sealing around the ball 261 and central inner union tubes 282 for sliding connection with the inner (return) pipes 12 of the circulation system. The seat union components 280 have outer tubular extensions 284 fitting into the outer union tubes 273 of the body portions whose internal diameter matches that of the outer pipes, and the end surfaces of these extensions provide stop abutments for the outer pipes. The inner union tubes 282 are mounted concentrically in the seat union components 280 by support members 286 (see FIG. 13) in the form of short walls or fins extending axially to minimise flow obstruction. Two opposed fins are shown; other numbers and shapes may be used.

[0073] FIGS. 14 and 15 show that the ball member 261 consists of a main outer tube 264 having a spherical outer surface 265 and a cylindrical inner surface 269 facing onto an inner tube 266 which is supported concentrically with the outer tube 264 by means of support walls 267 which, in the open condition of the valve, may extend as continuations of the support walls of the fixed seat unions 280. The internal diameters of the inner and outer tubes 264, 266 generally match those of the inner and outer pipes 12,11 of the main conduit, so that the valve is effectively of a full port type with minimal reduction of flow cross-section through the valve in the open condition. In the closed condition, with the actuating spindle 262 turned a quarter turn, the external ball surface 265 turns around to close off entirely the pipes at both sides of the valve 250, with sealing around the seats 281 of the seat union. Seals at these points may be provided by resilient or deformable seal members, such as PTFE rings (not shown). No discrete seal member is provided for sealing between the inner union tube 282 of the seat union and the inner tube 266 of the ball 261 in the open position. Close proximity suffices for ordinary operation because the same system water is present in both conduits and a modicum of leakage is not harmful provided that adequate pumping pressure is maintained.

[0074] FIGS. 12, 14 and 15 show an optional novel refinement of the isolator valve. In a conventional ball valve a spherical ball surface segment makes an annular outer seal which fully closes or blocks the opening of a single pipe. In the present valve there is an additional inner pipe (inner tube 282) defining its own inner conduit. If the side surface of the valve ball is spherical, it will substantially close off the end 283 of the inner pipe in the closed position although it will not fully seal it unless special measures are taken. As in the open position, a degree of leakage at this position is not serious. However in the present systems, a flow which continuously circulates by communication between outflow and return conduits is of special value because it enables sanitary operation. A further optional proposal here is therefore to provide, in the side (sealing) face of the ball member 261 on one or both sides thereof, a recessed portion 268 (recessed relative to a spherical shape envelope, such as for example a flat region) as indicated in dotted lines in FIGS. 12, 14 and 15. In the closed condition, the recessed portion 268 is spaced away from the end 283 of the inner union tube 282 and puts the outflow and return conduits into communication for substantial flow between the inner and outer conduits on that side of the valve, although the valve as a whole remains completely closed by the outer seals 281. If the valve 251 is positioned in or at the end of a branch conduit, this enables the branch conduitwhich might otherwise become static and non-sanitaryitself to maintain a circulating flow although the user point is out of operation, so that the whole system maintains operational effectiveness.

[0075] FIGS. 16(a) and (b) show a slightly modified form of the isolator valve 1250 including seals and insert unions. The general concept of operation is the same as before.

[0076] FIG. 17 shows schematically how the hot water flow circuit 1001 may be branched to serve multiple floors A, B, C, D of a building, and how isolator valves 1250 as described above may be positioned in the system e.g. to enable isolation of a branch from the rest of the system. Sanitary conditions and flow can be maintained in the active part of the system because the isolator valve 1250 has internal clearance which allows for return flow circulation as explained above.