Zurn 112-350xl - 1-1/2&quot; Double Check Backflow Preventer - 1 backflow preventer

 2024-09-16 12:15:21

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In classes I teach around the country a frequent question that is asked is should we replace backflow prevention assemblies or should we repair them when they fail our testing. As with so many issues today this one has many variables to it. How old is the assembly? Are the repair parts readily available? Is it less expensive for your customer to replace rather that repair? How difficult will the repair be? Is it simply time to update the assembly? The list goes on and on. I think the best answer may be it depends.

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It is said we live in a throwaway society. How often do we update our cell phones? If plumbers could convince people to replace the faucets in their homes as often as we change our cell phones we would have some very wealthy plumbers out there. When I was a child and the television in our home had issues my father called in a repairman. These days we simply go out and purchase a new TV. Backflow prevention assembly are a little different. We need to repair when it makes sense and replace when necessary. There is no simple answer.

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Sean, I enjoyed the article. New Jersey is another state that requires a repairers license to repair a device along with working or being a master plumber. My business focuses on testing and repair of backflow preventer so my truck is stocked with repair pairs for major manufactures such as Watts, Wilkins-Zurn, Febco, Ames and Apollo. I test for several plumbing contractors, and every so often ones of their guys tries to fix one on an initial installation. When they do I usually have to replace an o ring or part they tried to force back in place. Also sometimes the device gets damaged in shipment and will need a new test port. So having a good selection of parts helps maintain my business. When it comes to replacing devices, it’s a tricky. If it’s a regular customer I try and let them know in advance that their device is failing and that it’s no longer made for replacement. If it’s a new customer and the device needs to be replace I take them to the device and show them the problem and why it needs to be replaced. What happens from there is anyone’s guess.

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I hope this article has made you look at these questions a little differently. I would love to hear your thoughts on the issue. Please reach out and let me know.

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How long are backflow prevention assemblies made to last? Assemblies are built with the repair and replacement of internal parts in mind. The manufacturers and designers of backflow preventers understand the many different situations their products are installed in. The differences in external environments, water quality, water pressures, water temperature, flow rates, and any other number of factors in which the products have been installed can affect the life of any backflow prevention assembly. Each approved assembly has been built to an approved industry standard. These products have also been through a rigorous laboratory and in many cases a one-year field test process before being allowed to be sold and installed in water systems around the country. Backflow preventers are made to last and assemblies that have been installed for fifty plus years continue to provide the needed protection for our water systems. Replacing a functioning assembly only because of its length of service does not make sense. Many older assemblies are epoxy coated valves when evaluating these assemblies, it is important to look at the condition of this protective coating. If it is damaged, missing, or if it is showing signs of flaking it may be time to look at possible replacement of the assembly. Are the seats and check valve modules made up of leaded components? Are they in need of replacement? What is the cost of these parts compared to the replacement of the assembly? If an assembly repair requires only the replacement of the rubber parts and the rest of the assembly is in good shape then a repair makes perfect sense. If it will require several thousand dollars of replacement parts and the assembly coating is breaking down then we truly need look at replacement of the assembly in many cases and provide our customers with the correct options so they can make an educated decision.

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Backflow prevention assemblies are constructed of many different materials. Brass or bronze, stainless steel, plastics, and epoxy coated cast iron. The changes made to the Safe Drinking Water Act which went into effect on January 4th, 2014 resulting in a much lower lead content has also impacted the way backflow preventers built and the way we repair existing assemblies. Let’s exam the question we posed at the beginning of the article.

This question and question four are very similar. In my now forty plus years in the trade and thirty plus years testing backflow preventers I have seen the unnecessary replacement of water heaters, faucets, boilers, plumbing fixtures, and backflow preventers as a result individuals not having the skill or knowledge to make the needed repairs. In other case parts were replaced because of it being more profitable to the contractor to replace rather than repair. The truth is that assemblies should be replaced when it makes sense to do so. It needs to make sense to the consumer and to ensure the proper protection to the water systems. Each installation or situation is unique. We need to take an unbiased look and use the information available to make the best decision possible in each case.

My son works for a large mechanical contractor that tests backflow prevention assemblies on a regular basis. They have a policy that if an assembly is one inch or smaller and it fails an annual test the service technician should simple replace the assembly. They carry these smaller size replacement assemblies in their service trucks and because of the cost of labor it simply makes sense that instead of ordering parts and returning to make the repair, it is less expensive to their customers to replace the assembly than repair it. In larger assemblies that logic no longer is feasible. Repair rather than replace seems to be the correct decision in many cases.

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Most more modern assemblies are more repair friendly than some older assemblies. Anyone who was worked on a Hersey 6CM or a Cal-Valve knows what I am talking about. The newest generation of backflow prevention assemblies are shorter in lay length and have superior flow rates. The valves weigh less and to be honest are less challenging to repair. Captured springs and check modules allow for less complicated repairs. Trained personnel can make any necessary repair as long as the needed parts are available. Each situation should be looked at in its entirety and the proper decision made.

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In almost every case and with most existing assemblies’ repair parts are available to make a proper repair. The backflow industry is fortunate enough to have master parts distributors in place that have the necessary parts in stock and can get them to every area of the country with next day shipping. They stock parts for all manufacturers products and sizes. There is a related cost for this service but it allows backflow testers and repairs to access the parts they need on a timely basis. Most local plumbing supply houses do not stock backflow repair parts in any real manner and older assembly parts are never available in those types of location. Another service these part suppliers provide is repair advice and training. They also in many cases have on-line repair videos that allow individuals in the field to access these videos both before they begin a repair or even while repairing the valve on-site. Modern technology has made these services available to anyone with a smart phone and can be a life saver when an individual is repairing or servicing a valve they are unfamiliar with.

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One consideration that should be looked at in these situations is any local requirement for permits and inspections and those possible related costs. Also in many jurisdictions, the individual doing the testing may not be allowed to make repairs to an assembly. Many jurisdictions require that repairs be made by a licensed plumber. In other areas such as the state of Minnesota, the state requires that repairs be made not only by a licensed plumber but by a licensed plumber who holds a current repairer certification. This brings up another question we frequently hear, what is the definition of a repair? If I simply clean to internal parts of the assembly and don’t replace any of the parts is this considered a repair? The simple answer is yes, if you remove a cover to exam the internal working of a backflow prevention assembly for even a visual inspection it is considered a repair and this work should only be done by the individuals who have been approved by the authority having jurisdiction to complete this type of action.

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This question again has several variables. The most common is the assembly size. If we have a small assembly that has failed a test and we do not have a repair kit available it may make sense to simple replace the assembly to save the labor of ordering the parts and returning to make the repair. When I worked in the field I can remember a number of times that replace rather that repair saved the consumer money and time. It also allowed us to get the water service restored immediately. In some of the large facilities we worked in we encouraged the owners to always use the same manufacturer’s valves throughout their properties to allow for having on site an inventory of repair parts for the facilities. The age and internal condition of any assembly needs to be considered when making this decision. Also, the expense of replacement is important. Changing out a twelve-inch assembly cannot be compared to the cost of replace a three-quarter inch assembly.