Backflow Preventer, Method to Operate a Backflow Preventer, Retrofit Kit and Monitoring System for at Least One Backflow Preventer

This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63/341, 147 filed May 12, 2022, its entirety of which is incorporated herein by reference.

The present disclosure relates to a backflow preventer. Further on, the present disclosure relates to a method to operate a backflow preventer, to retrofit kit for a back flow preventer and to a monitoring system for at least one backflow preventer.

Backflow preventers serve prevention of contamination of potable water supplied by a potable water supply system like a municipal or a central water service. Certain types of properties that connect to a potable water supply system are required to have their water service connection fitted with a backflow preventer. Properties that are required to have their water service connection fitted with a backflow preventer are, examples given, properties with in-ground irrigation sprinklers, properties with swimming pools, metal plating facilities, cleaning facilities, processing or fabricating facilities, photo-processing facilities, laundries and dry cleaners, commercial car washes, greenhouses, hospitals, clinics, laboratories, medical and dental offices, funeral parlors, food processing plants, meat and fish packers, dye plants, auto repair shops, breweries, tanneries, exterminators, residential dwellings with water boilers that use rust-inhibitors, sewage treatment plants or handling facilities, premises with roof tanks and elevated storage lines, canneries, slaughterhouses, ice manufacturing facilities, printing facilities, supermarkets, premises with commercial or public kitchen, premises with water cooled equipment or chillers, barber shops and beauty salons. There are several other properties that are required to have their water service connection fitted with a backflow preventer.

Backflow preventers prevent possibly contaminated water in the plumbing of a property from flowing back into the potable water supply system. For example, water that has entered the piping of an underground irrigation system could be contaminated from contact with the soil. It is important that this water is prevented from reentering the potable water supply system intended for consumption. Backflow preventers prevent siphoning of water from the irrigation plumbing back into the home or potable water supply system.

Problems arise when check valves of the backflow preventers stick in the open position and allow possibly contaminated water to reenter into the home or potable water supply system. Such a failed backflow preventer is a common problem due to mineral deposits collecting on the check valves of a backflow preventer from the water flowing through the backflow preventer or due to failure of springs that hold the check valves of the backflow preventer closed. Since backflow preventers are prone to failure, testing of the backflow preventers is desired.

Usually, backflow preventers become tested on an annual basis. It is the responsibility of the property owner to have the backflow preventer tested annually and it is the responsibility of a certified tester to provide test reports to a respective authority observing the testing of backflow preventers. The problem with this is that the backflow preventer could fail a day after the same has been tested.

There is a need for a backflow preventer, for a method to operate a backflow preventer and for a monitoring system for at least one backflow preventer that allows an automatic monitoring of a proper condition of a backflow preventer.

DE 42 04 389 C2 discloses a backflow preventer having a first check valve connected between a first pressure zone and a second pressure zone of the backflow preventer, a second check valve connected between the second pressure zone and a third pressure zone of the backflow preventer, a first pressure sensor assigned to the first pressure zone configured to measure a first pressure being present within the first pressure zone, a second pressure sensor assigned to the second pressure zone configured to measure a second pressure being present within the second pressure zone, and a third pressure sensor assigned to the third pressure zone being configured to measure a third pressure being present within the third pressure zone. DE 10 2012 019 437 A1, US 2021/0372096 A1, EP 3 835 494 A1 discloses further backflow preventers.

U.S. Pat. No. 11,199,276 B2 discloses a backflow testing device. U.S. Pat. No. 7,313,497 B2 discloses a valve monitoring method and arrangement. U.S. Pat. No. 5,713,240 A discloses a method and apparatus for automatic remote testing of backflow preventers.

Against this background, one or more embodiments of a novel backflow preventer, a novel method to operate a backflow preventer, a novel retrofit kit for a backflow preventer and a novel a monitoring system for at least one backflow preventer are provided. The backflow preventer according to the present disclosure is defined in claim. The method according to the present disclosure is defined in claim. The retrofit kit according to the present disclosure is defined in claim. The monitoring system according to the present disclosure is defined in claim.

In some embodiments, the backflow preventer comprises a first check valve connected between a first pressure zone and a second pressure zone of the backflow preventer.

In some embodiments, the backflow preventer further comprises a second check valve connected between the second pressure zone and a third pressure zone of the backflow preventer.

In some embodiments, the backflow preventer further comprises a first pressure sensor assigned to the first pressure zone being configured to measure a first pressure being present within the first pressure zone.

In some embodiments, the backflow preventer further comprises a second pressure sensor assigned to the second pressure zone being configured to measure a second pressure being present within the second pressure zone.

In some embodiments, the backflow preventer further comprises a third pressure sensor assigned to the third pressure zone being configured to measure a third pressure being present within the third pressure zone.

In some embodiments, the backflow preventer further comprises a shut off valve positioned downstream of the second check valve. The backflow preventer further comprises a first actuator assigned to the shut off valve being configured to open and close the shut off-valve.

In some embodiments, the backflow preventer further comprises a bypass extending between the first pressure zone and the third pressure zone and a bypass valve positioned within the bypass. The backflow preventer further comprises a second actuator assigned to the bypass valve being configured to open and close the bypass valve.

In some embodiments, the backflow preventer further comprises a controller. The controller is configured to automatically close and open the shut off valve and the bypass valve for an automatic testing of the backflow preventer. The controller is further configured to automatically receive measurement signals from the first pressure sensor, the second pressure sensor and the third pressure sensor. The controller is further configured to automatically process the measurement signals received from the pressure sensors in order to determine if the backflow preventer is properly working or improperly working.

In some embodiments, the backflow preventer allows an automatic monitoring of a proper condition of a backflow preventer. The automatic monitoring can be executed daily by the backflow preventer without the need to schedule an appointment with a certified tester.

In some embodiments, the controller of the backflow preventer may further be configured to automatically provide data about the testing through a communication interface to at least one database. The backflow preventer may automatically provide data resulting from the automatic testing to a database of a respective authority observing the testing and/or to a database of the manufacturer of the backflow preventer. The backflow preventer may also automatically provide such data to the property owner. If an improperly working backflow preventer is determined, the backflow preventer may automatically initiate repair or replacement of the same.

In some embodiments, the backflow preventer and/or the controller thereof allows to determine if the first check valve and/or the second check valve of the back flow preventer is and/or are properly working or improperly working. So, the invention allows to detect which check valve may need to repaired or replaced.

In some embodiments, in order to test the shut off valve of the backflow preventer being positioned downstream of the second check valve backflow preventer the following steps are automatically executed: Close the shut off valve or keep the same closed. Measure the first pressure by the first pressure sensor. Measure the third pressure by the third pressure sensor. If the first pressure is greater than the third pressure, then a properly working shut off valve is detected. If the first pressure is not greater than the third pressure, then an improperly working shut off valve is detected.

In some embodiments, in order to test the first check valve of the backflow preventer the following steps are automatically executed: Close the shut off valve or keep the same closed. Measure the first pressure by the first pressure sensor. Measure the second pressure by the second pressure sensor. If a difference between the first pressure and the second pressure is larger than a threshold, then a properly working first check valve is detected. If the difference between the first pressure and the second pressure is not larger than the threshold, then an improperly working first check valve is detected.

In some embodiments, in order to test the second check valve of the backflow preventer the following steps are automatically executed: Close the shut off valve or keep the same closed. Measure the second pressure by the second pressure sensor. Measure the third pressure by the third pressure sensor. If a difference between the second pressure and the third pressure is larger than a threshold, then a properly working second check valve is detected. If the difference between the second pressure and the third pressure is not larger than the threshold, then an improperly working second check valve is detected.

The above method steps allow a reliable and automatic testing of a backflow preventer, namely of the shut off valve and/or of the first check valve and/or of the second check valve of the backflow preventer. The bypass valve becomes closed before and/or is kept closed for the testing of the shut off valve and/or for the testing of the first check valve and/or for the testing of the second check valve.

In some embodiments, for a backflow testing of the backflow preventer the following steps are automatically executed: Close the shut off valve or keep the same closed. Measure the first pressure by the first pressure sensor. Measure the second pressure by the second pressure sensor. If a difference between the first pressure and the second pressure is larger than a threshold, then open the bypass valve and provide fluid from the first pressure zone to the third pressure zone. Close the bypass valve. Measure again the first pressure by the first pressure sensor. Measure again the second pressure by the second pressure sensor. If the difference between the first pressure and the second pressure remains unchanged, then a properly working backflow preventer is detected. If the difference the first pressure and the second pressure does not remain unchanged, then an improperly working backflow preventer is detected.

In some embodiments, the retrofit kit of the present disclosure can be used to convert a prior art backflow preventer having a first check valve connected between a first pressure zone and a second pressure zone of the backflow preventer and a second check valve connected between the second pressure zone and a third pressure zone of the backflow pre-venter into a backflow preventer according to the present disclosure.

In some embodiments, the retrofit kit comprises: A first pressure sensor being configured to be connected to the first pressure zone and to measure a first pressure being present within the first pressure zone. A second pressure sensor being configured to be connected to the second pressure zone and to measure a second pressure being present within the second pressure zone. A third pressure sensor being configured to be connected to the third pressure zone and to measure a third pressure being present within the third pressure zone.

In some embodiments, the retrofit kit further comprises: A shut off valve being configured to be connected to the third pressure zone downstream of the second check valve. A first actuator being configured to open and close the shut off-valve. A bypass unit being configured to provide a bypass extending between the first pressure zone and the third pressure zone and a bypass valve positioned within the bypass. A second actuator being configured to open and close the bypass valve. A controller being configured to automatically close and open the shut off valve and the bypass valve for an automatic testing of the backflow preventer, to automatically receive measurement signals from the first, second and third pressure sensor, to automatically process the measurement signals received from the pressure sensors in order to determine if the backflow preventer is properly working or improperly working.

In some embodiments, the monitoring system for at least one backflow preventer comprise a first interface, the first interface being configured to receive data from the at least one backflow preventer determined during an automatic testing of the same. The monitoring system for at least one backflow preventer comprise further a second interface, the second interface being configured to send data to at least one database.

One or more embodiments of the present disclosure include a backflow preventer (), having a first check valve () connected between a first pressure zone () and a second pressure zone (), a second check valve () connected between the second pressure zone () and a third pressure zone (), a first pressure sensor () assigned to the first pressure zone () being configured to measure a first pressure being present within the first pressure zone (), a second pressure sensor () assigned to the second pressure zone () being configured to measure a second pressure being present within the second pressure zone (), a third pressure sensor () assigned to the third pressure zone () being configured to measure a third pressure being present within the third pressure zone (). The backflow preventer () further comprises a shut off valve () downstream of the second check valve (), a first actuator () assigned to the shut off valve () being configured to open and close the shut off-valve (), a bypass () extending between the first pressure zone () and the third pressure zone (), a bypass valve (), a second actuator () assigned to the bypass valve () being configured to open and close the bypass valve (), and a controller (). The controller () is configured to automatically close and open the shut off valve () and the bypass valve () for an automatic testing of the backflow preventer, is configured to automatically receive measurement signals from the first pressure sensor (), second pressure sensor () and third pressure sensor (), and is configured to automatically process the measurement signals received from the pressure sensors (,,) in order to determine if the backflow preventer is properly working. ()

shows a backflow preventer. Potable water may flow through the backflow preventerfrom an inlet portof the backflow preventerto an outlet portof the backflow preventerwhen the backflow preventeris installed in a pipe of a potable water system.

In some embodiments, the backflow preventerprevents a backflow of the potable water in the opposite direction from the outlet portto the inlet port. In some embodiments, the backflow preventercomprises a first check valveconnected between a first pressure zoneand a second pressure zoneof the backflow preventer. The first pressure zoneis an inlet pressure zone and the second pressure zoneis an intermediate pressure zone of the backflow preventer. The backflow preventercomprises further a second check valveconnected between the second pressure zoneand a third pressure zoneof the backflow preventer. The third pressure zoneis an outlet pressure zone of the backflow preventer. The first check valveand the second check valveare accommodated with a housingof the backflow preventer. The housing provides the inlet port, the outlet port, the first pressure zone, the second pressure zoneand the third pressure zone.

In some embodiments, both check valves,comprise springs which tend to keep the respective check valve,in a closed position. If a water consumption occurs downstream of the outlet port, the pressure with the outlet zonedrops and the check valves,open thereby allowing water flow towards the outlet port. If the water consumption downstream of the outlet portis terminated, the check valves,become automatically closed by the springs of the same. Further on, a water back pressure of a downstream outlet that would cause a backflow will also close a properly working check valve,.

In some embodiments, the backflow preventermay comprise a drain valve (not shown) in order to empty the second pressure zoneinto the environment.

In some embodiments, the backflow preventercomprises a shut off valvepositioned downstream of the second check valve. The shut off valveis positioned within third pressure zone. When the shut off valveis opened, the shut off valveallows a flow of potable water through the third pressure zonetowards the outlet port. When the shut off valveis closed, the shut off valvedoes not allow a flow through the third pressure zonetowards the outlet port.

In some embodiments, the backflow preventermay further comprise an optional second shut off valvepositioned upstream of the first check valve. The optional second shut off valveis positioned within first pressure zone.

In some embodiments, when the optional second shut off valveis opened, the optional second shut off valveallows a flow of potable water through the first pressure zonetowards the first check valve. When the optional second shut off valveis closed, the optional second shut off valvedoes not allow a flow through the first pressure zonetowards the first check valve.

In some embodiments, the backflow preventerfurther comprises a first pressure sensorassigned to the first pressure zone. The first pressure sensoris configured to measure a first pressure pbeing present within the first pressure zone. So, the first pressure sensoris configured to measure the inlet pressure pwithin the inlet pressure zone.

In some embodiments, the backflow preventerfurther comprises a second pressure sensorassigned to the second pressure zone. The second pressure sensoris configured to measure a second pressure pbeing present within the second pressure zone. So, the second pressure sensoris configured to measure the intermediate pressure pwithin the intermediate pressure zone.

In some embodiments, the backflow preventerfurther comprises a third pressure sensorassigned to the third pressure zone. The third pressure sensoris configured to measure a third pressure pbeing present within the third pressure zone. So, the third pressure sensoris configured to measure the outlet pressure pwithin the outlet pressure zone.

In some embodiments, the backflow preventermay further comprise an optional fourth pressure sensorassigned the inlet port. The optional fourth pressure sensoris configured to measure a fourth pressure pbeing present within the inlet port. In some embodiments, the backflow preventerfurther comprises a first actuatorassigned to the shut off valvebeing configured to open and close the shut off-valve.

In some embodiments, if the backflow preventercomprises the optional second shut off valve, the backflow preventerfurther comprises an actuatorassigned to the second shut off valvebeing configured to open and close the second shut off valve.

In some embodiments, the backflow preventerfurther comprises a bypassextending between the first pressure zoneand the third pressure zone. A bypass valveis positioned within the bypass.

In some embodiments, a second actuatoris assigned to the bypass valveand is configured to open and close the bypass valve.

In some embodiments, the backflow preventerfurther comprises a controller. The controllermay include any combination of a combination of at least one software component and/or at least one hardware component which are designed/programmed/configured to manage/control other software and/or hardware components (such as the libraries, software development kits (SDKs), objects, etc.).

Examples of hardware elements may include processors, microprocessors, circuits, circuit elements (e.g., transistors, resistors, capacitors, inductors, and so forth), integrated circuits, application specific integrated circuits (ASIC), programmable logic devices (PLD), digital signal processors (DSP), field programmable gate array (FPGA), logic gates, registers, semiconductor device, chips, microchips, chip sets, and so forth. In some embodiments, the one or more processors may be implemented as a Complex Instruction Set Computer (CISC) or Reduced Instruction Set Computer (RISC) processors; x86 instruction set compatible processors, multi-core, or any other microprocessor or central processing unit (CPU). In various implementations, the one or more processors may be dual-core processor(s), dual-core mobile processor(s), and so forth.

Examples of software may include software components, programs, applications, computer programs, application programs, system programs, machine programs, operating system software, middleware, firmware, software modules, routines, subroutines, functions, methods, procedures, software interfaces, application program interfaces (API), instruction sets, computing code, computer code, code segments, computer code segments, words, values, symbols, or any combination thereof. Determining whether an embodiment is implemented using hardware elements and/or software elements may vary in accordance with any number of factors, such as desired computational rate, power levels, heat tolerances, processing cycle budget, input data rates, output data rates, memory resources, data bus speeds and other design or performance constraints. In some embodiments, the controllermay receive sensor signals and send control signals to various components of the backflow preventervia a suitable data transfer interface. In some embodiments, the data transfer interface may include any suitable communication system that transfers data between components inside the computer system, include an internal data bus, memory bus, system bus, address bus, front-side bus, or other internal bus or any combination thereof. In some embodiments, examples of the bus may include, e.g., PCI express, small computer system interface (SCSI), parallel AT attachment (PATA), serial AT attachment (SATA), HyperTransport™, InfiniBand™, Wishbone, Compute Express Link (CXL), among others or any combination thereof.

In some embodiments, the data transfer interface may be configured to operate in the distributed network environment, communicating with one another over one or more suitable data communication networks (e.g., the Internet, satellite, etc.) and utilizing one or more suitable data communication protocols/modes such as, without limitation, IPX/SPX, X.25, AX.25, AppleTalk™, TCP/IP (e.g., HTTP), Bluetooth™, near-field wireless communication (NFC), RFID, Narrow Band Internet of Things (NBIOT), 3G, 4G, 5G, GSM, GPRS, WiFi, WiMax, CDMA, satellite, ZigBee, and other suitable communication modes. Various embodiments herein may include interactive posters that involve wireless, e.g., Bluetooth™ and/or NFC, communication aspects, as set forth in more detail further below.

In some embodiments, the controlleris configured to automatically close and open the shut off valveand the bypass valvefor an automatic testing of the backflow preventer. The controllercomprises a communication interfaceto send respective control signals cand cto the actuatorof the shut off valveand to the actuatorof the bypass valve.