Method and apparatus for valve assembly for a hot water tank

A method of replacing an inlet valve for a hot water tank, comprising removing the existing valve and inserting a new valve particularly adapted for use in the present invention. The new valve is connected to the pipe end portion of the inlet pipe by means of a compression nut and a ferrule, with the compression nut attaching to exterior threads on a first connecting portion of the valve. Then the flex tube connecting member is interconnected with the exterior threads of a second pipe connecting portion. The valve itself is a gate valve with a full flow through passageway, and the two exteriorly threaded connecting portions are to be connected to the compression nut and the flex tube connecting nut, respectively.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a method of installing a valve in an 
existing plumbing system, and to a valve and valve assembly particularly 
adapted for use in such method. 
2. Background Art 
For many years, the conventional method of providing a water distribution 
system for a building is to provide a network of pipes (made of copper or 
some other suitable material) which extend from a main inlet to various 
locations in the home or other building structure, with a valve being 
provided at each discharge location. There is generally a main shut off 
valve at an upstream location, this valve being positioned so that it can 
shut off water to the entire network in the building. Also, at each 
discharge location, there is quite often provided an additional local 
shutoff valve so that any single discharge valve can be isolated from the 
rest of the water distribution network. For example, at the location of a 
valve for a wash basin, there is quite often a local shutoff valve with a 
flexible fitting which leads from the end of the pipe to the valve. 
In addition, there are sometimes provided one or more shutoff valves at 
intermediate locations in the distribution network, with the flow through 
this shutoff valve servicing more than one outlet. A typical instance of 
such a shutoff valve is one which is positioned at the cold water inlet to 
a hot water heater. Typically, this shutoff valve has two connecting 
portions which are adapted to interfit with pipes in a soldered 
connection. One such soldered connection would be made to a pipe upstream 
of the valve, and the other soldered connection would be made to a short 
length of pipe, which in turn is soldered to a threaded fitting having 
exterior threads. This threaded fitting is in turn connected in threaded 
engagement with an interiorly threaded nut of a flex tube that would in 
turn lead to the cold water inlet of the hot water tank. 
During the initial installation of such a valve assembly of a cold water 
inlet of a hot water tank, the soldered connections can be made quite 
easily. However, in the event that a leak develops in the valve and it is 
desired to replace the valve, the following procedure is followed. The 
valve assembly is separated from the nut of the flex tube connection 
simply by unthreading the nut. Then this valve assembly is severed from 
the upstream pipe in a suitable manner (e.g. by sawing or cutting the pipe 
immediately upstream of the valve itself). Then a replacement valve is 
connected to the upstream pipe by making a soldered connection. In the 
cramped quarters of an existing hot water tank installation, the 
manipulation of the torch and the making of such a solder connection can 
be quite difficult. Also, there is made a couple of other solder 
connections, namely the solder connection with the short length of pipe 
and also to the fitting that is to engage the nut of the flex tube 
connection. 
To the best knowledge of the applicants, this same procedure of replacing a 
valve in an existing plumbing system has remained the same for many 
decades. It is believed that a number of factors have influenced the prior 
art relative to the present invention. One factor is that for many decades 
most plumbers have first gone through an apprenticeship training and have 
learned to accept certain traditional practices in the plumbing industry. 
Further, there are code regulations which have been in effect for a number 
of years, and these dictate certain practices, use of certain plumbing 
components, etc. In accordance with what might be called long standing 
"traditions" in the plumbing industry, manufacturers have produced their 
plumbing supplies to conform to these traditional practices. Possibly 
there has even developed what might be called a "communication gap" 
between the manufacturers of plumbing supplies and those who operate in 
the field installing plumbing components and fixtures, and that neither 
knows enough about what could be done by the other to have a broad enough 
perspective to make certain innovations. The present state of the art is 
such that there is, at least in terms of the steps the plumber has to 
take, somewhat time consuming and complex pattern in replacing a valve. 
This same pattern is repeated literally thousands of times a year, and its 
day to day repetition has been in turn repeated year after year. The same 
problem exists in modifying an existing plumbing installation where 
possibly a new component is to be added, such as a new water heater to be 
added as part of a remodelling program. 
Accordingly, it is an object of the present invention to provide an 
improved method of providing a valve in an existing plumbing system either 
as a replacement valve or one to be added to the system, and also to 
provide a valve and valve assembly particularly adapted for the same. 
SUMMARY OF THE INVENTION 
The method of the present invention is for installing a valve in a water 
distribution network of an existing plumbing system, where there is an 
existing distribution pipe and an existing main shutoff valve. The 
distribution pipe has an upstream end and a downstream outlet end, and 
also has an outside surface of a predetermined outside diameter, and an 
inside surface defining a passageway having a predetermined passageway 
diameter and passageway cross-sectional area. The existing main shutoff 
valve is located upstream of the upstream end of the distribution pipe. 
The method comprises determining an installation location where the valve 
is to be installed in the plumbing system. The existing shutoff valve is 
then operated to stop flow of water to the installation location. 
Then the distribution pipe is provided at the installation location with an 
open end pipe portion which is substantially undistorted and provides a 
substantially uninterrupted through passageway portion. Then there is 
provided a valve assembly comprising a valve, a compression nut, and an 
annular compression seal. 
The valve comprises a main body portion defining a central through 
passageway section having a cross-sectional area at least as great as that 
of the pipe passageway. There is a valve closure member having a first 
position closing said central through passageway section and a second 
position where said central through passageway section is substantially 
unobstructed. The valve has a first connecting portion defining a 
substantially unobstructed through passageway and having an exterior 
threaded surface portion with threads arranged to receive a compression 
fitting. The valve also has a second connecting portion defining a 
substantially unobstructed through passageway and having an exterior 
threaded surface portion with threads adapted to receive a conventional 
plumbing connection member with interior threads. 
The compression nut of the valve assembly has an annular integral 
structure, with an inner threaded surface to engage the threaded surface 
portion of the first connecting portion, and having a through opening to 
receive the pipe end portion. There is also an annular compression seal 
member adapted to be positioned adjacent said pipe end portion in sealing 
engagement with the first connecting portion and said pipe end portion. 
Then the valve is inserted at the selected installation location, with the 
compression nut and the seal member being placed adjacent the pipe end 
portion, and with the first connecting portion being in connecting 
relationship with said pipe end portion. The nut is threaded onto the 
first connecting portion to bring the seal member in sealing relationship 
with the pipe end portion. 
Then a conventional interiorly threaded connecting member is threaded onto 
the second connecting portion. 
After the installation of the valve is completed, the existing shutoff 
valve is then opened. 
In the preferred form, the first connecting portion has an interior surface 
configured to engage an exterior surface of the pipe end portion, and the 
pipe end portion is inserted into the first connecting portion of the 
valve. Where there is an existing valve at the installation location, the 
pipe end portion is provided by cutting said existing valve from the 
distribution pipe. Where the existing valve is also connected to a 
connecting nut of a flex tube member, the existing valve is unthreaded 
from the connecting nut. Then the second connecting portion of the valve 
is connected to the nut of the flex tube member. 
In a circumstance where the plumbing system comprises a water heater, a 
flex tube member connected to an inlet of the water heater, and an 
existing valve assembly, comprising an existing valve having a solder 
connection to an existing inlet pipe, the method further comprises the 
following steps. The flex tube connecting member is unthreaded from the 
valve assembly. Then the inlet pipe is cut so as to separate the existing 
valve from the system. Then the valve is installed in place of the 
existing valve by connecting the first connecting portion of the pipe end 
portion, and then threading a connecting nut of the flex tube member onto 
the second connecting portion. 
The valve assembly made according to the method of the present invention 
provides a substantially unrestricted flow passageway from the pipe end 
portion through the central through passageway of the valve. Desirably, 
the first connecting portion has an annular shoulder to engage an edge 
portion of the pipe end portion and thus locate the valve relative to the 
pipe end portion. 
In the preferred form, the closure member is a gate member, with the valve 
being arranged so that the gate member is moved totally out of alignment 
with the pipe end portion in its open position. 
Other features of the present invention will become apparent from the 
following detailed description.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
In FIG. 1, there is a simplified showing of a typical water distribution 
system for a home or other building structure, for which the present 
invention is particularly adapted. As shown herein, the building structure 
10 has an outside wall 12, a floor 14, footings 16, and an interior wall 
18. The water distribution system has a main inlet pipe 20 which is 
generally placed underground to prevent freezing. At some upstream 
location there is a main shutoff valve indicated somewhat schematically at 
22 at a location immediately outside the building 10. 
From the shutoff valve 22, there extends into the building structure 10 (as 
shown herein in the crawl space below the building structure 10), a main 
pipe 24, from which extend several distribution pipes, two of which are 
shown at 26 and 28. These pipes 26 and 28, as well as others in the water 
distribution system, are joined in a network by couplings, such as the two 
"T" couplings illustrated at 30. The ends of the pipes (such as shown at 
24, 26 and 28) are inserted into the connecting portions provided by the 
fittings 30, to form a water tight connection. Quite commonly the pipes 
24, 26 and 28 are bonded to the fittings 30 by use of solder applied to 
the connecting surfaces under heat. This method of making water tight 
plumbing connections is commonly called "sweating". 
One of the typical components of a water distribution system is a hot water 
heater, which generally comprises a hot water tank 32 having a cold water 
inlet 34 and a hot water outlet 36. The inlet 34 is typically connected to 
the water distribution network through a valve assembly, and such a valve 
assembly is shown somewhat schematically at 38. 
Generally, to utilize the space of the building structure more effectively, 
the hot water tank 32 is placed in a more remote or less used section of 
the home or other building structure, generally adjacent a wall, such as 
that at 18. Typically, there is a cold water inlet line 40 which, as shown 
herein, leads from a T-union 42 that in turn connects to one of the 
distribution pipes 28 located within the structure of the wall 18. 
Commonly, there is a valve 44 having a main valve portion 46 and two 
oppositely directed connecting portions 48 and 50, each of which is an 
unthreaded cylindrical member that is sized to fit around the end of the 
pipe to which it is to be connected. One connecting portion 48 of the 
valve 44 is connected to the water inlet line 40, and this is commonly 
done by a typical soldered or "sweated" connection. 
The connection to the inlet 34 of the tank 32 is commonly made by means of 
a flex tubing, such as shown at 52. One of the reasons for this is that 
the plumbing network is commonly installed in the building structure 10 at 
an earlier time during the construction. For example, in a typical 
residential structure, the house will be "framed", with the framed wall 
structure being a number of interconnected two-by-four pieces of wood. 
Normally, substantially the entire plumbing system for the house, 
including the various pipes, such as shown at 24-28, fittings 30, and 
various valves, such as shown at 44, are all interconnected by soldered or 
"sweated" connections. Subsequent to the installation of the main plumbing 
system, the drywall or other wall cover will be applied to the studs that 
make up the framework of the wall structure. After the drywall or other 
wall cover is installed, then items such as the water tank 32 will be put 
into place. 
Since a water tank 32 is generally a bulky structure, and since the precise 
location of the water tank 32 may vary to some degree depending upon 
convenience or other specific requirements, it is quite common to make the 
final connection between the valve 44 and the water inlet 34 through a 
flexible connection, such as the flex tubing 52, to allow for such 
variations in the precise location of the tank 32. 
A typical flex tube connection 52 comprises the main tube portion 54 of a 
foot or more in length, and two end fittings 56 and 58. These fittings 56 
and 58 are formed with interior threads to connect to a fitting having 
exterior threads, with one such exteriorly threaded fitting being the cold 
water inlet 34 for the tank 32, and the other being shown as a fitting 60 
that connects to the valve 44. This fitting 60 comprises an exteriorly 
threaded connecting portion 62 adapted to mate with the flex tube 
connecting portion 56, a middle nut portion 64 having flat sides to be 
gripped by a wrench or pliers, and a second connecting portion 66 defining 
a socket to receive a pipe section 68. The pipe section 68 is typically a 
short length of copper tubing (or tubing made of some other metal), 
extending between the connecting portion 50 of the valve 44 and the 
connecting portion 66 of the connecting member 60. 
At this point, let us review the overall makeup of the prior art valve 
assembly 38 that connect the cold water inlet pipe 40 of the plumbing 
network with the cold water inlet 34 of the tank 32. First, there is the 
valve 44, the short length of connecting pipe 68, the adaptor 60, and 
finally the flex tube connection 52. Further, there are three soldered 
connections, and two threaded connections. More specifically, there are 
the following soldered connections: 
(a) The connection between the cold water inlet 40 and the valve connecting 
portion 48; 
(b) The connection between the valve connecting portion 50 and the short 
tube length 68; and 
(c) The connection between the connecting portion 66 of the adapter 60 and 
the short pipe length 68. 
The two threaded connections are those that connect the flexible tube 
connector 52. Specifically, there is the connection between the flexed 
tube connecting portion 56 and the exteriorly threaded portion 62 of the 
adaptor 60. Also, there is the connection of the flex tube connecting 
portion 58 with the cold water inlet 34 of the tank 32. 
During the initial construction of the building structure 10, it is quite 
possible for the above valve assembly 38 to be installed with reasonable 
efficiency. During the initial installation of the entire water 
distribution network, the three connections between the inlet pipe 40, the 
valve 44, the short pipe connection 68 and the adaptor 60 can be made 
while the plumber is working on the entire installation, and has the 
equipment available to make the soldered connections. Further, with the 
building only being partially constructed, and with only the stud framing 
of the walls being erected, there is adequate room to maneuver and make 
the soldered connections. Accordingly, after the drywall or other wall 
cover has been installed, and the tank 32 moved into place, the connection 
with the flex tubing connector 52 can easily be made by making the two 
threaded connections with the flex tube connecting portions 56 and 58. 
However, let us examine the situation where it becomes necessary to repair 
a leak in the valve assembly 38, or possibly a situation where the water 
supply network is already in place and it is desired to install the tank 
32 of the water heater. (The latter situation could occur, for example, 
during a remodeling operation where a hot water tank 32 is installed to 
increase the rapacity of the system.) The common prior art method of doing 
this would be to reconstruct the assembly 38 as shown above. Thus, if a 
new valve assembly is being installed, it is necessary to employ the 
expertise of a person (presumably a qualified plumber) who would make the 
three soldered connections between the inlet pipe 40, the valve 44, the 
short pipe connection 68 and the adapter 66. If the wall structure 18 is 
in place, with dry wall or other wall covering applied to the basic wall 
structure, then it becomes necessary to operate the torch and other 
implements utilized in making the soldering connection in somewhat cramped 
quarters. 
Under circumstances where it is necessary to make a repair to the valve 
assembly 38, there are also difficulties. If one or more of the components 
are to be replaced, this would presumably entail the removal of one of the 
components (e.g. possibly a defective valve 44), or possibly remaking or 
repairing the soldered connections. This in turn would entail a "sweating" 
or soldering operation under circumstances where it is less than totally 
desirable to perform such an operation. 
This prior art system has, to the best knowledge of the applicants, been at 
least in the United States the common (if not universal) method of 
initially installing that portion of a water distribution system, and also 
the method of repairing the same. There have been standard practices which 
have been used in the plumbing industry for many years, and many of these 
have been followed without deviation. One reason for this is that most 
skilled plumbers have previously gone through an apprentice training 
program and have learned to accept certain traditional practices in the 
plumbing industry. Further, there are code reulations which have been in 
effect for a number of years, and these dictate certain practices. It is 
from this background of prior art that the present invention was conceived 
to provide a simplified and more convenient system of installing a valve 
assembly under these circumstances, while fully meeting all of the 
performance requirements of the plumbing industry. Reference is now made 
to FIGS. 3-5 to describe the present invention. 
In FIG. 5, the valve assembly 70 of the present invention is shown in more 
detail. This valve assembly 70 can be considered as comprising a central 
operating portion 72 and two connecting portions 74 and 75 positioned on 
opposite sides of the central operating portion 72. 
The central operating portion 72 is, in its present configuration, of a 
conventional configuration, and comprises a housing 76 defining a 
generally circular recess 78 to receive a generally disc-shaped closure 
member 80 which is formed as a conventional gate valve closure member. The 
recess 78 and closure member 80 may be tapered outwardly to a moderate 
extent in an upward direction to insure a snug fit of the closure member 
80 in the recess 78. 
The housing 76 has an upward annular extension 82 which has an open 
interior 84 to receive the closure member 80 when it is in its upper open 
position, as shown in FIG. 3. The closure member 80 is interiorally 
threaded at 85 to receive the lower threaded end 86 of a stem 88 which 
extends upwardly to join to an operating handle 90. To close the annular 
extension 82 and receive the stem 88, there is an upper housing member 92 
which threadedly engages the main housing member 76 and has a circular 
through opening to snuggly receive the stem 88. A closure cap 94 is 
threaded onto the top end of the upper housing member 92, and this also 
has an opening to receive the stem 88. 
The components of the central operating portion 72 of the valve 70 are, as 
shown herein, of more or less conventional configuration. By rotating the 
handle 90, the closure member 80 can be moved downwardly to completely 
occupy the recess 78 and thus totally stop flow through the valve 70. By 
rotating the operating handle in the opposite direction, the closure 
member 80 can be moved totally out of the recess 78 and leave an 
unobstructed through passageway. 
To describe the valve connecting portion 74, the end of the connecting 
portion 74 which is further away from the central valve portion 72 will be 
considered as being at a forward location, while that portion of the 
connecting portion 74 which is closer to the valve operating portion 72 
will be considered as being at a rearward location. The term "outside" 
will denote a distance further from the center axis of the connecting 
portion 74, while the term "inside" will denote a location closer to the 
center axis. 
The forward outer surface 96 of the connecting portion 74 is threaded and 
the extreme forward end has a rearwardly and inwardly tapering surface 98 
of a general frusto-conical configuration. The inner surface 100 which is 
located immediately rearwardly of the tapering surface 98 is cylindrical 
and has a diameter just slightly larger than the outside diameter of the 
waterpipe 40 to which it is to be connected. At the rear end of the 
surface 100 there is an annular shoulder 102, having a width dimension 
approximately the same as the thickness of the pipe 40. Extending further 
rearwardly from the stop shoulder 102 is an inside surface 104 which is 
stepped inwardly from the surface 100. This cylindrical surface 104 has a 
diameter the same as the inside diameter of the pipe 40 and provides a 
passageway which is totally unobstructed when the closure member 50 is in 
its fully open position. 
To secure a pipe section to a connecting portion 74 of the valve 70, there 
is provided for the connecting portion 74 a compression nut 106 and a 
compression ferrule or sealing member 108. The nut 106 and the ferrule 108 
are, as shown herein, of conventional configuration. 
The nut 106 is made as an integral piece and has interior threads 110 which 
engage the threaded outer surface 96 of the connecting portion 74. At its 
forward end, the nut 106 is formed with a cylindrical through opening 112 
just slightly larger than the outside diameter of the pipe 40, and 
rearwardly of this opening, the nut 106 has an annular shoulder 114 which 
faces rearwardly. 
The ferrule 108 is made as an integral piece and has a generally annular 
configuration. It is provided with an inwardly facing cylindrical surface 
116 which fits snuggly against the outside surface of the pipe 40. In 
addition, the ferrule 108 has a forward and a rear surface 118 and 120, 
respectively. The rear surface 120 slopes inwardly in a rearward direction 
to engage the surface 98. The forward surface 118 is positioned to engage 
the shoulder 114 of the nut 106. 
The other connecting portion 75 comprises a rear portion 122 (the term 
"rear" denoting proximity to the central portion 72) that has its outer 
surface formed with six flat surfaces of a hexagonal configuration to 
facilitate gripping with a wrench or pliers. The connecting portion 75 has 
its forward end 124 formed with threads to receive a compression nut 126. 
The interior surface 128 of the connecting portion 75 has a cylindrical 
configuration with a diameter the same as the interior diameter of the 
pipe 40 to which the other connecting portion 74 is joined. Thus, the 
valve assembly 70, with the closure element 80 in its open position, 
provides a substantially unobstructed flow passage from the pipe 40 
through the valve assembly 70. 
In the present invention, the nut 126 is made as part of the overall 
connecting portion 56 of the flex tube 52. There is a washer 130 that fits 
between an annular flange 132 attached to the flex tube 54 and a forwardly 
facing annular edge portion 134 of the connecting portion 75. Thus, it is 
readily apparent that the flex tube connecting portion 56 can be connected 
to the connecting portion 75 of the valve assembly 70 by threading the nut 
126 onto the forward threaded portion 124, with the washer 130 being 
compressed between the flange 132 and the surface 134 to provide a proper 
seal. 
To describe the operation of the present invention, let us assume that 
there is a completed building with an existing plumbing network, such as 
shown in FIGS. 1 and 2, and let it further be assumed that the valve 44 
has become defective and must be replaced. The first step is to move the 
main shutoff valve 22 to its closed position, and then open a tap in the 
network that is in the same flow system as the water tank 32 (i.e. a tap 
on a bathtub) to relieve pressure. This could either be a hot tap or a 
cold tap. 
The valve 44, along with the attached pipe section and fitting 60, is 
unthreaded from the connection 56 of the flex tubing 52. This leaves an 
open connection, as illustrated in FIG. 3. Some water seepage would be 
expected at this time, but this would have no substantial effect. Then, 
the copper pipe 40 is cut next to the connecting portion 48, this being 
accomplished either with tubing cutters or a metal saw. At this point, the 
cut edge of the pipe 40 should be examined, and any metal burrs should be 
removed if they are present. 
Then the valve assembly 70 of the present invention is inserted between, 
and connected to, the connector 56 of the flex tubing and the pipe 40. 
Specifically, the connecting portion 74 is slipped over the end of the 
pipe section 40, and the compression nut 106 is threaded in a manner to 
compress the ferrule 108 and make a watertight connection by use of a pair 
of wrenches engaging the nut 106 and the flat surfaces at 122 on the valve 
72. Then, the pair of wrenches are applied between the connecting portion 
75 at the location 122 and the nut 126 of the connecting portion 56. With 
the valve installation complete, the main valve 22 can be moved to its 
open position. The installed valve assembly 70 should then be checked for 
leakage. If any leakage appears, either or both of the nuts 106 and 126 
should be tightened to remedy the leak. 
In the event that there is no existing valve which is to be replaced, then 
generally the same procedure is followed as indicated above, except that 
it is not necessary to remove the existing valve. Thus, the valve assembly 
70 would be placed in connecting relationship with an open end of a pipe 
in the existing water supply network (or on the end of a pipe which has 
been specifically connected into the network for that installation), with 
the rest of the connection being accomplished as indicated above. 
It is to be understood that within the broader scope of the present 
invention, even though the present invention has been described relative 
to a valve leading to a hot water tank, this method and valve assembly 70 
of the present invention could also be applied in other similar situations 
where problems such as those noted above exist. Further, it is to be 
understood that various modifications could be made in the present 
invention without departing from the main teachings thereof.