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Reduced pressure zone device

A reduced pressure zone device (RPZD or RPZ), also known as a reduced pressure principle backflow prevention assembly, is a mechanical backflow prevention device designed to protect potable water supplies from contamination by preventing the reverse flow of potentially hazardous substances due to backpressure or backsiphonage. It achieves this through two independently acting check valves that create a reduced pressure zone, separated by a hydraulically dependent differential relief valve that automatically discharges water to the atmosphere if the zone pressure drops to near atmospheric levels, thereby maintaining an air gap equivalent to protect against contamination. The assembly typically includes four test cocks for verification and resilient-seated shutoff valves at each end for isolation during maintenance.^[1]^[2] The RPZ operates by ensuring that the pressure in the zone between the check valves remains at least 2 psi lower than the supply pressure upstream; if either check valve fails or backpressure exceeds the supply pressure, the relief valve opens to vent water, alerting users to a malfunction and preventing cross-connection. This configuration provides the highest level of protection among testable backflow preventers, suitable for both high-hazard (e.g., toxic chemicals) and low-hazard applications where continuous pressure monitoring is required. Unlike simpler devices like double check valves, the RPZ's relief mechanism makes it effective against both backpressure and backsiphonage scenarios, though it discharges water during faults, necessitating proper drainage.^[3]^[2] RPZ devices are commonly installed in fire protection systems, irrigation setups, and industrial processes involving potential contaminants, as mandated by local water authorities for high-risk connections to isolate potable water from non-potable lines. They must be tested annually by certified personnel to verify check valve and relief valve functionality, with records maintained for compliance. Installation requires a horizontal orientation (unless manufacturer-approved otherwise), with the centerline 30 to 60 inches above the floor, at least 18 inches of clearance below the relief valve to prevent submersion, and gravity drainage via an air gap sized at least twice the relief valve opening (minimum 1 inch) to handle discharge without flooding.^[1]^[3] Standards for RPZ assemblies emphasize protection from freezing, adequate support to prevent movement, and accessibility for testing, often aligning with guidelines from organizations like the American Water Works Association (AWWA) and OSHA for elevated platforms if needed. While providing superior safeguards, their complexity and water discharge can increase operational costs, making them ideal for scenarios where maximum public health protection outweighs these factors.^[1]^[2]

History

Early Development

The recognition of backflow risks as a public health threat emerged in the early 20th century, driven by contamination incidents that highlighted vulnerabilities in municipal water systems. One pivotal event occurred in 1933 at the Chicago World's Fair, where cross-connections in two major hotels allowed contaminated water from rooftop cooling towers to backflow into the potable supply, causing an outbreak of amoebic dysentery that sickened hundreds and underscored the need for reliable prevention measures.^[4] These early episodes, including industrial cross-connections that led to widespread absenteeism from waterborne illnesses, spurred initial research into backflow dynamics and device design, laying the conceptual groundwork for advanced protection systems.^[5] By the 1930s, efforts to mitigate cross-connection hazards intensified in Los Angeles, where the city's expanding water infrastructure faced risks from industrial and commercial ties to the public supply. Rudimentary pressure vacuum breakers were developed in this period to address backsiphonage in high-risk areas, such as the Bimini Baths, which had earlier drawn contaminated sodium-rich water from an accidental 1904 oil well strike into its systems.^[6] The Los Angeles Department of Water and Power (LADWP) responded by forming a cross-connection control group to tackle harbor-related contamination threats, fostering innovations like early double-check assemblies that prioritized atmospheric breaks over continuous pressure.^[7] The reduced pressure principle marked a significant advancement in 1945, when the E.C. Service Company—founded in 1933 by innovators Frank Carlton and Orien Kersey Entriken—applied for a patent on Model 6, the first backflow prevention device to employ this method instead of traditional backpressure reliance.^[6] Model 6 integrated two check valves with a differential relief valve and vacuum-breaking elements, creating a sustained low-pressure zone to reliably discharge potential contaminants under both backsiphonage and backpressure conditions; the patent was granted in 1950 after the company relocated manufacturing and partnered with Leonard Snyder.^[8] This prototype addressed limitations of prior vacuum breakers by providing continuous protection without relying on intermittent atmospheric vents, establishing the foundational architecture for modern reduced pressure zone devices.^[9]

Evolution and Adoption

Following the initial patent application for the reduced pressure principle backflow preventer in 1945 by the E.C. Service Company, the device saw key refinements in the 1950s and 1960s to enhance reliability and testability. Early evaluations by the National Bureau of Standards in 1952 confirmed the device's ability to prevent back-siphonage even when check valves were fouled with debris, establishing a foundation for further improvements. Manufacturers such as the Watts Regulator Company began producing commercial RPZ assemblies during this era, incorporating strainers to mitigate debris issues and refining check valve seating for better performance under continuous pressure. These advancements addressed limitations in earlier designs, making the devices more suitable for high-hazard applications.^[5]^[6] By the late 1950s and into the 1960s, the inclusion of test cocks became a standard feature, allowing for field verification of the differential pressure across check valves and the relief valve's functionality. This refinement, driven by ongoing research from the Foundation for Cross-Connection Control and Hydraulic Research at the University of Southern California, facilitated annual testing protocols that improved compliance and safety. Companies like Febco entered the market in this period, contributing to design variations that emphasized durability and ease of maintenance, further solidifying the RPZ's role in protecting potable water supplies.^[5]^[9] The 1970s marked a pivotal era for RPZ adoption, spurred by heightened awareness of water contamination risks. The passage of the Safe Drinking Water Act in 1974 prompted U.S. municipalities to update plumbing codes, mandating RPZ devices for high-hazard connections such as those in industrial facilities and sewage treatment plants to prevent backflow incidents. A key milestone was the publication of ASSE Standard 1013 in 1974, which formalized RPZ design specifications—including dual check valves, an intermediate relief valve, and four test cocks—ensuring consistent performance and driving widespread industry acceptance. By the mid-1970s, thousands of RPZ units were installed and tested annually in major cities like Los Angeles.^[5]

Design and Components

Primary Components

A reduced pressure zone device (RPZD), also known as a reduced pressure principle backflow prevention assembly, is engineered to protect potable water systems from high-hazard contamination by incorporating key mechanical elements that maintain a hydraulic separation.^[10] The primary components form a compact assembly compliant with standards such as ASSE 1013, ensuring reliable operation under continuous pressure conditions. At the heart of the RPZD are two independently acting check valves: the upstream (first) check valve positioned immediately after the inlet and the downstream (second) check valve before the outlet. These valves, typically spring-loaded and of the poppet or disc type, operate separately to establish and sustain the reduced pressure zone between them, preventing reverse flow while allowing forward passage of water.^[11] This zonal configuration is fundamental to the device's backflow prevention mechanism. Between the two check valves lies the differential pressure relief valve, a critical safeguard that automatically opens to vent water to the atmosphere if the zone pressure drops below 2 psi above atmospheric pressure.^[12]^[13] This hydraulically operated valve ensures the zone remains at a lower pressure than both the supply and downstream sides, discharging any potential contaminants externally rather than allowing backflow. In many designs, the relief valve serves as a third check by opening under backpressure if either primary check fails, providing an additional layer of protection without spring assistance.^[11] The assembly also includes inlet and outlet shut-off valves, usually ball or gate types, which enable isolation of the device for servicing without disrupting the entire water line. Complementing these are four test cocks—typically numbered #1 through #4 and located strategically (before the first check, between the checks, after the second check, and at the relief valve)—that facilitate on-site pressure and functionality testing to verify compliance with regulatory standards.

Construction Materials and Variations

Reduced pressure zone devices (RPZDs) are typically constructed with materials selected for durability, corrosion resistance, and compatibility with potable water systems. The main body is commonly made of bronze or lead-free bronze, which provides effective resistance to corrosion in standard water supply environments. ^[14]^[15] Stainless steel bodies are also utilized, particularly in applications exposed to harsher conditions, offering superior corrosion resistance due to the material's inherent properties. ^[16]^[17] Internal components, such as the seals in the check valves, often employ elastomeric materials like EPDM (ethylene propylene diene monomer) for reliable sealing and flexibility under varying pressures and temperatures. ^[18] Test cocks, used for assembly testing, are generally constructed from plastic for cost-effective, non-corrosive caps and plugs, or metal such as brass or stainless steel for more robust, threaded fittings. ^[19]^[20] Variations in RPZD design accommodate diverse applications and environmental demands. Sizes typically range from 3/4 inch to 10 inches in diameter, allowing installation in residential, commercial, and industrial water lines with varying flow capacities. ^[21]^[22] Stainless steel versions are specifically engineered for corrosive environments, such as coastal or chemical-exposed sites, where traditional bronze may degrade over time. ^[23]^[24] For fire sprinkler systems, certain RPZD models are designed to integrate with thermal expansion tanks, addressing pressure buildup in closed-loop configurations as required by plumbing codes. ^[25] Some modern RPZDs incorporate low-lead brass components, with lead content limited to less than 0.25% in wetted surfaces, to comply with the 2014 amendments to the U.S. Safe Drinking Water Act. ^[26]^[27]

Principles of Operation

Normal Flow Conditions

Under normal forward flow conditions, water enters the reduced pressure zone device (RPZD) from the supply side and passes through the first check valve, which is held open by the flow momentum overcoming its spring preload. This passage creates a pressure differential across the first check valve, typically ranging from 5 to 10 psi, as the valve's design incorporates a calibrated spring force that resists flow to establish the reduced pressure zone.^[12]^[28] The water then flows into the intermediate reduced pressure zone between the two check valves and proceeds through the second check valve, which also remains open during steady forward flow. The second check valve, featuring a lighter spring load, further contributes to maintaining the pressure in the reduced pressure zone at least 2 psi below the supply pressure, typically 5 to 10 psi lower and well above atmospheric pressure, ensuring the zone remains isolated from potential contaminants while allowing unimpeded downstream delivery. The overall pressure loss through the RPZD under these conditions averages 10 to 20 psi, depending on the device size and flow rate, which is attributable to frictional losses and spring resistances in both check valves per basic hydraulic principles.^[18]^[29] The relief valve, positioned between the check valves and connected to the reduced pressure zone, remains closed during normal operation. This closure is maintained by the differential pressure across a sensing diaphragm, where the higher supply-side pressure exceeds the zone pressure sufficiently to keep the valve seated, preventing any spillage or discharge.^[12]^[28] The pressure differential across the first check valve, denoted as \Delta P_1 = P_{\text{supply}} - P_{\text{zone}}, is fundamentally governed by the equilibrium between the upstream hydraulic pressure pushing the valve open and the spring force plus downstream pressure resisting it. In steady-state flow, this can be approximated using the orifice flow equation derived from Bernoulli's principle for incompressible fluids:

\Delta P_1 = \frac{1}{2} \rho v^2 + k \cdot F_{\text{spring}}/A

where \rho is water density, v is flow velocity through the valve orifice, k is a valve-specific constant, F_{\text{spring}} is the preload spring force, and A is the effective valve area; however, manufacturers calibrate the spring such that \Delta P_1 \approx 5 to $10 psi across typical operating flows to reliably establish the reduced zone without excessive total head loss.^[12]^[18]

Backflow Prevention Mechanisms

The reduced pressure zone device (RPZD), also known as a reduced pressure principle backflow preventer, provides robust protection against both backpressure and backsiphonage, distinguishing it from simpler devices like double check valve assemblies that only mitigate backpressure. Backpressure occurs when downstream pressure exceeds the supply pressure, potentially forcing contaminants upstream, while backsiphonage results from a sudden drop in supply pressure creating a vacuum that draws in pollutants. The RPZD's design incorporates two independently operating check valves separated by a reduced pressure zone, with a hydraulically operated relief valve connected to the atmosphere, ensuring that contamination cannot reach the potable water supply under these conditions. The relief valve opens when the supply pressure minus zone pressure is 2 psi or less (P_{\text{supply}} - P_{\text{zone}} \leq 2 psi), discharging water to maintain the reduced zone and alert to malfunction.^[30]^[31] During backsiphonage, a rapid reduction in upstream supply pressure causes the first check valve to close, isolating the supply. The relief valve then opens because the supply pressure drops to or below the zone pressure plus 2 psi, venting the zone to the atmosphere and creating an air gap that drains any water while admitting air to break the siphon, preventing contaminants from entering the supply. This mechanism ensures no reverse flow, as the open relief valve maintains the air gap until supply pressure stabilizes.^[12]^[32] In cases of backpressure, where downstream pressure surpasses the upstream supply, the second check valve closes to block reverse flow, isolating the zone from downstream. If the second check valve fails or leaks, the high downstream pressure enters the zone, raising the zone pressure. When the zone pressure approaches within 2 psi of the supply pressure (P_{\text{zone}} \geq P_{\text{supply}} - 2 psi), the relief valve opens to discharge the potentially contaminated water from the zone to the atmosphere, preventing it from forcing past the first check valve, which remains seated due to its pressure differential. This dual-check and relief system operates independently of normal flow conditions to provide protection.^[30]^[32]^[33]

Installation and Maintenance

Siting and Installation Guidelines

Reduced pressure zone devices (RPZDs) must be installed above ground level to ensure proper operation and accessibility. Specifically, the assembly requires a minimum clearance of 18 inches below the relief valve to facilitate drainage and prevent submersion during discharge events, which can occur at rates up to 125 gallons per minute.^[34]^[1] This elevation also protects against flooding risks, with installations generally positioned at least 1 foot above the 100-year flood plain elevation where applicable.^[1] Below-grade installations are generally discouraged due to potential submersion of the relief valve or test cocks, which could compromise the device's backflow prevention integrity, as well as heightened risks from freezing temperatures and maintenance difficulties; however, they may be permitted with safeguards such as gravity drainage, water level alarms, or sump pumps sized for maximum discharge on emergency power.^[34]^[1] In cases requiring vault or enclosure installations for protection against freezing or vandalism, specialized enclosures must be used that maintain adequate drainage, provide at least 2 feet of side clearance for servicing, and prevent water accumulation around the device. Drainage must be by gravity with an air gap sized at least twice the relief valve opening (minimum 1 inch) to handle discharge without flooding.^[34]^[1] The preferred orientation for RPZDs is horizontal, though vertical or other configurations may be used if explicitly approved for the specific model by testing standards.^[34] Unions should be incorporated at the inlet and outlet connections to allow for straightforward removal and replacement of the assembly without disrupting the entire piping system.^[35] An upstream strainer is required to protect the check valves and internal components from debris, sediment, and fouling, ensuring long-term reliability.^[36] The device's sensitivity to pressure differentials necessitates precise siting near the service connection or meter, with no intervening shutoff valves or interconnections that could introduce contaminants upstream.^[34]

Testing and Servicing Procedures

Testing and servicing of reduced pressure zone devices (RPZDs) are essential to ensure ongoing backflow prevention efficacy and compliance with health and safety standards. Annual testing is mandated for all installed RPZDs to verify the integrity of the check valves and relief valve, typically performed by certified backflow assembly testers using a calibrated gauge kit connected to the device's test cocks. The procedure involves measuring pressure differentials across the components under controlled conditions: the first check valve must hold a differential of at least 5 psi, the second check valve must be tight against backpressure, and the relief valve must open at no less than 2 psi above atmospheric pressure (maintaining the reduced pressure zone at least 2 psi below supply pressure).^[37]^[38] Servicing routines focus on preventive maintenance to address wear on internal components, with disassembly recommended every 3-5 years depending on water quality and usage intensity. This process includes removing the check modules and relief valve assembly, replacing seals, O-rings, and diaphragms, and cleaning springs and valve seats to remove debris or mineral buildup that could impair function. Only certified personnel should perform these tasks, as improper reassembly can compromise the device's performance and void certifications.^[39]^[12]

Applications

Suitable Use Cases

Reduced pressure zone devices (RPZDs) are primarily suitable for high-hazard applications where the potential for severe contamination of potable water supplies exists due to the introduction of toxic or hazardous substances. These devices provide robust protection against both backsiphonage and backpressure in continuous pressure systems, making them essential for scenarios where backflow could pose significant health risks. According to the U.S. Environmental Protection Agency (EPA), RPZDs are commonly installed in industrial settings such as plating plants and car washes, where chemicals or wastewater could reverse flow into the public water system.^[40] In agricultural and landscaping contexts, RPZDs are recommended for irrigation systems that incorporate fertilizers, pesticides, or other chemical additives, as these represent high-hazard connections to public water supplies. The American Water Works Association (AWWA) guidelines emphasize the need for RPZDs or equivalent protection in such irrigation applications to prevent contaminant ingress.^[40]^[41]^[42] Similarly, fire sprinkler systems with chemical additives, such as antifreeze or corrosion inhibitors, require RPZDs to safeguard against backflow, particularly in buildings where system pressures may exceed supply pressures or chemical additives are used.^[3] For industrial processes involving potential contaminants, such as manufacturing facilities with boilers, cooling towers, or chemical handling, RPZDs are mandated for connections to public water supplies to isolate health hazards like toxic substances. Examples include hospital autopsy rooms and funeral parlors, where biological or chemical risks are present. RPZDs are not intended for low-hazard domestic services, such as standard residential plumbing, where simpler devices like double check valves suffice; instead, they are preferred over atmospheric vacuum breakers in sites prone to backpressure, as the latter only address backsiphonage. The EPA and AWWA standards highlight that RPZDs are required for any high-hazard tie-in to ensure compliance with backflow prevention protocols.^[40]^[40]^[41]

Advantages and Limitations

Reduced pressure zone devices (RPZDs) offer the highest level of backflow protection, suitable for high-hazard applications where contamination could pose significant risks to public health. They are highly effective against both backpressure and backsiphonage, ensuring reliable containment in high-hazard applications by maintaining a reduced pressure zone between two check valves and discharging water if integrity is compromised.^[43] Additionally, RPZDs are testable via integrated test cocks, allowing for straightforward compliance verification and malfunction detection through relief valve discharge.^[44] Despite these strengths, RPZDs have notable limitations in operational efficiency and practicality. They can incur higher water loss during relief valve discharge events, potentially up to several gallons per occurrence if check valves leak or during testing, as the relief mechanism activates to prevent backflow.^[43] RPZDs are generally more expensive than double check valve assemblies due to their complex design and higher material requirements.^[45] Installation is restricted to indoor or above-ground locations to avoid freezing and ensure accessibility, often necessitating protective enclosures. Furthermore, they introduce a pressure loss of typically 10-30 psi depending on flow rate and size—which may require booster pumps in low-pressure scenarios.^[44]

Standards and Regulations

Certification Standards

The American Society of Sanitary Engineering (ASSE) Standard 1013-2021 establishes performance requirements for reduced pressure principle backflow preventers, including both potable water and fire protection variants, ensuring they protect against contamination through rigorous laboratory evaluation.^[46] Assemblies certified under ASSE 1013 must undergo hydrostatic pressure tests, where the complete device and its check valves withstand twice the manufacturer's maximum rated working pressure—typically 350 psi for devices rated at 175 psi—for a minimum of 10 minutes without visible leakage or permanent deformation.^[46] Additionally, these devices are subjected to backflow prevention tests demonstrating no measurable leakage across the check valves under specified differentials: the first check must maintain at least 3.0 psi (20.7 kPa) above the relief valve opening point, while the second check prevents flow at 1.0 psi (6.9 kPa).^[46] Certification also requires validation of the relief valve's operation under simulated contamination scenarios, where the device must discharge water at rates outlined in the standard when the zone pressure drops to 2.0 psi (13.8 kPa) or less below supply pressure, ensuring no backflow occurs while maintaining the reduced pressure zone at least 2.0 psi below supply pressure but not less than 1.0 psi above atmospheric.^[46] Shutoff valves integrated into the assembly must seal drip-tight at twice the rated pressure for 10 minutes.^[46] ASSE 1013 harmonizes with testing protocols from the University of Southern California (USC) Foundation's 10th Edition Manual of Cross-Connection Control.^[47]^[48] Beyond ASSE 1013, reduced pressure principle devices must appear on the USC Foundation's Approved List, which verifies compliance through independent laboratory testing for models from various manufacturers, ensuring ongoing approval based on performance in backsiphonage and backpressure conditions.^[49] In Canada, certification under CSA B64 Series:21 aligns with ASSE 1013 requirements, mandating similar hydrostatic endurance, relief valve responsiveness at low differentials (no less than 2.0 psi below inlet), and zero leakage in contamination simulations for potable water systems. IAPMO provides compliance certification for these devices under ANSI/ASSE 1013, listing approved models that meet the standard's criteria for high-hazard applications, including field-testable configurations with no leakage under laboratory-simulated backflow events.^[50]

Regulatory and Legal Requirements

In the United States, the Uniform Plumbing Code (UPC) Section 603.3.7 of the 2018 edition (updated in 2024) mandates the installation of reduced-pressure principle backflow prevention assemblies for protecting against high-hazard cross-connections, where backflow could introduce contaminants posing a health risk to the potable water supply.^[51] Similarly, the 2021 International Plumbing Code (IPC) requires these assemblies under Section 608.14.2 for high-hazard applications involving backpressure or backsiphonage, ensuring isolation of potential pollution sources such as chemical treatment systems or industrial processes.^[52] Internationally, regulations vary by region; in the European Union, the Pressure Equipment Directive (2014/68/EU) sets general safety requirements for pressure-containing devices, while backflow protection for potable water is governed by standards such as EN 1717 and harmonized standard EN 12729:2023, which covers controllable backflow preventers with reduced pressure zones for fluid categories posing health hazards.^[53]^[54] Compliance obligations typically include periodic testing by certified professionals in most U.S. states and localities, aligning with ASSE standards for performance verification without delving into detailed protocols; frequency varies (e.g., annually in many jurisdictions).^[55] Non-compliance, as enforced by the Environmental Protection Agency under the Safe Drinking Water Act, may lead to civil penalties up to approximately $70,000 per day per violation (as of 2024, adjusted annually for inflation) or immediate water service shutoff to mitigate public health risks.^[56]^[57]

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2021 International Plumbing Code (IPC) - 608.1 General.
Reduced pressure principle backflow prevention assembly and reduced pressure principle fire protection backflow assembly, High or low hazard, Backpressure or ...
[51]
Directive 2014/68/EU - pressure equipment - EU-OSHA
Oct 20, 2023 · Directive 2014/68/EU applies to the design, manufacture and conformity assessment of stationary pressure equipment with a maximum allowable pressure greater ...Missing: backflow | Show results with:backflow
[52]
https://codes.iccsafe.org/content/IPC2021P1/chapter-6-water-supply-and-distribution
[53]
Is Backflow Testing Required? Compliance Guide for 2025
Backflow testing is legally required in most states and must be performed annually for all properties with cross-connection control devices.<|separator|>
[54]
Safe Drinking Water Act and Federal Facilities | US EPA
Jul 22, 2025 · SDWA penalties against federal agencies may be up to $48,586 per day per violation. (The Federal Civil Penalties Inflation Adjustment Act of ...Missing: backflow | Show results with:backflow