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TP valve is leaking lots of water
What to look for:
TP valve leaking water
Water heater should be dry at all times
Is TP leaking, or water heater leaking?
Resource:
Leaking water heater

Use masonite to check if TP valve is releasing water.

The TP overflow tube must terminate in plain sight ... can terminate outdoors, but end of pipe must be visible for inspection  TP valve code

If TP valve is continuously running out hot water, tank will have less hot water.
Resource:
Leaking water heater
TP valve 'TP relief valve provides 2 in 1 protection against excessive pressure and excessive temperature in emergency conditions. Mechanical spring-loaded TP valve is reliable and fully automatic protection for hot water storage tanks and heaters.'
TP valve will automatically close when emergency conditions are over.
''Water heaters are pressure tested to 300 pounds per square inch (PSI) and have a working pressure of 150 PSI.
T&P valve will open when the pressure inside the tank exceeds 150 PSI, allowing pressure to vent safely.
T&P valve will open if water temperature at top of tank reaches 170°F-210°F depending on water heater" and valve rating.
Buy TP valves:
Replacement TP valves
Teflon tape

Resources:
TP valve code
Read about TP valves/ pdf
Read more about TP valves .pdf
1) Cody writes
Hi there, I found your website which had a ton of good information.
I have a water heater that is leaking from the temperature and pressure valve on top.
Naturally I replaced the valve only to continue experiencing a leak.
It seems like a random spurt throughout the day and not a ton of water but does make a mess.
Any idea what would cause the value to continue to leak?
Nothing has changed on the water supply to the house.
Any ideas would be appreciated! Thanks - Cody

2) waterheatertimer.org:
You have either very hot water or very high pressure that releases water when temp or pressure exceeds TP rating.
TP valve is not designed to be a permanent solution for problem.

Since leak is sporadic (unpredictable or not constant), there are 4 suspects:
(a) Bad TP valve ... replace TP with new one with same rating plate. You did that, and problem still happens.
(b) Large volume of hot water released sporadically? .... then malfunctioning thermostat is suspect.
(c) High water pressure (typically from city water supply) will cause periodic release of hot from TP valve ... depending on level of pressure, and frequency of pressure spikes. Expansion tank might solve problem.
If you are on rural water well, the pump and tank have pressure switch with adjustment screw
(d) Closed system ... where heated water cannot expand because of a check valve or pipe obstruction etc. The excess pressure releases from TP valve ... except the release would be more of a continuous drizzle when heater is heating water ... and then stops after heating cycle is over ...expansion tank will solve this problem.
Resource: Closed-system.html

Action if bad thermostat(s) is suspect:
... check water temps by opening the TP occasionally or running taps at full hot and see if water is extremely hot.
 ... 170-210 °F water inside tank is a dangerous hazard and would be immediately apparent at the hot water tap ... scalding in less than a second.
water pressure gauge.. electric thermostats are easy and cheap to replace
... gas thermostat is different pickle ...
Resources:
How to replace thermostat on gas water heater
How to replace thermostat on electric heater

Action if pressure spikes or closed system are suspect
... use a pressure gauge and attach to drain valve on water heater
... 50-60 psi is best ... Anything approaching 80 psi can cause TP valve expel water, usually when tank is heating.
80 psi is considered the cut off point, beyond which damage to heater and plumbing pipes and fixtures can occur.
Buy:
Water pressure gauges
Watts telltale Water Pressure Test Gauge, 276H300

3) Cody
Thank you so much for the response.
I can’t wrap my head around it being a pressure issue since nothing has changed on the incoming cold water line.
I do think the thermostats could be overheating.
I will check on the temp.
Really hoping I don’t have to hire a plumber to do an expansion tank.
I really like your site, thank you so much!

pressure reducing tank on top of heater4) waterheatertimer.org
Expansion tank is a solution if pressure tests high ... but depends on the pressure test
... pressure is a suspect if you changed plumbing or city installed new water meter with a check valve ... or city pressure has gone up.
.... a check valve on city water meter is fairly common ... and prevents natural expansion of hot water produced by a heater from pushing back out onto incoming supply line. This creates a 'closed system' that can be fixed with expansion tank.

...since you mention thermostats (plural) 
... I assume you have electric heater
... turn off power of course ... there is no reliable test for electric thermostats
... in this case if new upper and lower thermostats don't solve problem
...then it is could be cracked (shorted) element  ... How to test element

5) Cody
It’s been a day...
replaced both thermostats and elements.
The problem appears worse now
and now I have other leaks from working on older plumbing.
The heater is electric, GE made in 2004.
Everything looked fine that I took out today. 
I cleaned the bottom out of the tank too.
The city water meter and everything on the supply side did not change.
I did T into our main water line last year to do some yard irrigation,
...but all of that is turned off and wouldn’t affect the main supply.
I think I’ve tried everything and will need to call a plumber unless you have any other thoughts.
 I really appreciate your insight

6) waterheatertimer.org
Practically anything can be fixed
... but give me specifics
... what is worse than before?
Do you have galvanized pipe or copper, pvc ?
What other leaks do you have?
 I'm pretty good at this stuff if you're patient,
otherwise, forget plumber for now ... and do the pressure test
... avoid buying new electric heater ... they're about $417 around here, but if are you connecting to old galvanized?? Because galvanized pipe could be the problem if elbow is clogged with sediment, rust etc.
A simple dielectric union or brass fitting might solve problem.
... my email is geno03245w@gmail.com, or continue messaging on facebook @ https://www.facebook.com/waterheatertimer.org/
.. send photos ... photos help me see through walls better

high pressure on TP valve7) Cody 
It seems like there is a little more water coming out of the temp/pressure valve than before but perhaps not
The old supply line is leaking now and it can’t be replaced without soldering I think
I checked pressure on drain...
It’s over 90 psi at drain. Is that high?

8) waterheatertimer.org
Good grief ... your pressure is 90 psi
... max is 80 psi ... preferred is 50-60 psi
... move the pressure gauge to outside spigot to check cold water pressure.
.. might want to de-energize tank, run hot out of the tank for a bit
... then check pressures again
... which supply line is leaking? cold or hot?
Buy:
Water pressure gauges
Watts telltale Water Pressure Test Gauge, 276H300

9) Cody 
 My pipes are copper.
The cold supply is threaded onto the water heater where is leaking, and it's soldered to the copper shut off valve.
Outside spigot pressure reads exactly the same
Seems about 90psi

10) waterheatertimer.org
OK, the 90 psi pressure on inside and outside
..  the high pressure might be why you sprung a leak on the supply line 

Copper pipe is good ... that removes problems from old galvanized pipe.
Cut off, or unsolder connection to the shut off valve, and solder on a male adapter so new copper flex line can be attached.
Resource: How to solder pipes

.So now the problem is 90 psi is way high
... I think that's why the TP is leaking ... and probably the thermostats were ok. So don't throw away the old thermostats or elements etc.
... next, we need to check if this is a 'closed system'
Resource:
Closed-system.html

....This will narrow down causes and solutions ... for example, has the city water pressure spiked? Or maybe some other cause.
.... cool the tank down so it's not putting  pressure into the system and then check cold on outdoor spigot again.
If pressure goes down when tank is not hot, then that suggests a closed system .... if pressure is still high, then the city pressure is causing the problem...
High pressure from city might be occasional thing, or might get worse, or better ... but usually it's the customer's problem, unless you're in a wealthy area and can afford to have other ratepayers support improvements for you without taking your money.

Now here's another thing to check when you see high pressure on your water line, check the neighbor's outdoor spigot for pressure spike at same time.
Buy:
Expansion tanks
Resources:
Expansion tank installation/ pdf
The solution might be simple expansion tank installed on top of heater ... or installed anywhere on the incoming cold water line... easy and simple plumbing stuff for DIY.
If the expansion tank does not solve problem, a pressure reducing valve should probably be installed on incoming cold water line.
Buy:
Pressure reducing valves
Pressure regulating valves

115 psi pressure11) Cody
My Wife took long hot shower, got two different readings at outside spigot both as high or higher than before.
Range was 90-95 psi. Seemed to get a little higher right when shower was turned off at 95psi.

I took a shower and used most of the hot water now and saw pressure increase on outside spigot and water heater up to 115 psi or so!
Now the pressure has spiked to 115.
Let me know if that gives you any other clues whenever you can. Thanks!

12) waterheatertimer.org
City water supply is main cause of high pressure in some areas ... up to 100-150 psi is not unusual.
This means you need a pressure reducing valve and expansion tank.
Both are required.
Why? Installing a pressure reducing valve causes a closed system ... which means TP will still leak water when heater is on.
The expansion tank is the correct solution for a closed system ... while pressure reducing valve is correct solution for high water pressure from city.

14) Cody
Could the pressure reducing valve be installed underground ... or in the wall of the house?
We are on a concrete slab with copper pipes

softener on two water heaters15) waterheatertimer.org
Best to install pressure reducing valve inside house ... for two reasons:
(a) pressure valves fail in about 5 years and need replacement
(b) in event that pressure adjustments are needed over time
You can install the pressure reducing valve underground .... buy underground plumbing 'vaults' in the sprinkler department at local store, or bury 5 gallon bucket (except it will crack apart).
Insulate against freezing.
Buy: underground sprinkler vault

Note that the pressure reducing valve is installed first in line and then expansion tank.
So expansion tank is installed closest to heater, and can be installed straight up, or down, or off to either side.
.
15) Cody
Great, thanks again for all this info.
I am going to start by contacting our water company
Tank pressure Pressure on water lines should not exceed 80 psi.
High pressure can cause:
TP valve leaks
Early tank failure
Plumbing leaks
Shorter life for faucets

Action: Install pressure reducing valve and expansion tank
Check pressure using temporary pressure gauge on water heater drain valve

Buy pressure gauges
Water pressure gauges
Watts telltale Water Pressure Test Gauge, 276H300
Temperature-pressure gauge

Resource:
Read about checking water pressure
Pressure reducing valve Pressure reducing valve
Install pressure reducing valve when TP fails frequently or when pressure is greater than 80psi. High pressure can damage tank.
Buy:
Pressure reducing valves
Pressure regulating valves
Expansion tank
Install expansion tank on incoming cold water line to help with constantly drizzling TP when tank temperature must be kept high.
Buy:
Expansion tanks
Resources:
Expansion tank installation/ pdf
Closed system and expansion tank pdf
How to increase amount of hot water
TP valve with teflon tape
Standard 3/4" pipe thread



6 wraps teflon tape on new valve.
Most new TP already have Teflon tape on threads. More can be added if tank leaks around threads.

Buy TP valves:
Replacement TP valves at Amazon
1/2" TP valve at Amazon
Teflon tape at Amazon
Step-by-step: How to replace TP valve:
1) Turn off water.°
2) Open tub spout to release pressure
3) Turn off power to heater
        Electric heater: turn OFF circuit breaker
        Typical Gas heater: rotate knob to vacation setting, or move knob to pilot position
4)  Open bathtub tub spout on Hot side to release pressure
5) Let water cool
Caution: Make sure tank has cooled before removing TP valve
5) Open TP valve to lower water level.
        Or use drain valve on bottom of tank
        Resource:
        If water heater won't drain


6) Unscrew TP valve counterclockwise using 12-14" pipe wrench.
7) Install new valve and make sure threads have white teflon tape.
Teflon tape will seal threads against leak.
8) Connect overflow tube that was attached to old TP valve.
9) Refill tank with water.
Caution: Do not turn water heater ON unless tank is full of water or it can damage tank 
Wait for water to come out of bathtub spout in full stream before turning on water heater.
When bathtub spout is running, then tank is full. Turn off tub spout.
10) Open new TP valve for a moment to let last bit of air out of tank.
11) Turn on water heater.
       Electric: turn on circuit breaker
       Gas: Rotate knob to previous temperature setting
                Resource:
              How to adjust temperature on water heater
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