CPCPMS3033A - INSTALL SMALL BORE HEATING SYSTEMS
CONSTRUCTION, PLUMBING AND SERVICE
INTEGRATED FRAMEWORK
TRAINING PACKAGE
CPC08
CPCPMS3033A
INSTALL SMALL BORE HEATING SYSTEMS
Two pipe systemLEARNING GUIDE
ACKNOWLEDGEMENTS
National Plumbing Services Training Advisory Group
Plumbing Industry Commission Victoria
© Commonwealth of Australia 2015
Construction and Property Services Industry Skills Council
PO Box 151
Belconnen ACT 2616
Tel: 02 6253 0002
This work is copyright, but permission is given to trainers and teachers to make copies and contextualise the resources for use within their own training organisation or in a workplace where training is being conducted. This permission does not extend to making copies for use outside the immediate training environment for which they are made, or the making of copies for hire or resale to third parties.
This work was first published in 2004 with the assistance of funding provided by the Commonwealth Government through the Australian National Training Authority (ANTA). The2015 publication has been updated to reflect changes to the national units of competency.
The views expressed in this work do not necessarily represent the views of the Commonwealth of Australia or CPSISC. In addition, the Commonwealth of Australia and CPSISC do not give warranty or accept any legal liability in relation to the content of this work.
The website addresses and other contact information provided in this publication were compiled in good faith and were correct at the time of printing.
The updating of these resources was completed by:
National Plumbing and Services Training Advisory Group, with funding and support provided by the Construction and Property Services Industry Skills Council (CPSISC):
This guide was developed in consultation with representatives of the Plumbing Industry by NPSTAG and CPSISC to support the implementation of the CPC08 Construction, Plumbing and Services Training Package.
CONTENTS
What is this resource about?......
How do I use this resource?......
Flexible Delivery......
What do I have to do?......
Install small bore heating systems......
Unit Descriptor......
Element......
Performance Criteria......
Required knowledge...... 4
How will I be assessed?......
Are there any pre-requisites?......
Safety......
Workplace environment and safety......
What other resources will I need?......
Texts......
Web sites......
Video or audio cassettes......
Introduction......
Advantages of hydronic systems
Heat loss due to air changes
Heating units
Panel radiators
Features of panel radiators......
Skirting convectors
Features of skirting board convectors......
Natural convectors
Features of natural convectors......
Fan convectors
Features of fan convectors......
Planning
Work notices
Quality assurance......
Heating unit
Pipework
One pipe system
Two pipe system......
Isolation processes and procedures......
Determine system requirements......
Installation for pipework and emitters
Sizing the system
Expansion and contraction......
Insulation......
Types of pipes......
Steel
Copper
Cross-linked polyethylene pipes (XLPE)
Polybutelenes
Positioning of pipes and heater......
Suspended timber floor installation
Concrete slab floor installation......
Determining quantities of materials and equipment......
Checking materials......
Fabricate, install and test heating system......
WHS requirements......
Personal protective equipment......
Tools and equipment......
Workplace operations and procedures......
Setting out......
Fixing and supports......
Installation and jointing......
Insulating the pipework......
Installing the pipework......
Pressure testing the pipework installation
Installation of heating unit and emitters......
Testing and commissioning the system
The heating system......
Clean up......
Worksheet
Practical application......
Assessment checklist......
© Commonwealth of Australia 2015 1
CPCPMS3033A - INSTALL SMALL BORE HEATING SYSTEMS
What is this resource about?
Welcome to CPCPMS3033A – Install small bore heating systems. This resource will help you gain the skills and knowledge necessary to demonstrate competence in this unit.
How do I use this resource?
This resource is divided into four main sections:
- A learning unit, which contains background information on how to install small bore heating systems
- Worksheets, which prepare you for the practical application
- Practical application, which allows you to experience the installation of small bore heating systems
- Assessment materials, which help you to demonstrate competency.
To complete this unit of competence you will need to:
- read the information contained in the learning unit
- complete the worksheets as instructed
- have your answers checked by your trainer or supervisor
- work with your trainer or supervisor to practise how to install small bore heating systems
- read the assessment checklist together with the assessment sheets
- complete the assessment.
Learning Resources are not intended to be the only source of information nor are they intended to be an exhaustive form of instruction.
Flexible Delivery
The Trainer or Supervisor may adapt and deliver this Learning Resource to suit people from diverse backgrounds to meet equity principles and conform to Legislative policies.
What do I have to do?
To demonstrate competence in this unit you will be required to show the required level of skills and knowledge for each of the elements involved in installing small bore heating systems:
- Planning work activities
- Determining systems requirements
- Fabricating, installing and testing heating system
- Commissioning heating system and cleaning up.
If you are unsure of the meaning of these elements you should read the performance criteria.
CPCPMS3033A / Install small bore heating systemsUnit Descriptor / This unit of competency specifies the outcomes required to install small bore hydronic heated water heating systems.
Element / Performance Criteria
Elements define the essential outcomes of a unit of competency. / Performance criteria describe the required performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge and/or the range statement. Assessment of performance is to be consistent with the evidence guide.
1Prepare for work / 1.1Plans and specifications are obtained
1.2Work health and safety (WHS) and environmental requirements associated with installing small bore heating systems are adhered to throughout the work
1.3Quality assurance requirements are identified and adhered to according to workplace requirements
1.4Tasks are planned and sequenced in conjunction with others involved in or affected by the work and statutory and regulatory authorities’ requirements
1.5Tools and equipment, including personal protective equipment, are selected and checked for serviceability
1.6Work area is prepared to support efficient installation of small bore heating systems
2Identify system requirements / 2.1Configuration of pipework is checked for compliance with plans, specifications, authorities' requirements and other relevant information
2.2Position of pipes and heating units is determined from plans, specifications or site requirements, so as not to cause damage or interference to surrounding structures
2.3Allowances for fabrication or assembly are determined and transferred
2.4Quantity and type of piping materials and other materials required are calculated from plans and specifications
2.5Materials are identified, ordered and collected according to workplace procedures
2.6Materials and equipment are checked for compliance with docket and order form and for acceptable condition, and faults are reported
3Fabricate, install and commission heating system / 3.1System is set out to comply with plans and specifications
3.2Fixings and supports are installed to manufacturer recommendations, and plans and specifications
3.3Pipe system is installed and jointed in compliance with plans, specifications and manufacturer requirements for mechanical type joints
3.4Heating systemunit is installed according to plans, specifications and manufacturer requirements
3.5Heating system is installed in specified location without damage or distortion to pipework, surrounding environment or other services
3.6Sustainability principles and concepts are applied throughout the installation process
3.7Heating system is tested to comply with job specification, regulatory authorities' requirements, and relevant Australian standards and codes of practice; and details are recorded in required format
3.8Heating system is checked and adjusted for correct operation and balance, including the setting of nominated temperature and adding appropriate inhibitor
4Clean up / 4.1Work area is cleared and materials disposed of, reused or recycled according to legislation, regulations, codes of practice and job specification
4.2Tools and equipment are cleaned, checked, maintained and stored according to manufacturer recommendations and workplace procedures
4.3Documentation is completed according to workplace requirements
Required knowledge / Required knowledge for this unit is:
- characteristics and application of different fixing and joining techniques and methods
- effective isolation processes and procedures
- electrical and electronic principles and safety requirements
- job safety analysis (JSA) and safe work method statements (SWMS)
- WHS regulations relevant to installation of small bore systems
- personal protective equipment requirements and use
- processes of installing and commissioning small bore heating systems
- properties of water, including pressure and flow rates
- SI system of measurement
- statutory requirements
An up to date version of the ‘Unit Descriptor’ may be located on the Australian Government web site training.gov.au
How will I be assessed?
Your trainer or supervisor will decide with you how you will be assessed. Your assessment activity will include completion of the participant worksheet and practical task selected by your trainer or supervisor. Your assessment should allow you to demonstrate all the skills and knowledge required to install small bore heating systems.
This unit may be assessed in conjunction with other units of competence. Your trainer or supervisor will tell you if you will be assessed this way.
Are there any pre-requisites?
Prior to commencing CPCPMS3033A – Install small bore heating systems you must have successfully completed the following pre-requisites:
- CPCPCM2043A – Carry out WHS requirements.
It is also recommended that prior to commencing CPCPMS3033A – Install small bore heating systems you should have successfully completed the following competencies:
- CPCPGS3031A – Install gas piping systems
- CPCPGS3032A – Size consumer piping systems for Type A appliances
- CPCPGS3049A – Install a Type A gas appliance flue
- CPCPCM2052A – Weld oxy/acetylene equipment.
Project work may also group pre-requisite and or co-requisite competencies together to carry out such projects. It is recommended that the following competencies be grouped with this unit of competency:
- Nil.
Safety
Workplace health and safety (WHS) requirements need to be observed in accordance with legislation. You need to know the WHS laws governing your job. Revision of CPCPCM2043A - Carry out WHS requirements, before commencing this unit is advisable
In any work situation you can reduce the risk of injury to yourself and others by using appropriate personal protective equipment (PPE). The types of PPE that you will need include:
- overalls – used for the protection of the installer when working in different conditions
- boots – it is recommended that soft soled footwear is worn while working on roofs, as deep grooved footwear pick up small stones and debris that might damage or scratch the roof sheets
- safety glasses or goggles to protect the eyes from injury when cutting the sheets with a power saw
- ear plugs or muffs to protect the installer’s hearing from excessive noise
- dust masks or respirators to protect the user from breathing in dust or fine particles when cutting the sheets with a power saw
- gloves, for the protection of the installer’s hands when working with different types of pipes, tools and equipment.
Workplace environment and safety
Handling of materials / Manual lifting and handling techniques must always be followed according to WHS requirements. You should move materials into position by hand where possible. Excessive manual handling should be avoided and cranes and other mechanical lifting devices should be employed when necessary.Limited height scaffolds and elevating work platforms (EWP) / Operators must ensure they are familiar with all operating procedures detailed by manufacturers in the elevated working platforms operators’ manual. Personal protective equipment must be worn at all times by the person working in the basket of the EWP. This consists of safety harnesses, safety helmets, rubber soled shoes, safety vests and suitable clothing.
What other resources will I need?
To assist you the following resources have been suggested and should be available for you to do this competency.
Texts
- AS/NZS3500.0 - Plumbing and drainage.
- AS/NZS3500.1 - Plumbing and drainage.
- AS/NZS3500.4 - Plumbing and drainage.
- AS/NZS5601 - Gas Installations (relevant version).
- Plumbing code of Australia
- State and Territory requirements may override this Learning Guide.
Web sites
Video or audio cassettes
Introduction
In this unit you will look at gas fired small bore hot water heating systems with a maximum operating pressure and temperature range up to 100C, and pipes up to 25 mm in size. You will also look at how to install them, including the location, support, piping requirements and testing procedures.
A range of small bore heating systems are available to suit different environments. You need to be able to select a system that will meet the needs of the job specifications and the environment. A small bore heating system is one of the most efficient ways of heating a house. Gas fired hot water is generated and then piped quietly throughout the home to the areas where heating is required. The use of hydronic systems (a small bore recirculated water heating system) allow occupants of the house to heat each room separately and at the desired temperature. The temperature control can be automated or controlled manually.
The home is heated by a compact boiler that can be fired by various fuels but in most cases natural gas or LPG is used. The size and type of radiators used determine the amount of heat provided. The water is pumped through the system and returns to the boiler to be reheated.
Advantages of hydronic systems
Hydronic systems have several advantages over other forms of heating, such as:
- even, comfortable heat throughout the home
- radiators and or convectors can be added at a later date if the unit is sized adequately
- no dust is blown through the house therefore the system is allergy free
- easy installation and control system
- unused rooms can be switched off or kept at a lower temperature by just turning a knob because each radiator or convector can be individually controlled by thermostat
- quiet operation.
Worksheet
Now go to the Worksheet and answer Question 1.
A small bore heating system consists of:
- a heating unit (boiler), external model fired by natural gas or LPG
- pipework
- heat emitters (radiators, skirting board convectors, natural convectors and fan convectors)
- controls (valves, switches and thermostats used to maintain the desired temperature).
Worksheet
Now go to the Worksheet and answer Question 2.
Heat loss due to air changes
Health regulations require that the air inside domestic dwellings must be changed at least twice every hour, so that occupants have a good supply of fresh air.
The manufacturers of heating products have devised methods for you to calculate the size of the unit used for a particular installation. Always check with the manufacturer if you need further information. Ask your trainer or supervisor for an example to look at.
Flow diagram of typical hydronic Heating systemHeat emitters are the devices used to transfer the heat energy from the water into the room or space being heated. This transfer can take place in three different ways:
- conduction (the heat flow in a solid substance where heat is passed from particle to particle)
- convection (the heat flow in liquids or gases via its density).
- radiation (the heat is transferred in straight lines in all directions without warming the space through which it passes).
The size of the heat emitters is critical when sizing the system. To select the correctly sized heat emitter for each room the heat load calculations must be used, (refer to manufacturer’s or supplier’s sizing system). The manufacturer or supplier will supply simplified tables or formulas to make the task easier for domestic installations.
Ask your trainer or supervisor for a sample of these formulas or tables.
WorksheetNow go to the Worksheet and answer Question 3.
Heating units
Small bore hot water heating systems may include panel radiators, skirting convectors, natural convectors and fan convectors.
Panel radiators
A compact panel radiator is made from durable steel. Heat is given off from the panel radiators with by way of radiation.
The location of these radiators is critical to the efficient operation of the system. They should not be located in obscure positions or covered in any way. They are best located under or near windows and on external walls, in areas of greatest heat loss. The panels are manufactured in lengths from 400 mm to 3000 mm in increments of 100 mm. The height varies from 300 mm to 900 mm. The pressure loss through a radiator is relatively low and can be calculated by using the manufacturer’s literature.
Features of panel radiators
Panel radiators have a number of features that are a benefit to the consumer.
- Silent, no noise or draughts due to fans blowing hot air.
- Ideal for allergy or asthma sufferers.
- Individual control.
- Low running cost using an efficiently sized central boiler.
- Individual flow control at each radiator using a lock shield valve.
Panel radiator
Skirting convectors
Skirting convectors should be located under windows for maximum benefit, preventing the cold air spilling down the glass and across the floor. The skirting convectors come in lengths from 900 mm to 3000 mm and heights form 64 mm to 213 mm.
Features of skirting board convectors
Skirting board convectors have a number of features and benefits to the consumer which include:
- silent, no fans blowing hot air causing in no noise or draughts
- ideal for allergy or asthma sufferers
- individual control
- low running cost using an efficiently sized central boiler
- safe for children and senior citizens with low surface temperature
- all copper tails with no moving parts
- can be made to suit any wall length
- individual flow control at each convector using a lock shield valve.
Skirting board convector
Natural convectors