CPCPWT3025A - INSTALL WATER PUMPSETS
CONSTRUCTION, PLUMBING AND SERVICE
INTEGRATED FRAMEWORK
TRAINING PACKAGE
CPC08
CPCPWT3025A
INSTALL WATER PUMPSETS
LEARNING 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 water pump sets......
Unit Descriptor......
Element......
Performance Criteria......
Required knowledge...... 4
How will I be assessed?......
Are there any pre-requisites?......
What other resources will I need?......
Texts......
Web sites......
Safety......
Workplace environment and safety......
Introduction......
Pump sets......
Moving parts guard......
Quality assurance......
Common terms......
Plan work activities......
Personal protective equipment......
Working with hazardous materials......
Hazardous materials......
Tools and equipment......
Determine job requirements......
Water pressure and flow rates......
Pressure......
Flow......
Centrifugal pump sets......
How does the centrifugal pump work?......
Multi-stage pump sets......
Submersible pump sets......
Types of motors......
Connections......
Controls......
Pump base......
Types of motors......
Electric motors......
Connections......
Close coupled......
Long coupled......
Belt driven......
Controls......
Alignment processes......
Lining up a pump and motor......
To check for parallel alignment......
Vee belt alignment......
Belt tensioning......
Pump base......
Grouting in a pump set......
Fuel tanks and supply systems......
Assembly......
Clean up......
Worksheet......
Practical application......
Assessment checklist......
© Commonwealth of Australia 2015 1
CPCPWT3025A - INSTALL WATER PUMPSETS
What is this resource about?
Welcome to CPCPWT3025A - Install water pumpsets. 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 installing water pump sets
- Worksheets, which prepare you for the practical application
- Practical application, which allows you to experience installing water pump sets
- Assessment materials, which help you 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 practice installing water pump sets
- 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 water pump sets:
- Prepare for work
- Determine installation requirements
- Install water pump sets
- Clean up.
If you are unsure of the meaning of these elements you should read the performance criteria on the following page.
CPCPWT3025A / Install water pumpsetsUnit Descriptor / This unit of competency specifies the outcomes required to install and test water pumps.
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) andenvironmental requirements associated with installing water pumpsets 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 equipmentfor installing water pumpsets, including personal protective equipment, are selected and checked for serviceability
1.6Work area is prepared to support efficient installation of water pumpsets
2Identify installation requirements / 2.1Location of pump is determined following site inspection
2.2Pump base requirements are identified from drawings and specifications using relevant information
2.3Required materials and equipment are identified, ordered and collected according to workplace procedures
2.4Materials and equipment are checked for compliance with relevant Australian standards, docket and order form, and for acceptable condition
2.5Sustainability principles and concepts are observed when preparing for and undertaking work process
3Install water pump sets / 3.1Pump base is set out to comply with drawings and specifications
3.2Pump base is constructed according to drawings and specifications
3.3Pump and pump controls are installed according to relevant Australian standards, drawings, specifications and manufacturer instructions
3.4Fuel tank fitting, alignment of shafts and couplings, and the use of mechanical joints comply with relevant specifications and manufacturer instructions
3.5Pressure testing of piping system is conducted according to specifications
3.6Pumpset is tested according to specifications and test data is recorded in required format
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:
- atmospheric pressure
- fixing techniques
- job safety analysis (JSA) and safe work method statements (SWMS)
- levelling and alignment processes
- performance measures for various water pumpsets
- process of installing water pumpsets
- properties of water, including pressure and flow rates
- relevant statutory requirements related to installing water pumpsets
- SI system of measurements
- Australian standards applicable to the installation
- use of test equipment and procedures
- workplace and equipment safety 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 may include completion of the student 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 water pump sets.
This unit may be assessed in conjunction with other units of competence. Your trainer or supervisor will tell you if you are to be assessed this way.
Are there any pre-requisites?
Prior to commencing CPCPWT3025A - Install water pumpsets you must have successfully completed the following pre-requisite:
- CPCPCM2043A – Carry out WHS requirements.
It is also recommended that prior to commencing CPCPWT3025A - Install pump sets you should have successfully completed the following competencies:
- Nil.
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.
What other resources will I need?
To assist you the following resources have been suggested and should be available to you to do this competency:
Texts
- AS/NZ3500 – Plumbing and drainage.
- AS1692 Tanks for flammable and combustible liquids.
- Plumbing code of Australia.
- State or Territory regulations may override this Learning Guide.
Web sites
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.
Introduction
In this unit you will look at the skills and knowledge used in installing water pump sets.
Pumps when properly installed and maintained will operate satisfactorily for a long time.
The different types of pumps, motors and connections are:
- centrifugal pump sets
- multistage turbine pump sets
- submersible pump sets.
These will be looked at individually in this unit. Each type of pump set will be described along with the types of motors that can be used, the connections, assembly techniques and the control devices used.
Pump sets
The definition of a pump set is a pump, motor and coupling mounted on a steel frame or base.
The pump may be driven by an electric motor, petrol or diesel engine or perhaps hydraulically and may be arranged vertically or horizontally.
Moving parts guard
Because pump sets have moving parts it may be necessary to have guards installed. Guards may come as part of the pump assembly or manufactured to suit the situation in which they are to be used. Pump guards should be designed to prevent injury to all persons including people working near the pump. A guard should comply with all WHS requirements.
Vertically arranged pump setsQuality assurance
Most companies these days have a policy for assuring quality to the customer. This policy is designed to control the processes used within the company, record keeping, quality of materials used and the way the work is done. Making sure the correct pump is used for a particular application which it is designed for.
You need to be aware of your company’s particular quality assurance requirements. Your supervisor will be able to provide information on your company’s quality assurance policy. However some quality assurance measures such as making sure the finished installation meets the original specifications, or checking all deliveries against the order or delivery docket are just good business practice or even common sense. Other quality assurance measures, such as testing the completed installation, are often regulatory requirements as well. Read information supplied with pump carefully and make sure pump is installed to manufacturer’s specifications so that warranty is not void.
Common terms
Pump sets are systems involving mechanical, hydraulic and electrical components. To understand how they work and how to install and test them there are some terms you should know.
Term / DefinitionCapacity / The volume of liquid that is delivered by a pump per unit time.
The metric units of capacity are as follows:
- small capacities – litres per second (l/s)
- large capacities – cubic metres per second (m3/s).
Suction / The inlet or entry port of the pump.
Discharge / The exit port of the pump.
Head / Head is pressure expressed as a vertical column of water.
The metric units are metres of water (mw).
Static head / The vertical height that the water must be pumped.
Operating head / The difference in pressure (head) between the inlet port and the outlet port of an operating pump.
Suction head / The vertical height difference between the water level and the pump inlet or suction port.
Discharge head / The pressure (head) measured at the pump outlet.
Friction head / The frictional pressure losses which occur as the water passes through the pipe and fittings is expressed as the equivalent vertical head.
Cavitation / The formation of vapour bubbles in the eye of the impeller due to poor entry conditions. Cavitation makes a noise like gravel passing through the pump.
Impeller / The rotating blades or vanes inside a centrifugal pump.
Impellers may have an open or closed face design.
Volute / The casing around the impeller. This casing has a gradually enlarging passageway leading to the discharge port of the pump.
Baseplate / The steel frame on which a pump and motor assembly are mounted.
Grouting / A light concrete mixture that is poured around the baseplate of the pump after the baseplate has been mounted on its foundation.
Plan work activities
You need to plan the job you are about to do and consider how it may affect others. You should do this in conjunction with the others involved in, or affected by the work. Your company may have procedures regarding this that you will need to take into account.
Depending on the size of the job site you will need to coordinate the installation process with the site supervisor or other workers trying to get in and do their part of the job.
Other tradespeople your installation could affect or involve are listed below.
- Electricians.
- Pipe laggers.
- Painters.
- Floor finishers.
- Equipment commissioning personnel.
When installing a pump the installation must comply with the Australian Standard AS/NZS3500 and the manufacturers installation requirements.
Personal protective equipment
In any work situation you can reduce your chances of being injured by using personal protective equipment (PPE).
PPE that you will need to use when installing water pump sets includes:
- overalls
- boots
- gloves
- safety glasses or goggles
- ear plugs or muffs
- hard hats
- fume or dust masks.
Working with hazardous materials
In any work situation there are hazards. These hazards need to be identified and controlled to make the work environment as safe as possible. When you install a pump set you may find yourself working with hazardous materials. If you know which materials are hazardous you can take precautions and reduce the risk to yourself and others.
The following table includes:
- various hazardous materials you may come in contact with when installing a pump
- methods required to protect yourself from contamination
- correct disposal procedures.
Worksheet
Now go to the Worksheet and answer Questions 1 – 7.
Hazardous materials
Material / Used for: / Nature of riskCement / Grouting in pump
Pump foundations / Skin contact causing chemical burns and dermatitis
Inhaling the dust will cause nose and throat irritation.
Dust is irritating and corrosive to your eyes.
Adhesives, Solvent cements and pipe cleaning agents / Gluing insulation
Jointing of PVC pipes / Skin contact and breathing of fumes.
Causing chemical burns, dermatitis and mental confusion or intoxication.
Fluxes / Silver soldering of metal pipe work and fittings / Contact with skin, eyes and breathing of fumes during welding may cause chemical burns, dermatitis and lung tissue damage.
You should obtain and read the material safety data sheet (MSDS) for any hazardous materials you are going to work with. You also need to know where the MSDSs are kept in case you need to refer to them in a hurry (for example to get first aid information). Ask your trainer or supervisor to show you the material safety data sheets for the chemicals you will be using and how they work.
Tools and equipment
The tools and equipment needed to install pump sets include:
- hand and power tools:
- electric drills, both conventional and hammer drills
- adjustable shifting spanners or wrenches
- power saw
- hammer
- cold chisel
- screwdrivers – both plain and Philips
- string line
- measuring and alignment tools:
- tape measure
- steel ruler
- square
- level
- dial indicator
- straight edge
- concreting tools:
- hand trowels
- shovel
- bucket
- concrete mixer.
You may also need to use lifting or load shifting equipment to move the materials you use.