Commonwealth of Australia 2015 1
CONSTRUCTION, PLUMBING AND SERVICE INTEGRATED FRAMEWORK TRAINING PACKAGE CPC08 CPCPWT3020A Connect and install storage tanks to a domestic water supply LEARNING GUIDE Commonwealth of Australia 2015 2
ACKNOWLEDGEMENTS National Plumbing Services Training Advisory Group Commonwealth of Australia 2015 Construction and Property Services Industry Skills Council PO Box 151 Belconnen ACT 2616 Tel: 02 6253 0002 www.cpsisc.com.au 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 2015 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): Commonwealth of Australia 2015 3
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 ACKNOWLEDGEMENTS... 3 Contents... 4 What is this resource about?... 6 How do I use this resource?... 6 Flexible Delivery... 6 What do I have to do?... 7 Unit Descriptor... 7 Application of the Unit... 7 Elements and Performance Criteria Pre-Content... 8 Elements and Performance Criteria... 8 Required Skills and Knowledge... 10 Required knowledge... 11 How will I be assessed?... 11 Additional Information... 11 Introduction... 12 Types of storage tanks... 13 1. Preparing to install a vented water heater.... 20 2. Identifying the installation requirements.... 21 3. Installing and testing the installation.... 22 3.1 Locating the site for the storage tank/s.... 22 3.2 Installation of water heater or storage tank... 24 Commonwealth of Australia 2015 4
3.3 Jointing systems... 28 3.4 Pipe supports and fittings... 29 3.5 Testing and commissioning... 29 3.6 Flushing system... 30 4. Clean up the work area...32 4.1 Tools and equipment are cleaned, checked, maintained and stored... 32 4.2 Documentation is completed in accordance with workplace requirements33 Worksheet...34 Practical application...38 Assessment Checklist...41 Commonwealth of Australia 2015 5
What is this resource about? Welcome to CPCPWT3020A Connect and install storage tanks to a domestic water supply. 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 guide, which contains background information on connecting and installing storage tanks to a domestic water supply Questions, which prepare you for the practical examination. 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 practice connecting and installing storage tanks to a domestic water supply read the assessment checklist together with the assessment sheets complete the assessment/s 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 Guide to suit people from diverse backgrounds to meet equity principles and conform to Legislative policies. Commonwealth of Australia 2015 6
What do I have to do? To demonstrate competence in this unit you will be required to show the level of skills and knowledge for each of the elements involved to connect and install storage tanks to a domestic water supply: Prepare for work Identify installation requirements Install and test storage tank installation Cleaning up. Unit Descriptor This unit of competency specifies the outcomes required to connect and install storage tanks to a domestic water supply. Application of the Unit This unit of competency applies to the connection and installation of storage tanks to a residential or commercial water distribution pipe system, which may be a new work site or an existing structure being renovated, extended, restored or maintained. Commonwealth of Australia 2015 7
Elements and Performance Criteria Pre-Content Elements describe the essential outcomes of a unit of competency. Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide. Elements and Performance Criteria 1 Prepare for work. 1.1 Plans and specifications are obtained. 1.2 Work health and safety (WHS) and environmental requirements associated with connecting static storage tanks to a water supply system are followed. 1.3 Quality assurance requirements are identified and followed according to workplace requirements. 1.4 Tasks are planned and sequenced in conjunction with others involved in or affected by the work. 1.5 Tools and equipment, including personal protective equipment, are selected and checked for serviceability. 1.6 Work area is prepared to support efficient connection and installation. 2 Identify installation requirements. 2.1 Required materials that comply with relevant Australian standards and job specifications are determined from plans and specification. 2.2 Sustainability principles and concepts are observed when preparing for and undertaking work process. 2.3 Quantities of required materials are calculated from plans and specifications. 2.4 Materials and equipment are ordered and collected according to workplace procedures. 2.5 Materials and equipment are checked for compliance with relevant Australian standards, docket and order form, and for acceptable condition. Commonwealth of Australia 2015 8
3 Install and test storage tank. 3.1 Storage tank and associated pipework are set out according to plans, specifications and job instructions. 3.2 Pipe supports and fixings that comply with relevant Australian standards are installed to plans and manufacturer specifications. 3.3 Tank, piping and materials are installed according to plans, specifications and relevant Australian standards. 3.4 Jointing systems are confirmed as compliant with relevant Australian standards. 3.5 Installed system is pressure tested and commissioned according to relevant Australian standards and job specifications. 3.6 Test data is recorded in format required by job specifications and quality assurance procedures. 4 Clean up. 4.1 Work area is cleared and materials disposed of, reused or recycled according to legislation, regulations, codes of practice and job specifications. 4.2 Tools and equipment are cleaned, checked, maintained and stored according to manufacturer recommendations and workplace procedures. 4.3 Information is accessed and documentation completed according to regulatory authorities and workplace requirements. Commonwealth of Australia 2015 9
Required Skills and Knowledge This section describes the skills and knowledge required for this unit. Required skills Communication skills to: access information determine requirements enable clear and direct communication, using questioning to identify and confirm requirements, share information, listen and understand follow and give instructions record test results in writing use language and concepts appropriate to cultural differences use and interpret non-verbal communication, such as hand signals Literacy skills to: complete workplace documentation read and interpret: documentation from a variety of sources plans and specifications record test results in writing Numeracy skills to apply measurements and calculations Planning and organising skills to: plan and sequence tasks with others plan and set out work Teamwork skills to: work with others to action tasks relate to people from a range of cultural and ethnic backgrounds and with varying physical and mental abilities Technical skills to: determine system requirements for installation of a static storage tank identify and report faults in tools, equipment and materials Technology skills to: access and understand site-specific instructions in a variety of media use mobile communications technology Commonwealth of Australia 2015 10
Required knowledge characteristics and application of different pipe fittings and fixture supports, including fixing and joining techniques function and operation of a range of taps and valves job safety analysis (JSA) and safe work method statements (SWMS) levelling and alignment processes pressure test systems and procedures procedures for accessing information and processes for calculating material requirements process for connecting static storage tanks relevant statutory requirements related to the connection of static storage tanks SI system of measurement structural systems, building materials and building services 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 www.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 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 connect and install storage tanks to a domestic water supply. This unit may be assessed in conjunction with other unites of competence. Your trainer or supervisor will tell you if you are to be assessed this way. Additional Information AS/NZS 3500.0 AS/NZS 3500.1 AS/NZS 3500.4 http://www.nwc.gov.au/ data/assets/pdf_file/0016/10753/rainwater_handbooknwc_logo.pdf Commonwealth of Australia 2015 11
Introduction This unit specifies the competency required to connect and install a storage tank to the domestic (drinking) water supply. For more detail on larger installations, Section 8 in AS/NZS 3500.1 deals with water storage tanks and should be referenced. AS/NZS 3500.0 simply defines a storage tank as a container for storing water. The stored water acts as a reservoir of water to be used at a later date. The most common type of storage tank in use is a toilet cistern which is designed to effectively flush wastes from a toilet pan, usually a 6/3 litres dual flush. Toilet Suite Using the cistern as an example, a storage tank will have: A tank to hold a certain volume of water A means of controlling the water flow to the cistern a mini cistern-cock A means of controlling the water level within the tank from the drinking water (main) supply this is by a float valve. An air-gap between the incoming drinking water (outlet level of the float valve) and the weir level in the cistern must be at least 20mm. The air-gap is to stop cross-connection taking place. As with all storage tanks, the manufacturer builds this into the system so as long as the plumber installs an approved cistern, he/she will need to check the heights the water fills to against the water level indicator mark shown within the cistern. An overflow pipe housed internally within the cistern so that if the float valve is faulty and continues to fill the tank when the water reaches the weir level of the overflow pipe, it then runs down into the pan. An outlet pipe (flushpipe) to take the water to the pan. A means to isolate the flow from the tank-this is achieved by installing a full flow (ball or gate) valve to the outlet pipe of the storage tank. Note required on a toilet cistern, is only required if the storage tank is greater than 50 litres. Support for the tank, for the cistern it is usually two fixings, but for larger then it will be a platform structure if installed within a building, or on a concrete pad if installed outside. Commonwealth of Australia 2015 12
Types of storage tanks There are several types of storage tanks a plumber may work on. In general they would tend to be under 450L except for rain water tanks which can be up to 25,000 L. Storage tanks above this capacity would be for commercial or industrial type installation. The following is a selection of situations where you may be asked to install a water storage tank: Toilet cistern. As described previously. Rain water tank. With the effects of climate change and an increasing population the collection of rainwater for use within the house is becoming more important, and in some case being made mandatory by state or local governments. The rainwater tank system below shows how the drinking water (mains) supply can be used to supplement the rainwater supply in summer or times of drought. The drinking water as seen on the below left diagram only fills the tank up approximately 150mm then is closes the float valve. This leaves ample catchment for the rainwater as can be seen in the diagram to the right. Part Filled Operating Zone Rain Water Filling Zone Note: An air-gap must be maintained between the outlet point of the float valve and top of the overflow pipe to prevent cross connect to the drinking water supply. Refer the AS/NZS 3500.1 Backflow prevention, for further details. Commonwealth of Australia 2015 13
The rainwater tank system below has no back-up supply so the plumber would need to ensure the tank has been sized large enough to meet the demand of the occupants. Leaf Eater No back-up supply Note: To help maintain the quality of rain water in the tank, the following have been installed: 1. Leaf eater has been installed near the gutter. On the top face of the leaf eater a 10mm mesh is installed to stop leaves getting into the downpipe / rainwater tank. The leaves get caught on the mesh and are either washed of by the rain or blown off by wind. Below the mesh is a secondary filter of fine stainless steel gauze (like fly-wire). This traps finer particles such as dirt and will need to be cleaned regularly. 2. First Flush Diverter catches the first run-off from the roof which is likely to have the most contaminates. It is simply a T in the downpipe. The volume below the T is the amount of water to waste when it first rains. The drip pipe allows this to slowly escape ready for the next rain. As with the stainless steel gauze in the leaf eater, the first flush diverter will need regular maintenance to clean the small opening in the drip pipe and should be cleaned after each rainfall. Commonwealth of Australia 2015 14
Supply tanks. A supply tank is likely to be used in commercial or industrial situations and would usually be a large capacity tank. Situations that may require supply tank/s to be used are: 1. Fire tank to guarantee a supply in the case of a designated supply tank for the fire service is generally required. Refer AS/NZS3500.1 Section 6 Fire Supply Tanks 2. Insufficient flow or pressure. If the pressure and / or flow are not sufficient for a building, a receiving tank is installed at or near the ground level. The water is then pumped to an elevated tank in the plant room or roof of the building. From the elevated tank it then gravitates to the fixtures below (see the diagram to the right). As stated previously these tanks are likely to be of a large capacity and installed within a building. Because of this these tanks are almost always built in-situ and would be designed by an engineer with the aid of a plumbing consultant. Commonwealth of Australia 2015 15
Header tank or make-up tank. 3. Flush-o-meter make-up tank A flush-o-meter service would need a make-up tank to supply all of the flushometers installed below the tank. The tank is sized to meet the demand e.g. the number of flushometer and what they are feeding - toilet / urinal. The head or pressure is also taken into account. Refer AS/NZS3500.1 Section 10 Typical flushometer valve Flush-o-meter make-up tank 4. Vented (gravity fed / low pressure) water heater Vented water heaters have a make-up tank that supplies water to the heater at less than mains pressure supplied by the authority. A vent pipe must be installed which is permanently open to the atmosphere. The vent pipe stops pressure building up within the vented water heater. The make-up tank can either be separate to the heater, as shown on the diagram to the right or mounted on the side of the heater (Side fed water heater). See figure on page 19. The heaters are generally made of copper and therefore cannot withstand high pressures and are rated at less than 85 kpa. This means the supply tanks working water level must not be higher than 8.5m above the base of the heaters tank. Vented (separate fed) water heater Commonwealth of Australia 2015 16
Purpose of Storage Tanks To store & distribute water in high-rise buildings To physically disconnect mains supply from certain fixtures To provide a reserve of water for a fixture Make-up / Header Tanks Why is this necessary? Why is this necessary? What type of fixtures/fittings? What are they? Not enough pressure or flow in the mains supply To prevent cross connection Fixture that require large amounts of water in a short time A tank used to keep a constant head How would a storage tank help? How would it help? How would it help? How would it help? By pumping water from a lower tank to a storage tank on the roof / plant-room By providing an airgap A tank is sized to allow for the maximum demand This could be a minimum or maximum head height of the tank above the fixture/s keeps a constant head Examples Examples Examples Example High rise buildings flushometers fire service Flushometers fire service cooling water towers recycled water Flushometer fire service Gravity fed water heaters flushometers water cooling towers Based on Gary Cooks Cert IV Notes Commonwealth of Australia 2015 17
Purpose of the parts: Typical Parts of a Cold Water Storage Tank (Source: AS/NZS 3500.1) 1. Inlet stop tap or gate valve- to stop the flow of water into the storage tank to allow for maintenance by isolating it from the drinking water supply. 2. Float valve to control the water level within the tank. 3. Outlet of float valve From the outlet of the float valve, the vertical distance is determined for the air gap. 4. Cover to protect the storage tank from foreign debris entering. 5. Air gap prevent cross-connection taking place via siphonage. 6. Height of water above invert of overflow is a factor taken into account when determining backflow prevention. Several factors are taken into consideration. This is covered fully in the backflow prevention course. 7. Sludge diversion / sludge discharge pipe a system to allow for ready removal of the build-up of sludge within the storage tank. It is required on supply tanks exceeding 500L. 8. Signage to identify the intended use of the water in the tank. (This is not required on domestic storage tanks.) 9. Outlet / stop tap or gate valve To isolate the water from within the storage tank to the fixtures downstream on tanks greater than 50 litres. 10. Operational water level the working water level which is governed by the float valve. 11. Spill level the maximum level the inflowing water can build up to within the storage tank under any foreseeable circumstances taking into account; flow rates, pressure, overflow pipe size and all services closed. Commonwealth of Australia 2015 18
Materials The materials used in the manufacture of storage tanks are many and varied. All tanks must be made from approved materials. Small tanks may be ready made from copper, polyethylene and so on. The most commonly used materials for storage tanks are: Metals: Plastics: Galvanised mild steel Zincalume Aqua-plate Copper Stainless steel PVC-U Polyethylene Polypropylene Fiberglass Installing a Vented Water Heater The remainder of this Learning Guide will use, as an example, a 250L vented water heater for determining the requirements for installing a water storage tank. It is broken into four parts; 1. Preparing to install a vented water heater. 2. Identifying the installation requirements. 3. Installing and testing the installation 4. Cleaning up on completion of the task. Side fed vented water heater Worksheet Questions Complete questions 1-5 inclusive (Page 34). Commonwealth of Australia 2015 19
1. Preparing to install a vented water heater. As with all tasks, it is import that adequate preparation takes place to ensure the task is completed as efficiently as possible, meets the quality systems of an employer / industry and is done safely. To achieve this you will need to consider the following: Ensure that the storage tank is installed in the location as shown on the plans and is the one specified eg. 250L vented water heater. All safety factors are followed which could include; electrical hazards, hazardous materials and substances, service lines, surrounding structures and facilities, trip hazards, use of tools and equipment, work site visitors and the public, working at heights, lifting heavy appliances and working in proximity to others. This should be reflected in the JSA. The quality assurance requirements of your employer and the plumbing industry are met. The task has been planned for the most effective way ensuring other trades are working around you, they are not put at risk and the work will progress efficiently. You will have all the necessary tools, equipment and PPE to undertake the task and that it is in good working condition. The work area around the installation is cleared to support efficient installation. Worksheet Questions Complete questions 6-8 inclusive (Page 35). Commonwealth of Australia 2015 20
2. Identifying the installation requirements. It is import that you identify the actual installation requirements for each task. As this has been covered in previous units this section will cover it in question form. You will need to think about the following: What water service materials are to be used; copper / polybutylene / cross linked polyethelyne or other approved materials? What are the limitations of these materials? What standards or local codes you need to use? Am I using the latest version of the plans & specification how do I check? How you can build sustainable practices as part of the task? Can you improve on wastage? Are some materials more environmentally friendly than others? How can materials be recycled? Side fed vented water heater Have you done a take-off for the job? Have you included the heater, safe tray, safe waste, all valves, pipes and fittings? Have you checked your list then placed an order? On delivery of the materials, have you checked the ordered materials against those delivered? Have any of the materials or appliances been damaged? If there has been any damage, what do you do and when do you do it? Worksheet Questions Complete questions 9-10 inclusive (Page 35). Commonwealth of Australia 2015 21
3. Installing and testing the installation. This section will look at the actual installation of a 250L vented water heater from siting it to testing and commissioning with references to AS/NZS 3500.4. 3.1 Locating the site for the storage tank/s. The site of the storage tank should be specified in the plans and specification for the job. However the plumber needs to be aware of structural consideration as 250 liters of water will weigh 250 kilograms and then the tank weight will need to be added. AS/NZS 3500.4 states that for a storage water heater or cold water storage tank installed in roof spaces, they must: Be placed on a platform centrally located over at least one load bearing wall (tanks of up-to 450L capacity). As shown in the diagram below, they are generally placed over two load bearing walls (hallway). No load to be taken by the ceiling joists With truss roofs, the trusses are to be specially designed to take the load of the tank/s. Must be installed as close as possible to the most frequently used outlet or outlets e.g. kitchen sink. Typical construction of a platform Commonwealth of Australia 2015 22
Parts of the platform. 1. Load bearing wall. A wall without doorway or windows below the platform which is capable of taking the weight of the tank/s. An engineer it likely to be required to determine this. 2. Top all plate. Timbers placed on top of the load bearing wall may be integral or added. 3. Joists. Place on the top wall plate, with maximum centers of 450mm. When placed over two load bearing walls, the span they cover will determine the size of the bearers engineer to specify. Parts of the platform 4. Platform deck. The heater/storage tank will sit on the platform deck. It can either be constructed from 20mm (min.) waterproof particle board or 75 x 25mm (min.) timbers. The placement of the platform and tank must be as close as possible to the most commonly used outlet/s. In domestic installations, the kitchen sink is generally considered the most commonly used outlet. Accessibility and clearances The water heater / storage tank shall be installed so: The badge plate and instructions are positioned so they are readily visible. Access to the burner / element, thermostat, valve/s is unobstructed. The water heater / storage tank shall be removable without major structural alternations. Commonwealth of Australia 2015 23
3.2 Installation of water heater or storage tank Safe tray & safe-waste In the case of the water heater or storage tank leaking, a safe tray must be placed under them. From the safe tray, a safe-waste will take the leaking water away from the ceiling space to a place that will not cause any damage or inconvenience. The requirements for their installation are: Refer AS/NZS3500.1 Section 8 1. Safe tray. Made from materials not inferior to 0.06mm thick galvanized sheet steel with a minimal coating of 275 g/m 2, with the side walls having a turn-up of 50mm min. Polyethylene trays are generally used because the ease of use, corrosion resistance and price. Added to this, battens are built into the polybutylene trays which allow air flow under the tank and a fall is built into the tray to allow leakage to flow to the outlet. It shall have no portion of any attached feed tank closer than 75 mm to a vertical line from the edge of the safe tray and no portion of the heater or cold water storage tank or any attached auxiliary part closer than 25 mm to the vertical line It shall have placed between the tank and the safe tray, supports not less than 12 mm thick and of an area not less than 0.5 A, or more than 0.6 A, where A is the area of the base of the tank. The support shall project beyond the sides and walls of the tank but not closer than 20 mm to the sides of the safe tray. Placement of storage tank on safe tray Commonwealth of Australia 2015 24
2. Safe waste Made from; PVC-U, Galvanized steel pipe, seamless copper or sheet steel with PVC-U being the most commonly used. The minimum sizes of safe waste pipes shall be DN 25 for safe trays in under-sink situations or DN 50 for all other situations. Installation of the safe waste shall comply with the following: i. It shall have a continuous fall to its discharge point. ii. All seams in sheet metal pipe shall be uppermost iii. It shall include support in the vicinity of the tray and at intervals not greater than 1 m or horizontally and 2.4 m vertically. iv. The discharge position shall comply with the following: Where discharging outside the building, it shall discharge to a point within the property boundaries which is readily visible from within the property, clear of doors, windows and other openings and is unlikely to cause injury to people or damage to property. Where discharging inside the building, it shall discharge to a readily visible position that is unlikely to cause injury to people or damage to property. Where cold water storage tanks or cold water storage tank-fed water heaters are outside the building, it shall discharge to a readily visible location. 50mm safe waste Overflow pipe from make-up tank 50 mm Safe waste Commonwealth of Australia 2015 25
Storage tank The tank shall be placed on a structure that will support it when full and in such a manner that no load is transmitted to any pipes. All metallic tanks, or such other tanks as may be directed, shall be installed with a membrane of non-corrosive insulating material between the support and the underside of the tank. All tanks shall be accessible for inspection, repairs, maintenance and replacement. Storage tank (Source: AS/NZS 3500.1) Every tank shall be provided with a cover, designed to prevent the entry of dust, roof water, surface water, ground water, bird or animal life. The overflow pipe capable of discharging the inflow rates shown in AS/NZS 3500.1 - Section 8, or hydraulically calculated taking into account the maximum head available in the main (but not less than 500 kpa), friction losses, elevation of the tank, size of the orifice and type of overflow outlet. (Covered in Cert IV Backflow prevention course) The inlet pipe connection shall be fitted with a union coupling or flanges and a stop tap or gate valve in an accessible position. The outlet pipes shall be fitted by means of union couplings or flanges and shall be a minimum of one pipe diameter from the bottom of the tank. For tanks of more than 50 L capacity, each service outlet shall be fitted with a stop tap or gate valve installed in an accessible location. Commonwealth of Australia 2015 26
Air gap Check size of effective opening (float valve internal orifice) Refer to table 4.3 (AS/NZS 3500.1), in most domestic cases the size will be 9mm therefore the air gap will be either 20mm or 25mm. To check this you will need to depress the float valve fully down to allow maximum water flow. Mark the level at which the water no longer rises. Then measure from your mark up to the outlet of the float valve, this should be the minimum of your calculated air gap. This area will be covered in more detail within Certificate IV (Commission and maintain backflow prevention devices) Markings on tanks Except if installed in domestic or residential buildings, all tanks shall have their intended use identified with not less than two permanent notices attached to each tank in readily visible positions, one on the front of the tank and one on the cover. Notices shall: be not less than 450 mm 250 mm in size; have a red background; have the text in white, capital letters of not less than 25 mm in height; and If the storage tank is installed a confined space it must have an identification in accordance with AS/NZS 2865 where applicable. Tanks holding drinking water shall carry the following warning: Unconcealed water storage tanks WARNING: DRINKING WATER Unconcealed water storage tanks, installed inside buildings on or above a floor surface that is impervious to water and suitably drained to a trapped or untrapped floor drain or an external doorway, do not require safe trays. All tanks shall be installed on bases, plinths or supports designed to adequately support the weight of any such tank and its contents when filled to maximum capacity. Commonwealth of Australia 2015 27
Mains pressure water heaters may be installed on a safe tray without a safe waste provided an approved shut-off device is fitted adjacent to the cold water inlet and upstream of any expansion control valve. All other unconcealed water storage tanks that are installed inside buildings shall be installed on safe trays complying with what was stated previously about safe trays. NOTE: Free outlet-type storage water heaters, not exceeding 13.5 L capacity, and continuous flow water heaters do not require safe trays. Worksheet Questions Complete questions 11-15 inclusive (Page 35). 3.3 Jointing systems The materials used for the water system are likely to be either; copper, cross linked polyethylene, polybutylene or other approved materials. For the safe waste PVC-U is the most commonly used material. The jointing requirements of these materials have been covered in the units;, Fabricate and install non-ferrous pressure piping Set out and install water services Silver brazing copper tubing Commonwealth of Australia 2015 28
3.4 Pipe supports and fittings The pipe supports and fittings used for the water system have been covered in the units; Fabricate and install non-ferrous pressure piping Set out and install water services Saddles Clips Worksheet Questions Complete questions 16-18 inclusive (Page 36). 3.5 Testing and commissioning Testing When all draw-off points are closed, those pipes that are subjected to pressure shall be hydrostatically tested in accordance with the following: (a) (b) (c) (d) The completed heated water reticulation, excluding the storage container or water heater, shall not leak when tested with water at ambient temperature at a pressure of 1500 kpa for a period of not less than 30 min. Prior to testing, the heating medium shall be isolated. It may be necessary to disconnect fixtures, appliances and valves in order to prevent damage during testing. Testing shall be carried out on all piping prior to being insulated or concealed in ducts, chases or trenches. The complete system (including valves, pumps and other equipment) shall be tested under normal working conditions for a period of not less than 48 h. The system shall be checked visually for leaks. All safe trays and safe wastes shall be tested with water to ensure they do not leak under full flow conditions. Commonwealth of Australia 2015 29
(e) All drain pipes from expansion control and temperature/pressure-relief valves and all vent pipes shall be tested with water to ensure they are unobstructed and are open to the atmosphere. Water test bucket 3.6 Flushing system Prior to any new work having any valves or appliances such a water heaters, storage tanks or appliances connected to the system, the system must be flushed to remove any debris from within the system. Commonwealth of Australia 2015 30
Commissioning The heated water service shall be commissioned in accordance with the following: (a) (b) (c) The system shall be charged with water prior to the heating medium being applied to the heater. All air shall be fully purged from the system. The following items shall be checked for correct operation, as applicable: (i) Leakage from each temperature/pressure-relief valve, pressure-relief valve and expansion control valve. (ii) Stored water temperature in accordance with Clause 1.9.1 (60 0 min.) (iii) Hot water delivery temperature in accordance with Clause 1.9.2. (45 0 or 50 0 max. depending on the application). (iv) Water level in a gravity-type system. (v) Inlet isolating valve, fully open. (vi) Flow rate at outlet points. (vii) Pump. (viii) Flow and return temperatures. (ix) Inlet pressures where a reduced pressure valve is installed. (x) Vibration, noise or water hammer. (xi) Each multiple heater unit shall be checked for operation, individually. Operating Instructions Commissioning a float valve Operating instructions shall be made available to the owner or occupier of the premises. Commonwealth of Australia 2015 31
4. Clean up the work area Cleaning up the work site is not just a matter of appearance; it also has safety and health implications. It is good work practice to clean up as you go. Building sites are always short of space and build up of debris will only add to storage, health and safety issues. Most sites will have a site safety committee policy on cleaning up the work site. The disposal areas for site debris should be identified at the site induction. If not find out from your supervisor or builder. Clean up as you go if possible, but at least on a daily and weekly basis and on completion of an installation. Food and drink waste, wrappers and containers should be disposed of in the correct bin immediately after use. Any build up attracts vermin and associated health risks. Packaging debris should not be allowed to become a tripping or other hazard. Recycle or dispose of to the appropriate bin as soon as practicable. Off cuts and surplus material that may be used later in the job should be held in a safe storage area until required. Off cuts and surplus material that is not suitable for re-use should be recycled or disposed of to the appropriate bin at the end of each day s work or sooner if practicable. Do not use cupboards, empty rooms or corners to store rubbish and debris. On completion of an installation check the whole of the work area. Remove materials to the store, tools and equipment to the correct location and rubbish and debris to the appropriate bins. Sweep the completed work area clean and correctly dispose of sweepings. 4.1 Tools and equipment are cleaned, checked, maintained and stored For efficient and safe installation, tools need to be maintained and stored. Tools and equipment may be the responsibility of the site manager, contractor, or others such as hire companies. You may be responsible for a tool kit and personal protective equipment (PPE). Do not overload or abuse any tools, plant or equipment. Keep a running check on your tool kit and your PPE. Check, clean and maintain it at the end of each day. Check and maintain company equipment on a regular basis according to company policy. Keep all equipment such as scaffolding, ladders and lifting machines in good working order. Clean and maintain hire equipment according to hire agreement and good practice. On completion of installation collect, clean and maintain all tools and equipment. Commonwealth of Australia 2015 32
4.2 Documentation is completed in accordance with workplace requirements On completion of work it may be necessary to report on what happened. In addition to time and materials this is another opportunity to express any concerns you might have with the effectiveness of the safety procedures. Fill out OHS/WHS monitoring report Complete checklist and store PPE. Complete checklist and store toolkit. Complete checklist and store company equipment. Complete checklist and return hire equipment. Worksheet Questions Complete questions 19-22 inclusive (Page 37). Commonwealth of Australia 2015 33
Name: Worksheet CPCPWT3020A Connect and install storage tanks to a domestic water supply The student should complete this worksheet before attempting the practical installation. 1. Define the term storage tank. 2. State two situations that may require a storage tank for both domestic and commercial/industrial situations. Domestic 1. 2. Commercial/Industrial 1. 2. 3. Why is it becoming more important to use rain water storage tanks? 4. What is meant by a vented system? 5. State two materials that storage tanks can be constructed from. Plastic 1. 2. Metal 1. 2. Commonwealth of Australia 2015 34
6. State four items of PPE that you may require when installing a storage tank. 7. When installing a 250L vented water heater in a ceiling space, what can be used to safely lift the heater? 8. Why is it important to consider other trades working on a job site? 9. Name three water service materials that you could use when connecting to a water storage tank. 10. If, on delivery of the water storage tank, it is damaged, what should you do? 11. State two options that can be used for the platform deck timbers. 12. What material is a safe tray generally made from in domestic situations? 13. What is the maximum spacing for supports for a safe waste? a. Vertically b. Horizontally Commonwealth of Australia 2015 35
14. What is required on the inlet pipe to a storage tank? 15. Why is the air gap important in a storage tank? 16. Name four tools you would use when working with cross linked polyethylene. 17. Name four tools you would use when working with copper. 18. Using AS/NZS 3500.1, what is the maximum spacing for supports for: Nominal pipe size DN 15 Copper PVC-U, cross-linked polyethylene, polybutylene Horizontally or graded Vertically 18 20 22 25 Commonwealth of Australia 2015 36
19. When testing the water service to and from a storage tank, what is the test pressure and how long must the test last? Pressure: Time: 20. How are safe wastes and safe trays tested? 21. When commissioning a water service, how would you check for water hammer? 22. When commissioning a water service on the downstream end of the storage tank, why is it import that there is no air in the system? The worksheet may form part of the assessment and should be checked and signed off by your trainer or supervisor. Trainer or Supervisor s Signature:. Date of Completion:. Commonwealth of Australia 2015 37
Name: Practical application CPCPWT3020A Connect and install storage tanks to a domestic water supply Your trainer or supervisor will now work with you to demonstrate practical competence, the following points will be covered. Prepare for work. Plans and specifications are obtained. Work health and safety (WHS) and environmental requirements associated with connecting static storage tanks to a water supply system are followed. Quality assurance requirements are identified and followed according to workplace requirements Tasks are planned and sequenced in conjunction with others involved in or affected by the work. Tools and equipment, including personal protective equipment, are selected and checked for serviceability. Work area is prepared to support efficient connection and installation. Commonwealth of Australia 2015 38
Identify installation requirements. Required materials that comply with relevant Australian standards and job specifications are determined from plans and specification. Sustainability principles and concepts are observed when preparing for and undertaking work process. Quantities of required materials are calculated from plans and specifications. Materials and equipment are ordered and collected according to workplace procedures. Materials and equipment are checked for compliance with relevant Australian standards, docket and order form, and for acceptable condition. Install and test storage tank. Storage tank and associated pipework are set out according to plans, specifications and job instructions. Pipe supports and fixings comply with relevant Australian standards are installed to plans and manufacturer specifications. Tank, piping and materials are installed according to plans, specifications and relevant Australian standards. Jointing systems are confirmed as compliant with relevant Australian standards and manufacturers requirements. Installed system is pressure tested and commissioned according to relevant Australian standards and job specifications. Test data is recorded in format required by job specifications and quality assurance procedures. Commonwealth of Australia 2015 39
Clean up Work area is cleared and materials disposed of, reused or recycled according to legislation, regulations, codes of practice and job specifications. Tools and equipment are cleaned, checked, maintained and stored according to manufacturer recommendations and workplace procedures. Information is accessed and documentation completed according to regulatory authorities and workplace requirements. On completion of this practical application you will be assessed. To prepare for your assessment make sure you read the assessment checklist, the assessment task and Questions. Trainer or Supervisor s Signature:. Date of Completion: Commonwealth of Australia 2015 40
Assessment Checklist CPCPCM2043A Carry out WHS requirements Criteria Yes No Have the worksheets been successfully completed? Has the practical task been completed? Are the job specification and local authorities or utilities requirements available? Trainer or Supervisor s Signature:. Date of Completion: Commonwealth of Australia 2015 41