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CPCPWT3025A - INSTALL WATER PUMPSETS

CONSTRUCTION, PLUMBING AND SERVICE

INTEGRATED FRAMEWORK

TRAINING PACKAGE

CPC08

CPCPWT3025A

INSTALL WATER PUMPSETS

LEARNING GUIDE

ii © Commonwealth of Australia 2015


ACKNOWLEDGEMENTS

National Plumbing Services Training Advisory Group

Plumbing Industry Commission Victoria

© Commonwealth of Australia 2015

Construction and Property Services Industry Skills CouncilPO Box 151Belconnen ACT 2616Tel: 02 6253 0002www.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 work was first published in 2004 with the assistance of funding provided by the Commonwealth Government through the Australian National Training Authority (ANTA). The 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):

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.

© Commonwealth of Australia 2015 iii

http://www.cpsisc.com.au/


Contents

What is this resource about?.................................................................................................1

How do I use this resource?.................................................................................................1

Flexible Delivery..................................................................................................................1

What do I have to do?..........................................................................................................2

Install water pump sets.........................................................................................................3

Unit Descriptor.....................................................................................................................3

Element.................................................................................................................................3

Performance Criteria............................................................................................................3

Required knowledge.............................................................................................................4

How will I be assessed?.......................................................................................................5

Are there any pre-requisites?................................................................................................5

What other resources will I need?........................................................................................6

Texts.....................................................................................................................................6

Web sites..............................................................................................................................6

Safety....................................................................................................................................7

Workplace environment and safety......................................................................................7

Introduction..........................................................................................................................8

Pump sets.............................................................................................................................8

Moving parts guard..............................................................................................................8

Quality assurance.................................................................................................................9

Common terms...................................................................................................................10

Plan work activities............................................................................................................11

Personal protective equipment...........................................................................................11

Working with hazardous materials.....................................................................................11

Hazardous materials...........................................................................................................12

Tools and equipment..........................................................................................................13

Determine job requirements...............................................................................................14

Water pressure and flow rates............................................................................................15

Pressure..............................................................................................................................15

Flow....................................................................................................................................16

Centrifugal pump sets........................................................................................................17

How does the centrifugal pump work?..............................................................................17

iv © Commonwealth of Australia 2015


Multi-stage pump sets........................................................................................................19

Submersible pump sets.......................................................................................................20

Types of motors..................................................................................................................22

Connections........................................................................................................................22

Controls..............................................................................................................................22

Pump base..........................................................................................................................22

Types of motors..................................................................................................................23

Electric motors...................................................................................................................23

Connections........................................................................................................................24

Close coupled.....................................................................................................................24

Long coupled......................................................................................................................24

Belt driven..........................................................................................................................25

Controls..............................................................................................................................25

Alignment processes..........................................................................................................25

Lining up a pump and motor..............................................................................................26

To check for parallel alignment.........................................................................................27

Vee belt alignment.............................................................................................................28

Belt tensioning...................................................................................................................29

Pump base..........................................................................................................................30

Grouting in a pump set.......................................................................................................33

Fuel tanks and supply systems...........................................................................................35

Assembly............................................................................................................................35

Clean up..............................................................................................................................40

Worksheet...........................................................................................................................41

Practical application...........................................................................................................48

Assessment checklist..........................................................................................................50

© Commonwealth of Australia 2015 v


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.

© Commonwealth of Australia 2015 1


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.

2 © Commonwealth of Australia 2015


CPCPWT3025A Install water pumpsetsUnit Descriptor This unit of competency specifies the outcomes required to

install and test water pumps.

Element Performance CriteriaElements 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.

1 Prepare for work 1.1 Plans and specifications are obtained

1.2 Work health and safety (WHS) and environmental requirements associated with installing water pumpsets are adhered to throughout the work

1.3 Quality assurance requirements are identified and adhered to according to workplace requirements

1.4 Tasks are planned and sequenced in conjunction with others involved in or affected by the work and statutory and regulatory authorities’ requirements

1.5 Tools and equipment for installing water pumpsets, including personal protective equipment, are selected and checked for serviceability

1.6 Work area is prepared to support efficient installation of water pumpsets

2 Identify installation requirements

2.1 Location of pump is determined following site inspection

2.2 Pump base requirements are identified from drawings and specifications using relevant information

2.3 Required materials and equipment are identified, ordered and collected according to workplace procedures

2.4 Materials and equipment are checked for compliance with relevant Australian standards, docket and order form, and for acceptable condition

2.5 Sustainability principles and concepts are observed when preparing for and undertaking work process



3 Install water pump sets 3.1 Pump base is set out to comply with drawings and specifications

3.2 Pump base is constructed according to drawings and specifications

3.3 Pump and pump controls are installed according to relevant Australian standards, drawings, specifications and manufacturer instructions

3.4 Fuel tank fitting, alignment of shafts and couplings, and the use of mechanical joints comply with relevant specifications and manufacturer instructions

3.5 Pressure testing of piping system is conducted according to specifications

3.6 Pumpset is tested according to specifications and test data is recorded in required format

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 specification

4.2 Tools and equipment are cleaned, checked, maintained and stored according to manufacturer recommendations and workplace procedures

4.3 Documentation 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 proceduresworkplace 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

http://training.gov.au/Search/Training?searchTitleOrCode=&nrtSearchSubmit=Search&includeSupersededData=true&includeSupersededData=false&homePage=true&javaScriptEnabled=true&typeAllTrainingComponents=true






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.



IntroductionIn 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.

Horizontally arranged pump sets

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.


Motor

Coupling

Pump

Base


Vertically arranged pump sets

Quality 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.


Motor

Inlet

Outlet

Pump

Inlet


Common termsPump 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 Definition

Capacity 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 activitiesYou 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 risk

Cement Grouting in pump

Pump foundations

Skin contact causing chemical burns and dermatitisInhaling 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.

Hand trolleys will be required when moving the pump or heavy equipment around the site.

Rollers may be used to shift heavy equipment into place when the space is too small for forklift or other lifting machinery.

Forklifts are essential when lifting heavy pumps and motors from the back of transport vehicles or shifting equipment on site.

Chain blocks are used to lift and swing heavy equipment into place when suitable overhead support is available.

Hoists when available can be used in place of chain blocks.

Jacks are used to lift and support equipment while positioning is carried out.

You may also be required to work from limited height scaffolds and elevated work platforms so you should be aware of the safety regulations associated with these.



Determine job requirementsTo plan a pump set installation you first need to gather together information from a number of sources. The table below shows some information sources the type of information each source can provide.

Source of information The information provided

Plan or specification Pump details. This may be a pump that has been selected by the design engineer to do the job or the information that will allow the correct selection of a pump.

Job instruction Scheduling details.When you can expect to start the installation.

Installation requirements. The details of pipe sizes, connection requirements, pump position and materials required.

Site inspection Verify the pump installation can be successfully carried out.

Some of the following questions can be answered after visiting the site.

Do you have access to the site? Is the pump location ready for installation? Is the power source available?

Will you need special equipment such as scaffolding, lifting equipment, lighting, generators etc?

Which personal protective equipment you will need?

Pump manufacturer Pump manufacturers will supply:

All physical dimensions of the pump and the connection details.

The correct installation requirements for the pump.



Water pressure and flow rates

You need to understand the basic properties of water to be able to effectively install a pump set. These properties are:

pressure

flow rates.

When it comes to pumps and pumping, flow and pressure are linked, you cannot change one without varying the other. Generally pumps use metres head of water as the pressure units and litres per second as the flow rate units.

Pressure

The System International (SI) Units of measurement which are used throughout this unit include:

Millimetres (mm)

Metres (m)

Pascals (Pa)

kiloPascals (kPa)

megaPascals (mPa).

However in pumps and pumping the term ‘head’ is used for the pressure generated by the pump or the pressure the pump needs to overcome.

Metres head of water (H).

Metres head of water is the vertical height in metres of water a pump must raise water. If you need to convert metres head of water to kiloPascals there is general rule of thumb. For a pump to push water up a vertical pipe one metre it requires a pressure of approximately 10 kPa at the pump discharge point. The pump would have a head of one metre. So three metres of head is approximately equal to 30 kPa.

(For exact conversions you must use the value of 9.81 kPa per metre for cold water and 9.4 kPa per metre for hot water.)

The following table shows the conversion of metres head of water using the approximate value of 10 kPa per metre and the true value for both cold and hot water. You can see for accurate conversions there is a difference so you should always use the true value.



Conversion table

Metres head of water (H)

Approximate conversion

10 kPa/ metre

True conversion

Cold water (4oC) 9.81 kPa/metre

True conversion

Hot water (100oC) 9.4 kPa/metre

1 10 kPa 9.81 kPa 9.4 kPa

5 50 kPa 49.05 kPa 47 kPa

10 100 kPa 98.1 kPa 94 kPa

100 1000 kPa 981 kPa 940 kPa

You can see how the conversion value changes as the water temperature changes.

Flow

The SI unit of flow rate is the cubic metre per second (m3/s) and litres per second (L/s).

Generally when you talk about the flow rate on smaller pumps litres per second is used. However for larger flows the cubic metre per second is used.

If you need to convert m3/s to L/s, there are one thousand litres in one cubic metre. Multiply the cubic metre per second by 1000.

Example

To convert two cubic metres per second to litres per second, multiply the cubic metre per second by 1000.

2 m3/s x 1000 = 2000 L/s

A flow rate of one thousand litres per second is the same as a flow rate of one cubic metre per second.

For example, if you had a pump with a flow rate of 0.250 m3/s this would mean the flow rate would also be 250 L/s.

Example

If you need to convert litres per second to cubic metres per second:

divide the L/s by 1000

convert 1500 L/s to m3/s. (Divide the litres per second by 1000.)

1500 L/s 1000 = 1.5 m3/s.



Centrifugal pump setsA centrifugal pump set consists of a centrifugal pump, motor, base and coupling.

They have applications that range from small domestic pressure pumps and swimming pool pumps made in plastics, to high pressure process pumps for oil refineries and very large machines for water, sewerage and wastewater treatment. Vertical multi-stage pumps for ground-water pumping from boreholes and for other similar applications, are widely used. Slurry pumps for abrasive solids-handling are supplied to the local mining industry and to overseas miners.

Centrifugal pumps are very simple and consist of a casing (known as the volute) inside which an impeller is mounted on a rotating shaft that is supported by bearings. Where the shaft passes through the pump casing the water is prevented from leaking out by a shaft seal.

The diagram below shows a sketch of a centrifugal pump.

Centrifugal pump set

Centrifugal pumps supply a relatively smooth flow of water across a variety of operating conditions. This makes them suitable for most pumping applications. Some of the many applications where centrifugal pumps can be used include: circulating water pumping sewerage well pumps fire fighting pumps.

How does the centrifugal pump work?Imagine swinging a full bucket of water on the end of a string in a circle over your head.

The water is kept in the bucket by centrifugal force.

The impeller in a centrifugal pump spins the water around and centrifugal force causes the water to be thrown outward, the same as in the bucket.


Inlet

Outlet

Pump shaft for connection to drive device


The casing or volute on the pump is spiral shaped to channel the water around to the exit or discharge point. This means the pump must rotate in the correct direction.

Note

Ask your trainer or supervisor to show you brochures of different pump types and their applications.



Multi-stage pump setsAs the name suggests multi-stage centrifugal pump sets are centrifugal pumps with a number of impellers in series. A three stage centrifugal pump would have three impellers inside it.

The water enters the first stage impeller and is flung outwards. It then passes through a passageway to enter the second stage impeller and again is flung outwards. It again passes through a passageway to enter the third and final impeller which discharges the water out the discharge port.

Three impeller stages

Multi-stage pumps are manufactured in vertical and horizontal packages.

There could be as few as two impellers and as many as 15 or 16 impellers in series. The number of impellers in a multi-stage pump will depend on the application and pressure requirements.

The multi-stage pumps are used where the head is very high. This means a high amount of water pressure.

Examples of multistage pumps



Submersible pump sets

Submersible pumps are generally closed coupled pump and motor assemblies mounted inside of waterproof housing. The housing has three connections the inlet and outlet water connections, and the electrical connections.

Multi-stage borehole pumps

Submersible drainage pump

Submersible pumps can be used in all pumping applications from foundation dewatering, raising water from wells to pumping sewage.


Float switch

Pump

Motor

Outlet


The whole assembly can be lowered into a sump or a well.

Submersible pump in a sump or well



Types of motors

This pump may be driven by the same types of electric motor or engine as a normal centrifugal pump.

As usual the motor power rating must be suited to the pump and application. It is normal for pump manufacturers to select a suitable pump motor to suit the customers’ requirements.

Connections

Submersible pumps have the motor close coupled to the pump and the motor is housed in a waterproof housing or the motor windings are encased in an epoxy resin to make it waterproof.

The pipe connections will vary, however the pump has a hose connection for the discharge water.

The borehole pump has a screwed connection located on the top of the pump as shown in the bore or well.

Controls

Submersible pumps use a variety of controls depending on the pump size and application.

Small submersible pumps usually have an inbuilt float control system. This will automatically switch on the pump when the water level increases or decreases to a preset height and switch it off again when the water level falls to the predetermined level.

Larger submersible pumps have separate liquid level controllers that sense the water height and switch the pump on and off as required. Separate liquid level sensors usually incorporate level alarms to ring a bell or flash a light if the water level reaches critical levels.

Sophisticated controls used on submersible pumps will monitor the pumps operation, protect it from lightning and protect the pump from overloading.

Pump base

Submersible pumps do not require special bases to be constructed. They do however require a level concrete base on which to sit.

The diagram shows a submersible pump mounted in a sump or pit.

The pump is fitted with a mesh screen to prevent solids from entering and damaging or blocking the pump.



Submersible pump mounted in sump or pit

Types of motors

Centrifugal and multi-stage centrifugal pump sets may be driven by any form of motor or engine. However the electric motor is the most convenient method of driving a pump.

Electric motors

The electricity network throughout Australia is supplied at two voltages. These are 240 volts and 415 volts and have a frequency of 50 Hertz. The electricity supply is often referred to as alternating current or AC. An electrician should connect an electric motor. You should be aware that if the motor is wired in correctly it can force the pump in the wrong direction. This can be dangerous so make sure you and the electrician are sure which way the wiring is set.

The electric motor used on most pump applications is called a squirrel cage induction motor.

The main type of casing or enclosures used on pumps is a totally enclosed fan cooled (TEFC). The casing has no openings and the motor is cooled by an external fan on the non-drive end of the motor shaft. The motor is not air tight or waterproof. It is normally used in dirty, oily or damp applications.



Connections

Centrifugal and multi-stage centrifugal pump sets can be connected to the motor by the following connection types:

close coupled

long coupled

belt driven.

Close coupled

Close coupled pumps have a flange mounted electric motor bolted directly onto the pump back casing. Close coupled pump and motor shaft are directly connected. The pump and motor alignment are fixed. Its compact size saves space and is simple to mount. Centrifugal pump bearings, housing and shaft seal can be serviced or repaired without disturbing the pipe connections.

Closed coupled connection

Long coupled

Long coupled pumps are connected to the motor shaft with flexible couplings and spacer pieces. This type must be mounted on a frame or base usually they have a larger capacity. Long coupled centrifugal pump bases need to be carefully levelled, fixed and grouted. They are used where the pump motor is too large or heavy to move. The coupling spacer is removable to allow the pump to be serviced or repaired.

Long coupled connection


Outlet

Inlet

Motor

Motor

CouplingPump

Base


Belt driven

Belt driven pump speeds can be varied to match the required flow rate requirements of the job. The pump base needs careful levelling, fixing and grouting between from 3% to 5% extra power is required to overcome belt friction losses.

Belt driven connection

Controls

Pumps can be controlled by almost any form of electrical switch from a manually operated switch to a full computer-controlled building management system.

A few of the many different controlling devices used on pumps include the following.

Time clocks. Switch pumps on or off at set times each day.

Pressure switches. Measure a falling or increasing pressure and turn the pump on or off.

Thermostats. Measure temperature and switch the pump on or off as heating or cooling is required.

Manual switches. Pump is switched on the end of manually as required.

Float switches. Sense a change in water level and switch the pump on when the water level increases and switch the pump off when the water level decreases.

Alignment processes

When a pump and motor assembly are mounted on the pump base in the factory the pump shaft and motor shaft are carefully aligned. This alignment is usually disturbed during transportation of the pump to the site. You must carefully check this alignment when the pump is installed.


MotorPump

Belt

Base

Pulley


To check the alignment you should use a dial indicator gauge mounted on one half of the coupling assembly as shown in the diagrams that follow.

When a pump and motor are assembled in the factory the base plate is placed on a flat surface and the motor and pump are aligned so the shafts run true to one another.

When the pump assembly is mounted in place on site, this alignment must be checked and readjusted if it has moved. If it is not checked and the pump is started, the pump coupling, bearings and shaft seal may be damaged.

The alignment must be checked for radial and angular displacement as shown in the diagrams below.

Radial displacement/angular displacement/aligned correctly

Lining up a pump and motor

Dial indicator gauges are the easiest way of checking for misalignment.

To check for angular misalignment these steps should be followed.

Bolt the pump tightly onto the baseplate, making sure that the pump’s feet and baseplate are clean and free from burrs.

Loosely bolt the motor to the baseplate making sure motor feet and baseplate are clean and free from burrs.

Clamp the dial indicator gauge to the pump half of the coupling.

Place a chalk mark on the motor half of the coupling and place the button of the dial gauge on the chalk mark, on the machine face of the motor coupling.

Set the dial indicator at zero.

Rotate both coupling halves through 40° keeping the button of the dial indicator gauge on the chalk mark.

Check the reading on the dial indicator gauge and write it down.

Rotate both coupling halves through a further 45° keeping the button on the dial indicator gauge on the chalk mark.

Once again check the reading on the dial indicator gauge and write it down.

Rotate both coupling halves again through a further 45° keeping the button of the dial indicator gauge on the chalk mark.




Rotate both coupling halves through a further 45°. This should bring back to the starting point and the dial indicator should read zero. If it does not, repeat the previous steps being careful not to bump or move the dial indicator gauge during the process.

Compare the four readings taken from the dial indicator gauge. The readings should be within + or - 0.025 mm. of each other. If they are not the motor needs to be moved and the process repeated until the alignment is true and correct.

Chalk mark on the motor coupling with dial set at zero

To check for parallel alignment

This procedure is very similar to the angular misalignment check. However, the dial indicator button rests on the outside circumference of the motor coupling half.

The following steps should be taken to check for parallel alignment.


Loosely bolt motor to the baseplate making sure motor feet and baseplate are clean and free from burrs.

Clamp the dial indicator gauge to the pump half of the coupling.

Place a chalk mark on the motor half of the coupling and place the button of the dial gauge on this chalk mark on the outer circumference of the motor coupling.

Set the dial indicator at zero.

Rotate both coupling halves through 45° keeping the button of the dial indicator gauge on the chalk mark.

Check the reading on the dial indicator gauge and write it down.

Rotate both coupling halves through a further 45° keeping the button on the dial indicator gauge on the chalk mark.


Rotate both coupling halves again through a further 45° keeping the button on the dial indicator gauge on the chalk mark.


ClampGauge

Motor Pump



Rotate both coupling halves through a further 45°. This should bring back to the starting point and the dial indicator should read zero. If it does not, repeat the previous steps being careful not to bump or move the dial indicator gauge during the process.

Compare the four readings taken from the dial indicator gauge. The readings should be within + or - 0.025 mm. of each other. If they are not the motor needs to be moved (left to right and or up and down) and the process repeated until the alignment is true and correct.

Mark outer circumference of motor coupling

Note

To lift the motor, shims of the appropriate thickness are placed under the motor feet. To lower the motor, shims of the appropriate thickness are placed under the pump feet.

Note

The correct alignment tolerances for the coupling used on each pump set must be obtained from the manufacturer of the coupling.

Once the alignment is complete the motor and pump should be tightened down on the baseplate and the alignment rechecked.

Vee belt alignment

Belt driven pumps need to have the motor and pump pulleys carefully aligned.

Failure to align the pump and motor pulleys will result in an early failure of the vee belts.



A string line is all that is needed to align the pump and motor pulleys. The alignment procedure is as follows.


Loosely bolt the motor to the baseplate making sure motor feet and baseplate are clean and free from burrs.

With the string line pulled taut, hold it so it just touches right across the face of the pump pulley and passes across the face of the motor pulley.

Observe the string line where it passes across the face of the motor pulley and adjust the motor until the string line evenly touches across the face of the motor pulley. As a general rule for vee belt and pulley alignment the misalignment should not exceed + or - 5 mm per 500 mm.

Fit the vee belts over the two pulleys and adjust the belt tension as described below. Using the string line recheck the alignment of the two pulleys. If they have not moved, bolt the motor tightly onto the baseplate.

Aligning a vee belt

Belt tensioning

The correct tension for a vee belt is the lowest tension at which the belt will transmit power when the drive is at full load.

Experienced personnel check belt tension using their finger, however it is recommended that a tension tester be used to set the vee belt tension.

If too little tension is applied the vee belt may slip and if the tension is too high the motor and pump bearings will rapidly fail.

Contact the belt manufacturer or supplier to obtain the correct tension and tensioning procedure for the belts supplied with the pump set.

Note

It is important for your safety and the safety of others that you correctly refit the belt guard before starting the motor.



Pump base

As mentioned previously when the motor and pump set are assembled in the factory the motor and pump shafts are carefully aligned. When bolting the pump base onto the foundation, this alignment must be carefully kept by placing metal spacers between the steel pump set base and the concrete foundation.

Foundations need to support the pump and motor assembly and, if necessary, prevent vibration and noise transmission through the building.

To adequately support the pump and motor assembly the concrete foundation should be at least a rectangular block. It should also have a mass of about five times the weight of the pump and motor assembly. The pump base is bolted onto the concrete foundation block.

Concrete foundation supporting pump and motor assembly

On small pump sets the steel spacers are usually good enough. However on larger pump sets a concrete slurry will need to be poured into the gap (approximately 20 mm to 40 mm) between the steel base and the concrete foundation. This is known as grouting in the pump.

Grouting in a pump will stop the coupling alignment from altering over time

When a pump set is to be installed onto a solid foundation the following steps should be followed.

Accurately locate the position and orientation of the pump set and mark it on the floor.

Set out the foundation block using the pump set dimensions. The foundation should be at least 200 mm longer and wider than the pump set base dimensions. These are available from the manufacturer’s data sheet or by measuring the actual pump set base.

Fill the foundation with concrete, level off the surface and allow it to cure.

Lift the pump set onto the foundation using a forklift or other suitable lifting device and shim the base until the pump set is level.

Bolt the pump set firmly onto the concrete foundation using masonry anchors.



Grout in the pump set base if required. (See grouting in procedure below).

Connect suction and discharge piping so that stress and strain is not applied to the pump.

Clean the work area and pump set.

The dimensions of the foundation block must be large enough to accommodate the pump baseplate with about 100 mm to spare on each side. The pump baseplate dimensions are available from the pump manufacturer.

A typical set of dimensions may look like the following.

Overall length lo 685 mm

Length of baseplate l1 655 mm

Distance between bolt holes l2 520 mm

Distance of bolt hole from end of baseplate k 55 mm

Centre of discharge flange to end of pump (suction flange) a 80 mm

Width of baseplate b0 381 mm

Bolt hole spacing b1 315 mm

Thickness of bolt down bracket h2 10 mm

Height or centre of suction flange h1 191 mm

Height of pump set h0 331 mm

If you were setting out a foundation block for this pump set, the dimensions of the foundation block would need to be:

Length l1 (655 mm) + 200 mm = 855 mm

Width b0 (381 mm) + 200 mm = 581 mm.



Pump sets

Pump set dimensions



Grouting in a pump set

Once the pump set is levelled and bolted to the foundation it needs to be grouted in to prevent any movement and alteration to the pump coupling alignment.

When a pump set is to be grouted in the gap between the base and the foundation must be between 20 mm and 40 mm. This allows the grout mixture to easily enter and fill the space.

To grout in a pump set that has been levelled and bolted down (as detailed previously) the following steps are followed.

Build a dam around the pump set base by clamping timber against the base (use sash cramps if available).

Cover the pump set with plastic to protect its finish.

Mix a slurry of cement, sand and very fine aggregate and pour this slurry into the centre of the pump set base.

Using a suitable tool force the grout mix in between the steel pump set base and the foundation unit you are sure the gap has been completely filled.

Level off the grout inside the pump set base and allow it to cure.

Clean up any spilled grouting mix from the work area and leave the pump set clean.



Grouting space and dam

To stop noise being transmitted through the building the pump and motor assembly are mounted on a concrete filled base that is held up on four springs or resilient mounts. This assembly is known as an ‘inertia block’.

Pump mounted on a inertia block

Inertia blocks are usually made of structural steel channels filled with concrete which allows for the easy attachment of mounts and machines. Inertia blocks are at least 150 mm thick, are very rigid and have a weight at least equal to the weight of the pump and motor combined.

Inertia blocks used for pumps with a reciprocating engine must have a weight of several times the combined pump and motor assembly to adequately prevent vibration from being transmitted to the building. These inertia blocks must be specially designed for each application by a noise control engineer.

Inertia blocks used with centrifugal pumps and electric motors are supplied by the pump manufacturers to suit their individual pumps.

When a pump set is ordered the inertia block must be ordered at the same time to suit the pump set.



When the inertia block is delivered to site you will need to:

construct a concrete plinth that is at least 100 mm wider and 100 m longer than the inertia base

fill the inertia block with concrete that has a minimum density of 2100 kg/m3 and smooth off the top surface of the concrete

lift the pump set using a forklift or other lifting device, level it using shims and bolt it down tightly onto the inertia base using suitable masonry anchors

lift the pump set with attached inertia base and fit the spring mounts. Pay attention to the spring mounts as they may have different spring ratings at each end. Check this with the pump supplier

connect suction and discharge piping so that stress and strain is not applied to the pump

check the inertia base is free to operate by cleaning any debris and rubbish from between the inertia base and the concrete foundation block.

Fuel tanks and supply systems

The pump installation may require the installation of fuel tanks and fuel supply systems.

The fuel tank shall comply with AS1692 Tanks for flammable and combustible liquids.

Where the fuel tank is supplied separately to the motor the tank should be mounted on a separate frame with vibration resistant mounts if it is mounted on the pump baseplate.

Assembly

A centrifugal pump is used in a reticulated system such as a heating water or cooling water system. The assembly consists of:

the suction side: suction gate valve suction strainer flexible coupling suction gauge

the discharge side: discharge gauge flexible coupling check valve gate valve.



Pump in a reticulated system

The gate valves are used to isolate the pump assembly from the water supply when any of the components require servicing or replacement.

Note

If throttling of water flow is required it must be carried out using the discharge valve not the suction valve. In this case a globe valve or similar throttling valve must be used as the discharge valve instead of a gate valve.

The suction line strainer catches any metal filings or other particles before they pass into the pump. This strainer must be cleaned regularly.

The flexible coupling allows for movement in the pipework and isolates vibrations created by the pump.

The check valve is required where a reverse flow may occur such as when pumps are pumping in parallel or when pumping to a header tank.

Worksheet




Testing

When you have finished assembling the pump you need to check that the system is free from leaks, the flow is correct and that the assembly complies with the job specifications.

To check the system is free from leaks you need to hydrostatically pressure test the piping system in accordance with the job specification or AS/NZS3500.1 Section 13 Testing and Commissioning.

This section of the standard calls for a test pressure of 1500 kPa to be maintained for a period of 30 minutes.

To hydrostatically test the piping and pump you will need to obtain a Hydrostatic test bucket (commonly called a test bucket).

Hydrostatic test buckets consist of:

a hand operated piston pump

a water reservoir

two isolating valves.

Hydrostatic test bucket

To test a piping system for leaks you need to take the following steps.

Check the system components and find out the maximum pressure they can withstand. (You may not exceed the lowest of these pressures unless the component is isolated from the pressure test.)

Isolate the pump and section of pipe work to be tested.

Connect the test bucket to the section to be tested and fill it with water.

Fill the system with water. It is very important you take a lot of care to remove all the air from the system.

Close the drain valve and open the system valve on the test bucket.

Gently pump the hand operated piston pump and carefully watch the system pressure. If all the air has been removed from the system it should only take a pump or two to raise the pressure to about the half way point.

Check the pump and pipe work for water leaks. If you find any, drain the system and repair them before continuing with the test.

Pump the system to the test pressure. This will be twice the working pressure of the system or 1500 kPa depending on the job specifications.

Close the system isolating valve on the test bucket and record the pressure reading on the pressure gauge.



Observe this pressure for 30 minutes and record any fall in pressure. If the pressure falls it means you have a leak.

Drain and flush the system if the pressure test is completed correctly.

If the piping system is complete open any valves you closed prior to the pressure test and fill the system with water.

The system should now be ready to start.

Before starting the pump there are several points you must check. Failure to do this could result in damage to the pump.

Electrical wiring. This must be carried out by a registered electrician and must comply with all codes.

Direction of rotation. Remove the coupling between the motor and the pump and start the motor. Confirm that the direction of rotation is the same as that indicated on the pump casing. If correct refit the coupling.

Pump gland. There are two types of shaft seals used on pumps mechanical seal and packed glands. Mechanical seals do not drip. Packed glands (stuffing boxes) require a drip rate of approximately 20 drips per

minute. If it does not drip, the gland instantly over heats and destroys itself and the pump shaft.

Priming the pump. Do not operate a pump dry. Before you operate the pump you must prime it with clean water. The pump must be completely filled with water before it is switched on.

Other considerations. Carefully read the manufacturer’s installation and starting instructions before you switch the pump on.

Next you will need to test the pump set and record the test data. This test also needs to be in accordance with the specification.

Testing the pump flow requires specialised knowledge not covered in this module. However if you have all the information listed below you will be able to contact the pump manufacturer and they can use this information to check the flow rate of the pump.

To test the performance of the pump for correct flow and operation you will need to record the:

operating pressures at both the suction and discharge sides of the pump

flow rate required and application

pump data from name plate.



Trouble shooting

Listed are some common causes for poor pump performance.

No water pumped or pump is not delivering enough water.

Suction line and pump casing not properly primed (air in the system).

Speed too low (wrong motor, pulleys or engine is revving too slowly).

Discharge head too high (check the friction head).

Suction lift too great. If pumping from a well or pit the maximum practical distance between the water level and the pump inlet is about 8 metres.

Wrong direction of rotation. (Check the rotation direction arrow on the pump casing.)

Impeller, suction pipe or foot valve clogged (check strainer in suction line).

Air leak in suction line (should have been found during pressure testing).

Suction and or discharge piping is too small in diameter.

Pump operates for a while then stops pumping.

Pump not properly primed.

Air pocket in suction line.

Air leak in suction line.

Suction strainer blocked.

Pump is noisy when operating.

Pump and motor out of alignment. Check pump alignment.

Foreign matter rotating with impeller. Visually inspect pump suction inlet port.

Pump is cavitating. (Pump suction lift too great.)

Pump vibrates during operation.

Pump and motor out of alignment.

Foundation insufficiently rigid.

Unsupported suction or discharge piping.

Stuffing box becomes hot.

Packing too tight or not dripping enough water. (Approximately 20 drips per minute required on packed gland seals.)



Clean upAs with any job, you should allow time to clean up afterwards. Clean up includes:

cleaning, maintenance and storage of your tools and equipment. Equipment should be cleaned and oiled after each job and before packing away. Failure to correctly maintain your tools and equipment will mean costly replacements next time you require your tools.

clearing the worksite. All sites require the installer to leave the site clean and free of debris and rubbish. This means that everyone will be working in a safe, clean environment and can move around the job without fear of tripping over anything and causing injury.

sorting left over materials for storage, recycling and or disposal. Store in a manner that will not cause damage or deterioration to any useful excess materials. Recyclable material should be sorted into like material and disposed of correctly. Rubbish must be disposed of in the correct manner where it will not create contamination problems.

safely disposing of waste materials. Waste materials like cement, concrete and grouting mix need to be disposed of correctly. Do not pour wet cement mixtures into drains or sewers because you will cause blockages that will be expensive to repair. Other waste like sweepings, off-cuts, rags, paper and packaging material must be disposed of in suitable rubbish bins.

Worksheet




Name:………………………………………………………

Worksheet

CPCPWT3025A - Install water pumpsets

The student should complete this worksheet before attempting the practical installation.

The worksheet may form part of the assessment and should be checked and signed off by your trainer or supervisor.

1. Name the pressure units used with pumps.

2. Name the flow units used with pumps and explain where each is usually used.

3. Describe the term used to define ‘the vertical height in metres of water’ a pump must raise water.



4. Complete the following table.

Metres head of water

Cold water (4ºC)9.81 kPa/m

Hot water (100ºC)9.4 kPa/m

1 ………..kPa ………..kPa ………..kPa

4 ………..kPa ………..kPa ………..kPa

17 ………..kPa ………..kPa ………..kPa

50 ………..kPa ………..kPa ………..kPa

5. Complete the conversion table.

Metres head of water

Approximate conversion

True conversion True conversion

10 kPa/ metre Cold water (4oC) 9.81 kPa/m

Hot water (100oC) 9.4 kPa/m

3 KPa KPa KPa

7 KPa KPa KPa

10 KPa KPa KPa

25 KPa KPa kPa

6. Complete the following table.

Convert Conversion factor Answer

1.2 m3/sX or ÷

By

1000

……..L/s

0.183 m3/s ……..L/s

10 L/s ……..m3/s

190 L/s ……..m3/s



7. List the PPE you will require when installing a pump set.

8. List four main components that make up a centrifugal pump set.

9. Briefly describe how a centrifugal pump works.

10. List four types of pump sets discussed in this module.



11. List the two pump sets that require careful alignment of the motor and pump shafts couplings.

12. Describe the steps required to align the pump and motor for angular alignment.

13. Describe the steps required to align the pump and motor for parallel alignment.



14. Explain why a pump is grouted in.

15. Explain why an inertia base is used and from where it is purchased.

16. In the space below sketch the suction and discharge lines of a pump showing the correct positions of the valves and fittings.

17. Explain the term ‘multi-stage pump’.



18. Where would a submersible pump be used?

19. In the space below sketch a ‘test bucket’ and list the steps necessary to correctly pressure test a system.

20. Why is it necessary to prime a pump before switching it on?

21. What would the symptoms be when you started a pump and it was running in the wrong direction?



22. Explain why having an insufficiently rigid foundation could cause the pump to vibrate during operation.

23. List three possible causes of a noisy pump during operation?

24. Why is it necessary for a packed gland type pump shaft seal to leak water during operation and how many drips should there be per minute?

Trainer or Supervisor’s Signature:…………………………………

Date of completion:…………………….



Name:…….………………………………………………

Practical applicationCPCPWT3025A - Install water pumpsets

Your trainer or supervisor will now work with you to demonstrate and explain Installing water pump sets.

The following points will be covered:

Drawings and specifications are obtained from job supervisor

WHS requirements associated with installing water pump sets, and the workplace environment, are adhered to throughout the work

Quality assurance requirements are identified and adhered to in accordance with workplace requirements

Tasks are planned and sequenced in conjunction with others involved in or affected by the work

Tools and equipment for installing water pump sets, including personal safety equipment, are selected and checked for serviceability

Work area is prepared to support the efficient installation of water pump sets

Location of pump is determined following site inspection

Requirements for pump base, if required, are determined from drawings and specifications

Required materials and equipment are identified and ordered or collected in accordance with workplace procedures

Materials and equipment are checked for compliance with standards, docket or order form and for acceptable condition

Pump base is set out to comply with drawings and specifications

Pump base is constructed in accordance with drawings and specifications

Pump is installed in accordance with standards, drawings and specifications and manufacturers’ instructions

If required, the fitting of fuel tanks, alignment of shafts and couplings and the use of mechanical joints are to comply with relevant specifications and manufacturers’ instructions

Pressure testing of piping system is conducted in accordance with specifications

Pump set is tested in accordance with specifications and test data is recorded in the required format



Work area is cleared and materials disposed of or recycled in accordance with State or Territory legislation and workplace procedures

Tools and equipment are cleaned, checked, maintained and stored in accordance with manufacturers’ recommendations and workplace procedures

Documentation is completed in accordance with 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:……………………



Assessment checklist

CPCPWT3025A - Install water pumpsets

Criteria Yes No

Have the worksheets been successfully completed?

Has the practical task been completed?

Have the job specification and local authorities or utilities requirements been adhered to?

Trainer or Supervisor’s Signature:…………………………………….

Date of completion:………………….


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