Cpcpfs3031a - Fabricate and Install Fire Hydrants and Hose Reel Systems

CONSTRUCTION, PLUMBING AND SERVICE

INTEGRATED FRAMEWORK

TRAINING PACKAGE

CPC08

CPCPFS3031A

FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

LEARNING GUIDE

ii © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

ACKNOWLEDGEMENTS

National Plumbing Services Training Advisory Group

Plumbing Industry Commission Victoria

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 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.

Contents What is this resource about?...... 1 How do I use this resource?...... 1 Flexible Delivery...... 1 What do I have to do?...... 1 Fabricate and install fire hydrant and hose reel systems...... 2 Unit Descriptor...... 2 Element...... 2 Performance Criteria...... 2 Required knowledge...... 5 How will I be assessed?...... 5 Are there any pre-requisites?...... 5 What other resources will I need?...... 5 Texts...... 5 Web sites...... 5 Video or audio cassettes...... 5 Safety...... 6 Workplace environment and safety...... 6 Introduction...... 7 Hydrant systems...... 7 Components of hydrant and hose reel systems...... 10 Hydrant...... 10 Booster connection...... 10 Block plan...... 10 Thrust block...... 11 Isolating valve...... 11 Pressure gauge...... 12 Cabinet...... 12 Valves...... 14 Gate valve...... 14 Reflux valve...... 15 Butterfly valve...... 15 Globe valve (Ball valve)...... 16 iv © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Block plan for hydrant system...... 16 Emergency instructions...... 17 Location plate...... 17 Components of the hydrant system...... 17 Structural systems, building materials and building services...... 17 Pipe supports, fixing devices and brackets...... 18 Trench support systems...... 21 Testing the installation...... 22 Regulations...... 23 Quality assurance...... 24 Plan work activities...... 25 Site inspections...... 26 First site inspection...... 26 In progress site inspection...... 26 Final site inspection...... 26 Others involved in the work...... 27 Determine installation requirements...... 27 Selecting appropriate materials...... 27 Using appropriate materials...... 29 Quantities...... 29 Ordering and checking the delivery...... 29 Tools and equipment...... 30 Types of lifting devices and scaffolds...... 31 Mobile scaffolds...... 32 Installation...... 33 Moving and handling materials...... 33 Setting out...... 34 Underground pipe work...... 35 Vertical pipe work...... 35 Horizontal pipe work...... 37 Pipe supports and fixings...... 38 Pipe joints...... 38 Fire hose reels...... 39 Location...... 39

Mounting...... 39 Water supply...... 40 Commissioning procedure...... 40 Installing the hydrant main...... 41 Testing the installation...... 42 Air test...... 42 Hydraulic test...... 43 Other testing...... 43 Commissioning the system...... 43 Combined system...... 43 Hydrant system...... 44 Recording data...... 44 Clean up...... 44 Work site...... 44 Tools and equipment...... 45 Worksheet...... 46 Practical application...... 55 Assessment checklist...... 57

vi © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

What is this resource about?

Welcome to CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems. This resource will help you gain the skills and knowledge necessary to demonstrate competence in this unit.

How do I use this resource?

This resource is divided into four main sections:  A learning unit, which contains background information on CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems  Worksheets, which prepare you for the practical application  Practical application, which allows you to experience fabricating and installing fire hydrants and hose reel systems  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 fabricating and installing fire hydrants and hose reel systems  read the assessment checklist together with the assessment sheets  complete the assessment.

Learning Resources are not intended to be the only source of information nor are they intended to be an exhaustive form of instruction.

Flexible Delivery

The Trainer or Supervisor may adapt and deliver this Learning Resource to suit people from diverse backgrounds to meet equity principles and conform to Legislative policies.

What do I have to do?

To demonstrate competence in this unit you will be required to show the level of skills and knowledge for each of the elements involved in Fabricate and install fire hydrants and hose reel systems:  Plan work activities  Determine installation requirements  Install and test system  Clean up.

If you are unsure of the meaning of these elements you should read the performance criteria on the following page.

CPCPFS3031A Fabricate and install fire hydrant and hose reel systems Unit Descriptor This unit of competency specifies the outcomes required to fabricate and install fire hydrant and hose reel systems.

Element Performance Criteria Elements define the Performance criteria describe the performance needed to essential outcomes of a demonstrate achievement of the element. Where bold unit of competency. 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. 1 Prepare for work 1.1 Design drawings and job specifications are obtained from relevant authority 1.2 Work health and safety (WHS) and environmental requirements associated with fabricating and installing fire hydrant and hose reel systems 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 1.5 Tools and equipment for fabricating and installing fire hydrant and hose reel systems, including personal protective equipment, are selected and checked for serviceability 1.6 Work area is prepared to support efficient fabrication and installation of fire hydrant and hose reel systems

2 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

2 Identify installation 2.1 System requirements are identified from job design criteria, requirements specifications and standards 2.2 Piping and materials are selected according to standards, design drawings, job specifications and authorities' requirements 2.3 Below ground piping and materials are checked to ensure compliance with standards and authorities' requirements 2.4 Required materials and equipment are identified, ordered and collected according to workplace procedures 2.5 Materials and equipment are checked for compliance with standards, docket or order form and for acceptable condition 3 Fabricate, install and 3.1 System is set out according to plans, specifications and job test system instructions 3.2 Pipe supports and fixings are installed to plans and manufacturer specifications 3.3 Piping and materials are installed according to design drawings, job specifications and standards 3.4 Pipework is connected to the water source according to standards and authorities' requirements 3.5 Piping system is tested according to standards and job specifications 3.6 Test data is recorded in format required by job specifications and quality assurance procedures 3.7 Sustainability principles and concepts are applied to installation process 4 Clean up 4.1 Work area is cleared and materials are disposed of, reused or recycled according to legislation, 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 workplace requirements

Required knowledge Required knowledge for this unit is:  characteristics and application of different pipe fittings and fixture supports, including fixing and joining techniques

 excavation processes and procedures

 job safety analysis (JSA) and safe work method statements (SWMS)

 levelling and alignment processes

 materials and assemblies relevant to installation of fire hydrant and hose reel systems

 pressure test systems and procedures

 process of fabricating and installing fire hydrant and hose reel systems

 relevant statutory and authority requirements related to fabricating and installing fire hydrant and hose reel systems

 SI system of measurements 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 http://training.gov.au/Search/Training? searchTitleOrCode=&nrtSearchSubmit=Search&includeSupersededData=true&includeSupersededDat a=false&homePage=true&javaScriptEnabled=true&typeAllTrainingComponents=true

4 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

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 in Fabricate and install fire hydrants and hose reel systems.

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 CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems you must have successfully completed the following pre-requisite:

 CPCPCM2043A – Carry out WHS requirements

It is recommended that prior to commencing CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems you should have successfully completed the following competencies:  BCGCM2003B – Install trench support

What other resources will I need?

To assist you the following resources have been suggested and should be available for you to do this competency:

Texts  AS2118 Automatic Fire Sprinkler Systems.  AS4118 Fire Sprinkler System Components  AS2419 Fire Hydrant Installations.  AS2441 Installation of Hose Reels.  AS/NZS3500 – Plumbing and drainage.  Plumbing code of Australia.  State or Territory regulations may override this learning guide.

Web sites

Video or audio cassettes

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 Operators must ensure they are familiar with all operating procedures and elevating work detailed by manufacturers in the elevated working platforms operators’ platforms (EWP) 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.

6 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Introduction

In this unit you will look at the fabrication and installation of fire hydrants and hose reel systems, which are used for fire protection. Hydrants and hose reels may be on a separate line, such as in a warehouse or factory installation, or they may be combined with the sprinkler system, as in a multi- story building.

Hydrant systems

A separate hydrant system can be made up of a water supply, in the form of a ring main, with hydrants at the required locations and branches off to hose reels within the building to the requirements of AS2419.1. The hydrant main will also have fire brigade booster and suction connections. The system will be controlled by a variety of valves, fittings, gauges and switches according to the drawings and the specification.

Hydrant ring main

Hydrant systems vary according to the occupancy, character and construction parameters of the site but in general the following apply.  Where possible external hydrants should be used to cover the whole area.  External coverage is based on using a 60 m hose with a 10 m hose stream connected to a dual hydrant or a 30 m hose and 10 m hose stream connected to a single hydrant.

 With dual hydrants two outlets are connected to one hose to provide the water for a 60 m hose.  In multi storey buildings, one storey down and multiple storeys up can be covered, provided: - no more than 30 m of hose is laid in a stair way - a minimum of 1 m of hose projects into the area being covered by the hose stream.

 Where internal hydrants are used to protect parts of the building, all points must be covered by a 10 m hose stream from a 30 m hose, connected across the floor to the hydrant.  For roof areas that have occupant access, the area of access must be covered by a 10 m stream from a 30 m hose.  Open yards must be covered by a 60 m hose and 10 m water stream.  Hydrants should be in accessible locations at least 10 m from any building and with hard standing areas for pump appliance vehicles.

Note For more detail on system design requirements refer to AS2419.1 Section 4.

Before you can fabricate and install fire hydrants and hose reel systems there are several issues that you must know including:  properties of piping materials relating to water pressure and flow rates  components of hydrant and hose reel systems  structural systems, building materials and building services  pipe supports, fixing devices and brackets  testing and commissioning piping for fire protection systems  trench support systems  regulations  quality assurance (QA)  planning.

8 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

 For fire hydrant systems refer to AS2419.1 section 10: Fire hydrant systems will be tested to a minimum of 1700 kPa or as specified.

Fire hydrants and hose reel assemblies should be fabricated and installed as detailed on the drawings. The drawings will show the size, type and location of all the hydrants, boost and suction points, valves, components and associated pipe work making up the system.

It is common practice for hydrant assemblies, boost points, hose reels, pipe sections and similar components to come to the site pre-fabricated. They are then located and assembled to suit the drawings and the specification.

Your trainer or supervisor will provide you with full scale specifications, block plans and locations applicable to this learning guide.

Fire hydrant specifications

Components of hydrant and hose reel systems

Pipes

Pipes for hydrant mains are generally 100 mm or more in nominal diameter and made of steel, galvanised steel, ductile iron, cast iron or copper as described in AS2419.1 section 6. Above or below ground pipe work should be protected from physical damage such as from earth movement and traffic damage. Where necessary pipes should be protected from corrosion. This may include:  galvanising  coating  wrapping  cement lining.

Hydrant

A hydrant is a valved connection point to a water supply line, designed to allow fire fighters to take water for fire fighting.

Booster connection

A booster connection is a valved connection point designed to allow the fire brigade to pump water into a hydrant system to boost pressure.

Block plan

A block plan is a plan of the risk (site) that clearly indicates the location of all mains, hydrants and isolating valves making up the system. The block plan is normally located in the hydrant booster cabinet or at the control valve.

For a block plan, hydrant system, refer AS2419.1 Clause 2.3.

10 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Hydrant block plan

Thrust block

A thrust block is normally made of mass concrete, poured in-situ after the pipe work has been installed. Thrust blocks are normally installed at bends or fittings where the pressure in the pipes may cause movement in the backfill or bedding. Thrust blocks should be sized and located as shown on the design drawings.

Isolating valve

An isolating valve is downstream of the water authority valve, normally open and strapped or locked in the normal operating position. A hydrant system must have an isolating valve between the source of supply and the hydrant system and in other locations as defined in AS2419.1 Section 8. Additional isolation valves are located so that any ring or pressure zone can be isolated in 25% increments with a minimum of 50% of hydrants available to protect each fire compartment.

Worksheet Now go to the Worksheet and answer Questions 1 – 6.

Pressure gauge

Pressure gauges used in hydrant systems must comply with AS2419.1 Section 9. The gauge must have a scale reading 125% greater than the hydrostatic test pressure at the gauge location, a dial face not less than 65 mm. The gauge must be installed with a gauge cock to permit removal for testing.

Cabinet

Internal or external cabinets may be required to house fire hydrants and booster connections or for hose reels. The layout and dimensions of the cabinets must comply with AS2429.1 section 7. Cabinets protect equipment from the weather, unauthorised interference and vandalism.

Note The cabinet must be lockable, as specified, and clearly labelled FIRE HYDRANT or FIRE HYDRANT – HOSE REEL or HYDRANT -BOOSTER as appropriate.

Booster cabinet

External cabinets should be on a concrete plinth and have legs providing a minimum clearance of 50 mm. A plinth is a raised concrete base or pad that stands above the surrounding ground level. Internal cabinets and recesses must have a minimum 40mm fall from the back to the front.

12 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Hard standing area

This is an area provided to allow plant, vehicles or equipment to stand, without becoming bogged or stuck. The area would typically be surfaced with compacted crushed rock, concrete or bitumen.

Fire hydrant and hose reel systems

A typical fixed fire protection system may be made up of the following.  Non return valves, control valves, including isolation valves.  Piping systems including use of pumps.  Hydrants and hose reels.  Drains.  Standard symbols which are used to show common components of the fire hydrant and hose reel system. A legend of the symbols used will appear on the drawings. Sample symbols are as follows.

Legend of symbols

Valves

All fire protection systems include a range of valves and associated devices. Therefore it is necessary to be able to identify a range of valves in common use and the standard symbols used to denote them on drawings.

A valve is a device used to control flow in pipes. In normal practice an ‘open’ valve allows flow and a ‘shut’ valve stops flow. There are many types of valves and further variations of each type. The most common types used in sprinkler fitting are:  gate valve  Non return valve  butterfly valve

Gate valve

The main control valve is normally a gate valve fitted with a rising spindle or stem. When the valve is closed the spindle is flush with the hand wheel. When the valve is open the spindle or stem projects through the hand wheel. This gives an immediate visual signal to the operator, fire brigade or others that the valves are open or shut without having to do further checks. This is very important in the event of fire. A gate valve is slow to open and shut but very secure when closed.

Gate valve

14 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Non return valve

(Spring check valve or swing check valve) A non-return valve allows flow in one direction only. Typically it is installed in locations that will allow the system to fill but will not allow the flow to return or drain. A non-return valve is normally installed immediately after the main control valve. A non-return valve opens automatically to allow flow in the designed direction and closes automatically if flow is reversed.

Swing check valve

Butterfly valve

This type of valve has a diaphragm like a pair of butterfly wings. It can be operated rapidly from open to shut and is very suited to power control.

Butterfly valve

(Ball valve)

The ball valve takes its name from the ball shaped closing device. A 90 degree turn of the operating lever moves the valve from fully open to fully closed. Additional tabs on the valve for use of padlock or similar devices make this valve very useful for ‘lock on’ or ‘lock off’ situations.

Ball valve

Block plan for hydrant system

The block plan must comply with AS2419.1 Section 7 and will include the following.  A layout of the site and adjacent streets.  A diagram of the water supply including details of: - mains - connections - storage tanks - pumps - hydrants - booster connections - valves.  Contractor and date of installation and extensions.  Design information such as pressures and heights.  An outline block showing requirements for combined and separate hydrant systems.

16 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Emergency instructions

Emergency instructions are also shown in the display cabinet which is attached to the wall unit.

Location plate

A location plate must be fitted to the outside of an external wall as close as possible to the main stop valve.

Worksheet Now go to the Worksheet and answer Questions 7 – 8.

Components of the hydrant system  Valves.  Cabinets.  Block plan.  Hose reels.  Fittings.

Structural systems, building materials and building services

Installation of valves and supporting pipe work will require fixing to and penetrations through walls, floors, partitions and ceilings. Therefore you will need to be familiar with common building materials such as reinforced concrete, structural steelwork, brick and block work, timber and plaster. You need to be able to recognise commonly used building materials and identify them on drawings.

Fire protection systems are commonly installed with other building services such as:  air conditioning  mechanical and electrical services  water supply  sewerage  drainage.

Air conditioning Ducting

You need to be able to identify these services on drawings and on site so clashes between systems can be avoided. Accidental cross connection between services must also be avoided, particularly with water supply.

Pipe supports, fixing devices and brackets

All pipes, valves and associated equipment, must be held securely and accurately in place in a way that allows for normal building movement. Pipes are commonly of medium or light walled steel, copper or plastic. Valves and supporting pipe work are attached to structural steel, reinforced concrete, brick or masonry and to timber as well as below ground. There are a range of proprietary brands available to suit these applications.

18 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Brackets and support systems in common use include:  u-bolts  u-hangers  bolted clamps  bolted clips  girder clips and clamps  purlin clips or clamps  angle brackets  metal straps  hanging bolts  angle trapeze  concrete thrust blocks for underground.

In supporting pipes from a structure there are five main considerations. You will need to be familiar with the relevant Australian Standards.  Can the bracket support the weight of the water filled pipe plus a safety margin?  Can the structure being connected to safely carry the weight of the filled pipes?  Does the spacing, bracket size, thickness, shape and fixing method meet the requirements of AS2419.1 Section 8?

In general the code requires that fixings are bolted or screwed to the supporting structure. Nails are not approved for fixing brackets under any circumstances. Support brackets, clamps and so on have to continue to work effectively for the life of the building. Therefore any fixing that could work loose over time is not suitable. Fixings that require wooden or plastic inserts are not suitable. Preferred fixings include:  inserts with screw fittings cast in concrete  expansion type bolts  through bolted fixings  bolted clamps or clips.

Most propriety brands of support systems have been tested and comply with the relevant Australian standard, provided they are installed to the manufacturers’ recommendations.

In practice approved proprietary support systems are used in most cases with specials being designed for unusual applications. There are a number of suppliers that provide a full range of support systems on a national or international basis. There are also local suppliers that may be able to offer all or part of the range. Your supervisor will demonstrate to you the fixing system preferred by your company as well as other systems you are likely to find in your work area.

Typical support systems

20 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Typical support system

Trench support systems

Trenches are required for below ground installation of pipes and fittings. Typically this may be for the water main connection from the Water Supply Authorities connection point, at the boundary to the control valve installation, to connect from the static storage tank within the site or for the hydrant main.

Trenches are considered to be a hazardous working environment and should not be worked in without adequate protection.

There are a number of trench support systems available to suit a range of variable trench conditions. Variable conditions that affect the choice of trench support system include the following.  The depth and width of the trench.  The nature of the material through which the trench must be excavated, rock, soil, sand, clay and various combinations and layers.  The moisture content.  The water table.  Adverse weather conditions, rain, drying winds.  Adjacent excavations.  Adjacent loading conditions such as excavated materials.  Vibration and shock loads from plant or machinery.

As a general guide the deeper the trench and the less self-supporting the sides are, then the more support the trench will require. Support systems are designed to be easy to install and dismantle yet strong enough to provide the support required. Never work in a trench outside of the support system. Below are a number of trench support systems for a range of depths and soil types.

Typical use of soldier sets in a trench

Testing the installation

Worksheet Now go to the Worksheet and answer Questions 9 – 11.

On completion of construction of a hydrant main, it should be tested to AS2419.1 Section 10. This section calls for a hydrostatic test pressure of 1700 kPa or 1.5 times the highest working pressure, whichever is the greater. The test must be applied for a minimum of two hours.

The testing procedure adopted will depend on the size and nature of a job. In general a small job may be installed and then tested. A larger job may be installed in stages with preliminary tests at the end of each stage and a full test on completion. For multi storey buildings it is often convenient to test each floor level or each zone as work progresses before testing the completed installation.

22 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Progressive testing has the advantage of finding any problems with each stage or section of the work, before final finishes, such as carpets, are installed. This will minimise potential damage and reduce costs.

Whatever testing procedure is specified for a particular job the following steps would normally be included.  Visually check the installation to see that it is complete according to the drawings and the job specification.  Complete any work shown up by visual check.  Fill installation with water and test to AS 2419.1 and the job specification. In general this will mean using the installed pump or connecting a pump for the purpose and bringing the pressure in the system up to 1700 kPa (or as specified). It is good practice to bring the system up to test pressure in increments of 200 kPa while maintaining a good visual check of the system. Once the test pressure has been reached it must be maintained for a minimum of two hours or as specified for that particular job.  remedial work before retesting the system.  Remember that a quality job is one that is safely, accurately and correctly installed first time. Repeated work costs time and money.

Should a leak occur during testing, minimise the damage by collecting the water and diverting it to waste.

For larger discharges such as from a hydrant care should be taken to divert water to a suitable drain point to avoid local damage.

Regulations

When working on any task you must observe the regulations and the WHS requirements in accordance with the State or Territory legislation. Installation of hydrants and hose reel systems must comply with AS2419.1 Fire Hydrant Installations, AS2441 Installation of Fire Hose Reels.

These regulations are in place to protect all involved in the work and those affected by the work and its application. In the case of a fire sprinkler system there are rules regarding WHS that protect the workers installing the system from loss or injury. They also protect other workers and the general public. Other regulations, such as Australian Standards and codes of practice, specify how things should be done or the quality of materials used so that the completed installation is safe and performs the task it was designed for. The Australian standards that you require are listed at the front of this module under TEXTS. They should be available through your work place or college or contact Standards Australia at the web address given. You put yourself, your workmates and others at risk of death or injury if you ignore WHS regulations.

To ignore Australian Standards and other regulations will risk failure of the system. Failure of a fire protection system could lead to death or injury or great financial loss to those involved.

You should look upon rules and regulations as part of the system that adds to good work practices to guarantee a good job.

Quality assurance

Most companies now 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.

You need to be aware of your company’s particular quality assurance requirements. A number of quality assurance issues are dealt with in the next section, ‘Plan work activities’. Most companies have or are developing quality assurance procedures that are set out in a quality assurance manual or handbook. The purpose of the manual is to guide the employee to follow good working practices that are designed to produce the quality job that has been promised to the customer.

For the installation of fire hydrant and hose reel systems, this may include policies on the following.  Planning the job.  Checking drawings and specifications.  Selecting fittings and materials.  Setting out work.  Checking dimensions.  Application of safety equipment.  Use of power tools and equipment.  Recording information.  Cleaning up the job site.

In the absence of a manual you should still apply safe and efficient work practices.

24 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Plan work activities

Planning your work may include the following steps.  Read the drawings and the specification to familiarize yourself with the work.  Check the work site against the drawings to confirm orientation and work space.  Check for normal work hazards.  Check for special hazards, such as working over machinery, high temperatures or working at height.  Identify entry and exit points and storage areas.  Confirm location of other services, such as air conditioning ducts, that may affect your work.  Plan with your supervisor, the builder or other contractors, a cooperative work strategy that avoids conflict.  Organise your equipment, such as ladders, scaffolds or scissor lifts and personal safety equipment for safe working.

Working with others is an essential part of good work practice. Others may include your supervisor, the builder, other trades, suppliers, union representatives and others.

Failure to work cooperatively with others leads to:  conflict on the job  mistakes being made  clashes over work space and storage space  damage to stored or installed material  lost, damaged or abused equipment  low esteem in the work place  delays to the job and cost overruns.

Worksheet Now go to the Worksheet and answer Questions 12 – 14.

Site inspections

First site inspection

The first site inspection will be to check the orientation of the job and to confirm the starting point of the work.  Are you on the correct site, or part of site.  Have you completed the induction process for that site.  Does the work space comply with that shown on the drawings.  Check the location of other services where relevant.  Confirm starting point and check dimensions.  Check work safety and clear area.  Confirm storage area with builder or others.

In progress site inspection

Site checks made while work is being completed confirm:  ongoing work safety  work progress  location of other services where relevant  satisfactory working with others.

Final site inspection

A final site inspection will check the following points:  work completed satisfactorily  plant, equipment and tools cleaned, maintained and stored in accordance with company policy  the site is cleaned and safe, and all rubbish removed.

26 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Others involved in the work

All construction work involves working with others. It is important to meet and discuss the job with those you need to work with. Most building sites will have an induction process that you must go through before you can work on the site. This would normally include the following.  Site specific information such as entry and exit points and procedures.  Location of all facilities including toilets and first aid.  Site specific WHS requirements and procedures.  Introduction to key personnel that you need to liaise with.  Relevant job information.

Determine installation requirements

To plan the fabrication and installation of fire hydrants and hose reels you need to gather together information from a number of sources. Some of this information will come from the standards and regulations mentioned in the last section. The rest of the information you need comes from the design drawings or job specification that you should have obtained from your job supervisor at the beginning of the job.

Selecting appropriate materials

Using the drawings or specification, and a site inspection will allow you to decide which materials and system components will be needed for the job. You will need to calculate the quantity and types of materials to order and ensure that they comply with the relevant standards and the job specification.

It is normal practice for hydrant installations and associated pipe work and fittings to be pre-fabricated off site into lengths that suit the handling methods available. Fabricated components are then set out according to the drawings and joined with pipe cut to suit on site from standard lengths. Hose reels also are normally supplied as a complete unit ready for mounting and connection on site.

Hose reel assembly

28 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Where manual handling is anticipated 6 m lengths may be the maximum. Where mechanical handling is available up to 12 m may be acceptable. Long lengths cause handling, lifting and moving problems and should only be used where access and safe handling methods have been resolved. Large diameter pipes will generally be fabricated off site and come with ends prepared for threaded, roll grooved or flanged connection into the control valve set. Smaller diameter pipes will be cut to length and threaded or roll grooved on site from standard lengths (6 m). Valves, fittings, hangers and clamps etc will be boxed or palleted according to quantity. Concrete thrust blocks for below ground installation are normally poured in-situ, after the pipe work has been installed.

All materials delivered to the job will be detailed on checklists. The materials must be checked off the list. Any variations or missing items must be noted and the checked list returned according to company policy. This normally forms part of the quality assurance procedures.

Using appropriate materials

The drawings and the specification will detail which valves, fittings, materials and system components will be needed for the job. You will need to calculate the quantity and types of materials to order staged to suit the planned progress of the job.

The materials you may use in hydrants and hose reel systems may include:  light or medium walled black mild steel  light or medium walled galvanized mild steel  copper  cement lined cast iron  valves, gauges, switches, pumps and fittings approved for the purpose and complying with the relevant standards.

Other materials are not necessarily excluded by the standard but are not in common use. Refer to Australian Standards AS/NZS3500.1 and AS2419.1.

Quantities

The drawings show the job layout with key dimensions and a legend to explain the component symbols.

Total lengths of each diameter of pipe and quantities of valves, fittings gauges etc can be calculated from the drawings and summarised in a table or material schedule.

Ordering and checking the delivery

On completion of the materials list follow company procedures to order materials. This may require you to order direct. However it is more likely the orders will go through a purchasing officer. Fabricated items may go to one contractor and fittings and valves etc may come from a number of suppliers.

On small jobs all the materials may be delivered at once but on larger jobs delivery needs to be staged to match the progress of the job. In either case deliveries must be checked against the order, variations or missing items noted and the documentation processed according to company policy. This process is likely to be a part of the company quality assurance process. If deliveries are not checked on arrival and errors are found during installation there may be long delays for reordering materials or time delays for modifications.

Tools and equipment

Installation work can be dangerous if the correct precautions are not taken. Personal Protective Equipment (PPE) is recommended and in most cases is compulsory under most site conditions. Using PPE will help you do your job safely with minimal risk of injury.

It is in your best interest to wear the PPE supplied as appropriate for the task in hand, and to keep the PPE in good order. PPE is designed to protect you from falling objects, crushed toes, noise, dust and grit, sun and rain. Normal PPE supplied and used for installing control valve assemblies and associated work is listed below.  Overalls.  Boots.  Shirts.  Hard hat.  Safety glasses.  Ear muffs or plugs.  Safety vests.  Bluey (coat).  Gloves.

To work safely and effectively it is important to have the correct tools for the job and to maintain them in good working order. A typical list of tools required for installation work is shown below. You may be required to purchase your own tools, or they may be supplied by your employer. In either case you are responsible for the ongoing maintenance and replacement as required.  Tool box.  Mash hammer.  Claw hammer.  Stiltsons.  Shifting spanner.  Hacksaw.  Chalk line.  Plump bob.  Straight tin snips.  Ratchet spanner.  Round or flat file.  Flat screwdriver.  Phillips head screwdriver.  Cold chisels.  Deep sockets 14 mm, 16 mm & 18 mm.  Tape.  Key hole saw.  String line.  Multi grips

30 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

You will also need to use power tools, cutting, threading or grooving machines. You will need to be trained to use each item of equipment as required. Do not use any equipment unless you have been instructed in its correct use.

Types of lifting devices and scaffolds

For working above normal accessible heights you may need to use scissor lifts and or fork lifts. Both of these items require a licence to operate. Do not attempt to operate this equipment until you have been trained to do so.

Scissor lift

Working at height may also require the use of ladders and scaffolds. Scaffolds may be erected by others but the use of ladders and scaffold is the subject of WHS training. Do not attempt to build a scaffold unless you have been trained to do so.

Independent scaffold Modular scaffold

Before using a scaffold check the following.  Company policy and site safety committee policy on the use of scaffolds.  All scaffolds and accessories must conform to the scaffolding regulations.

 All scaffolds over 4 m in height must be erected by certified scaffolders.  Scaffold boards, kick boards, access ladders, mid rails and top rails must all be in good condition and securely in place.

Mobile scaffolds  Only trained personnel should erect a mobile scaffold.  Never move a mobile scaffold with a person on it.  Mobiles are suitable for solid level surfaces only.  Lock caster wheels before use.  Guard against striking hazards such as overhead power lines, beams, bracing and other parts of the structure or other obstacles.

Worksheet Now go to the Worksheet and answer Questions 15 – 19.

Mobile scaffold

When using a ladder follow good WHS practices including the following.  Check company policy and site safety committee policy on use of ladders.  Choose a ladder suitable for the task.  Check that the ladder is sound  Place the ladder on a firm footing, with a slope of no more than 4 in 1.  The ladder should extend at least 1 m above the platform it is intended to reach.

32 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

 Ladders should only be used to gain access or to complete simple tasks. Use a platform or scaffold for lengthy or more complex tasks.

Installation

You can now begin to install hydrants and hose reel systems and associated devices and piping. All work should be in accordance with the drawings and specification, and regulatory requirements. All materials used must be installed to manufacturers’ specifications.

Moving and handling materials

Manual lifting and handling techniques must always be followed according to WHS requirements and manual handling or correct lifting best practice. You should consider the following before moving materials into position by manual or mechanical handling methods.  The quantity of material.  The weight and length of individual objects.  The access to the work or storage area.  The distance or height to be carried.  The help available.

Material should be stored on site as close as practicable to the installation point. Materials should be stored in a clear area with good access for pick up and delivery. Materials should be safe from damage from all site users.

When manually handling materials for installation the following precautions should be taken.  Before lifting any load assess the risk. Never lift a load that is too heavy for you. Get help from a fellow worker or mechanical help.  Large diameter valves may need two persons to lift them or mechanical assistance such as a fork lift.  Long lengths such as pipes, may need two persons to lift to prevent deflection, as well as to carry the load.  When lifting make your legs do the work, not your back. Follow correct lifting practice.  Make sure your carry path is clear.  Wear PPE provided including gloves as protection against sharp edges and corners.

When mechanically lifting materials for installation the following precautions should be taken.  Do not use a fork lift, scissor lift or other mechanical lifting equipment without first being trained to do so.  Conform to company policy and site safety committee requirements.  Do not exceed the Safe Working Loads (SWL) for lifting equipment.  Maintain a clear path for lifting equipment including overhanging loads.  Guard against striking overhead power lines, bracing, beams or other parts of the structure or installations such as air conditioning ducts.  Protect other workers and the public from the path and working area of the equipment.  Complete all documentation such as daily and periodic checks and log book requirements.

Setting out

To set out hydrants and hose reel systems and associated equipment and pipe work consider the following. Set out must comply with plans or specifications and or job instructions.  Check the drawings for all setting out dimensions and levels.  Check the drawings for starting point of contract. The main water supply to the job may be part of the sprinkler fitting contract or it may be installed by others.  If the water supply main is part of the contract it will probably require an underground connection from the street main (town water supply) to the work site (building).

Consider the setting out of the pipe work in three sections.  Underground pipe work.  Vertical pipe work.  Horizontal pipe work.

34 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Underground pipe work

Underground pipe work would generally apply to the main connection to the building and mains connections from one building to another or for a separate hydrant main. Underground connections sometimes form part of other contracts. If the underground work is part of your contract follow these steps.  Locate the connection on the street main.  Locate the connection point to the building.  Locate the connection point for the hydrant main.  Mark the centre line of the pipe along the ground with pegs or other markers.  Use lime or marking paint to draw a line on the ground from peg to peg marking the centre line of the pipe and the trench excavation.  For complicated setting out tasks a surveyor will be required to peg the line.  Excavate the trench to the required width and depth and install the appropriate trench support system.  Never enter an unsupported trench.  Install pipes according to the drawings and the specification. Use the specified bedding and backfilling.  Pour concrete thrust blocks as required for underground installations.  Keep the trench open for as short a time as possible. Program your work so that backfilling can follow installation as fast as is practical and safe to do so.

Vertical pipe work

In combined systems mains pipes deliver water vertically through the building for distribution at various levels to the sprinkler system and to hydrants and hose reels. These pipes may also change direction and penetrate walls, floors and other parts of the structure. To set out pipes you will need to follow these steps.  Extract dimensional information from the drawings.  Pipes will be located on the drawings with dimensions from grid lines and from fixed parts of the structure such as floors, walls and ceilings.  Use the dimensions from the drawings to mark the centre lines of the pipe on the part of the structure to which it will be fixed, such as a wall or column.  Set the distance out from the wall by marking the centre of the pipe on the floor or ceiling. Marking the centre of pipes requires two dimensions at right angles to each other.  Where pipes penetrate parts of the structure ‘cored holes’ need to be cut. The centre lines and diameter of the holes must be marked on the structure. Cutting the holes may be part of your contract or it may be the builder or others. Program your work so that the holes are marked and cut in advance of fitting the pipes.  The layout of pipe work is indicated by marking the pipe centre line on the structure. Vertical and horizontal dimensions will be required to accurately locate the pipe. Vertical dimensions are often indicated by reduced levels (RL). An RL of 10.4 indicates a height of 10.4 m above a starting point or ‘datum’. Check with your supervisor if you cannot find the datum on the drawing. The datum is typically the ground floor level or a similar point that has been chosen as a starting point.

Layout of pipework

Person on ladder transferring key points to floor

Horizontal pipe work

In a combined system, horizontal pipe work distributes the water supply at each level of the structure. This pipe work is normally connected to the underside of the floor or roof above. To set out horizontal pipe work, follow these steps.

36 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

 Extract dimensional information from the drawings.  Pipes will be located on the drawings with dimensions from grid lines and from fixed parts of the structure such as floors, walls and ceilings.  Use the dimensions from the drawings to mark the centre lines of the pipe on the part of the structure to which it will be fixed, such as the underside of the floor.  Marking centre lines on the underside of a floor may be difficult because of the many obstructions and the problems of working at height. In these circumstances it is common practice to set out the pipe work on the floor and use a plumb bob or laser to transfer key points to the structure above.  Mark the pipe centre lines on the floor and mark the location of fittings on the centre lines. Mark dimensional check points on the centre lines. Check points are often called for on the drawing to provide a progressive check that no dimensional errors are creeping in as the work progresses.  In a separate hydrant hose reel system the horizontal pipe work may be the underground pipe work discussed above.

Pipe supports and fixings

Pipe supports and fixings are used to hold the pipe work securely in place but at the same time allowing for normal building movement. Pipe supports must carry a minimum of twice the load of the water-filled pipe plus 115 kg at each support point as set out in AS2419.1 The standard also specifies type and size of material for pipe support and fixing devices and the minimum recommended spacing. All supports must be capable of passing the verification test loads as set out in AS 2419.1 section 8.

There are a number of manufacturers that supply a range of pipe support systems that have been tested and comply with the requirements of the standard. Where these are used and installed correctly to the manufacturers’ recommendations a verification test is not likely to be required. Where non- standard or special supports or fixings have been used they may be required to pass the verification test.

The installation of pipe support systems progresses with the installation of the pipe work.

In underground installations straight lengths of pipe are supported by the pipe bedding and backfill material. At bends and intersections where additional thrust may cause movement, concrete thrust blocks are cast in-situ. They will support the pipe work and prevent unwanted movement.

Thrust blocks

Pipe joints

Pipes are joined to valves, fittings or other pipes, by a range of methods to suit the type of material, the pipe diameter, the location and the erection procedure.

Fire hose reels

Hose reel assembly must comply with AS/NZS1221 and installation with AS2441. In general the installation requirements are as follows.

Location

Hose reels should be located as shown on the drawings but not in fire isolated exits. Where the hose reel is located externally or in aggressive environments it must be protected by a cabinet. Cabinet to be marked ‘FIRE HOSE REEL’ in contrasting letters a minimum of 50 mm high. Where a hose reel is obscured from view a sign must be provided ‘FIRE HOSE REEL’ in contrasting letters a minimum of 50 mm high.

Worksheet Now go to the Worksheet and answer Questions 20 – 23.

38 © Commonwealth of Australia 2015 CPCPFS3031A - FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Mounting

Hose reels must be mounted with the full diameter of the drum facing the access point and with the drum spindle height between 1.5 m and 2.4 m from the floor. The drum must have suitable clearances all round, and the hose must be free to run out in any direction as set out in AS2441 Section 10.

The hose reel support structure and fixings must be able to support the fully charged hose reel in operation.

Person discharging hose

Water supply The water supply to the hose reel must be sufficient for delivery of 0.33 L/s from the hose. Pipe work to the hose reel would normally be 25 mm black steel pipe, galvanised pipe or copper. Hose reels are normally supplied as a complete unit and should be installed to the manufacturer’s recommendations.

Commissioning procedure

This is set out in AS2441 Section 11 and includes the following checks.  Leakage from the valve or discharge nozzle does not exceed 5 ml in three minutes.  The hose can be easily withdrawn in any direction.  The rate of flow from the nozzle is not less than 0.33 L/s.  Any defects found are corrected.  The hose is rewound in even layers correctly engaged in the interlock and the valve shut.  The discharge nozzle is opened and shut to depressurise the hose.

Note When you make these checks make sure you have a suitable container, to collect the discharged water or are connected to an appropriate drainage point.

Installing the hydrant main

Hydrant mains will vary in size and complexity according to the job requirements but all have common elements. A typical installation might follow the procedure set out below.  Check drawings and specification.  Check tools and equipment including mechanical handling.  Check access to site.  Check storage area.  Check itemised list of material and equipment. A typical check list would generally include the following items. - Fabricated sections of pipe. - Standard lengths of pipe for on site fabrication. - Pre-fabricated components such as booster and suction risers. - Main control valves. - Stop valves. - Check valves. - butterfly valves. - Pressure switches and gauges. - Cabinets and enclosures. - Drain cocks. - Diesel and electric powered pumps. - Bends, reducers, blank ends, flanges, couplings and other fittings. - Jointing tape, hemp, soap and gaskets.

Installation normally begins at the ‘trident’ which immediately follows the isolation valve from the water supply and is progressively installed from there. The trident is the point at which the water supply branches into three lines for water main, sprinkler main and hydrant main. The order of construction will depend on specific job and planning requirements and preferences but a typical installation might follow these steps.

Typical trident

 Locate starting point.  Set out underground pipe work using offset dimensions from the building. For complex setting out use a surveyor.  Excavate trenches according to drawings and the specification.  Install appropriate trench support system.  Progressively lay pipe and install fittings, keeping within protected section of trench.  Install thrust blocks in accordance with the drawings.  Do not keep sections of trench open any longer than necessary but the pipework must be tested before the trench is closed.  Install vertical pipe work within the structure where required.  Install horizontal pipe work within the structure as required.  Install branches to hose reels.  Install cabinets and hose reels as indicated on the drawings.  Label cabinets, hose reels and pipe work.  Test the completed installation.

Testing the installation

The installed hydrant mains, valves, fittings and associated pipe work has to be tested in accordance with AS2419. This calls for a hydraulic test pressure of 1700 kPa or 1.5 times the design pressure, whichever is the greater, to be maintained for a minimum of two hours. When conducting the tests ensure that all unauthorised persons are clear of the work site.

Air test  Visually check that the installation is complete.  Check that the stage being tested has been isolated from other stages.  Connect the compressor to the test point, such as a removed stop cock, pressure gauge or valve.  Connect with a hose connection, pressure gauge and lock shut valve.

Connection to compressor

 Bring pressure in system up to test pressure specified (usually 300 kPa). Take care not to greatly exceed the test pressure as this could damage the system. Hydrant pipes are not designed for high air pressure.  Hold test pressure for specified time (usually 30 minutes). The air pressure should not drop more than 20 – 30 kPa over the test time.  If the installation passes the air pressure test proceed to hydraulic test.  If the installation fails the air test, identify leaks or faults, correct leaks or faults and re test.  Record test data on the company form provided and follow company policy to enter document into the record system. This process would normally be part of the company quality assurance procedures.

Hydraulic test  Visually check that the installation is complete.  Check that the stage being tested has been isolated from other stages.  Check that the system pump is installed or connect temporary pump for test.  The pump may be installed at an isolation valve, or a temporary connection made at the start of the stage to be tested. Areas not forming part of the test are to be blanked off.  Open control valve to fill system with water.  Open the bleed valve at a remote point in the system to allow for removal of air from the system. Where no bleed valve is included in the design open a hydrant valve at the furthest point and close when water comes through.  Start the pump and bring pressure up in intervals of 200 kPa. Hold the pressure for 30 minutes at each interval. This will allow the hemp in the joints time to swell and adjust to the pressure. If there are any signs of leaks from sprinkler heads or joints, these can be tightened as the test proceeds.  On reaching test pressure (1700 kPa or as specified) hold for two hours or as specified.  If for any reason the test fails, identify and correct faults and re-test.  The builder or representative is required to witness the start and finish of the test time and to sign off on successful completion of the test.  Record test data on the company form provided and follow company policy to enter document into the record system. This process would normally be part of the company quality assurance procedures.

Other testing  Check that all gauges comply with AS1349 and AS2419.1 section 9. This includes that the maximum scale value must be at least 125% of the hydrostatic test pressure and the dial face 65 mm minimum diameter.  Every hydrant within the system is to be opened to prove there is water at each point.  Pressure gauges installed with gauge cock to facilitate removal for testing.

Commissioning the system

Combined system

To commission the system it must be complete, tested, inspected and passed relevant authority.

Hydrant system

To commission the hydrant system a number of additional tests must be run that check the total system not just the hydrants, mains and hose reels. These include discharge from hydrants, pump flow, mains pressure, hydrant flow, running pressure. Additional tests will also be required for systems that include a booster or booster in series, and for systems including pumps and tanks. All these test requirements are detailed in AS2419.1 Section 10.

Recording data

Test data must be recorded in the format required by the job specification and quality assurance procedures.

The test data would normally be recorded on a standard company form, similar to the following example.

The relevant form will be signed by the supervisor conducting the test and the builder or representative along with the relevant authority witnessing the test.

The document will be retained by the company as part of the quality assurance procedures. Copies will be available to the builder, relevant authority and the client.

Clean up

The work site must be cleared of debris. Cleaning up the work site is not just a matter of appearance; it also concerns safety and health issues. 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. Tools and equipment must also be cleaned, maintained and stored.

Work site  Most sites 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 they’re not, find out from your supervisor.  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 as build up attracts vermin and associated health risks.  Packaging debris should not be allowed to become a tripping or other hazard. Dispose of to the correct 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 disposed of to the correct bin at the end of each days’ 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 - rubbish and debris to the correct bins.  Sweep the completed work area clean and correctly dispose of sweepings.

Tools and equipment  Most sites have a site safety committee policy on cleaning up the work site.  Clean up as you go if possible, but at least on a daily and weekly basis and on completion of an installation.  Tools and equipment may be the responsibility of the plumber, the contractor or others such as hire companies.  A sprinkler fitter will be responsible for a tool kit and personal protective equipment (PPE).

Worksheet Now go to the Worksheet and answer Questions 24 – 30.

Worksheet

CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems

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. Why is a fire protection system installed?

2. Outline two fire protection systems that use hydrants.

3. Hydrant systems may be tested at different pressures. What are they?

4. Sketch a hydrant and a booster connection.

5. Outline the requirements of block plans.

6. Isolating valves are used for dividing a system into how many compartments?

7. External cabinets are for what purpose?

8. Explain the purpose and operating position of the stop valve on a fire hose reel system.

46 © Australian National Training Authority 2004 – Version 1 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

9. What type of fixing is not allowed for pipe supports?

10. Outline a range of preferred fixing methods to concrete steel and masonry.

11.

(a) Name the standard and section that covers pressure testing of hydrant systems

(b) What is the normal test pressure?

 Australian National Training Authority 2004 47 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

12.

(a) Is an air test compulsory?

(b) Why do an air test?

13. How would you minimize damage from leaks to the system?

14. List areas you would expect to be covered by the company quality assurance policy.

48 © Australian National Training Authority 2004 – Version 1 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

15.

(a) List at least six ‘others’ you may have to work with on an installation.

(b) What are the benefits of working cooperatively?

16. Draw and dimension a range of fabricated sections of pipe that incorporate hydrants or boosters.

17.

(a) What does PPE stand for?

 Australian National Training Authority 2004 49 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

(b) List four items of PPE.

18. List the equipment required to work at height and outline the training required for each item.

19. What are the main hazards to guard against when using scaffolds?

20. Which part of your body should do the work when manually lifting?

21.

(a) List the steps to set out a trench for underground pipe work.

50 © Australian National Training Authority 2004 – Version 1 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

(b) Draw a cross section of a trench showing trench support, pipe, bedding and backfill

22. When would you use a cabinet to protect a hose reel?

23. Hose reels are mounted with the spindle between and

above the floor level.

 Australian National Training Authority 2004 51 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

24. The hose must be able to deliver L/s

25. List six checks you would complete during commissioning of a hose reel.

26. Where would you expect to begin installation of the hydrant main?

27. Why would you air test a piping system?

28. List likely reasons for a failed air test and suggested solution.

29.

(a) Which standards and clauses cover hydraulic testing of hydrant pipe work?

52 © Australian National Training Authority 2004 – Version 1 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

(b) What steps would you take to bring the system up to test pressure?

(d) Which representatives should witness the test?

(e) What is your company procedure for recording test data?

30. Outline your company policy on cleaning and maintenance of:  toolkit  PPE  hire equipment.

Trainer or supervisor’s signature:………………………………………..

Date of completion:…………………………………

 Australian National Training Authority 2004 53 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Name:…………………………………………………………

Practical application

CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems

Your trainer or supervisor will now work with you to demonstrate and explain fabricate and install fire hydrants and hose reel systems.

The following points will be covered.

Design drawings and job specifications are obtained from relevant authority

WHS requirements associated with fabricating and installing fire hydrant and hose reel systems, 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 fabricating and installing fire hydrant and hose reel systems, including personal safety equipment, are selected and checked for serviceability

Work area is prepared to support the efficient fabrication and installation of fire hydrant and hose reel systems

System requirements are identified from job design criteria, specifications and standards

Piping and materials are selected in accordance with standards, design drawings or job specifications and authorities’ requirements

Below ground piping and materials are checked to ensure compliance with standards and authorities’ requirements

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

System is set out in accordance with drawings, specifications and job instructions

Pipe supports and fixings are installed to plans and manufacturers’ specifications

Piping and materials are installed in accordance with the design drawings, job specifications and standards

Pipework is connected to the water source in accordance with standards and authorities’ requirements

54 © Australian National Training Authority 2004 – Version 1 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Piping system is tested in accordance with standards and job specifications

Test data is recorded in the format required by the job specifications and quality assurance procedures

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:………………………………

 Australian National Training Authority 2004 55 CPCPFS3031A FABRICATE AND INSTALL FIRE HYDRANTS AND HOSE REEL SYSTEMS

Assessment checklist

CPCPFS3031A – Fabricate and install fire hydrants and hose reel systems

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:…………………………….