ATS :2010. Title: Pumps for general use in rainwater service. applications

Transcription

1 ATS :2010 Title: Pumps for general use in rainwater service applications ATS PUMPS January doc Page 1

2 CONTENTS PREFACE SCOPE APPLICATION REFERENCED DOCUMENTS DEFINITIONS MATERIALS MARKING PACKAGING DESIGN PERFORMANCE REQUIREMENTS AND TEST METHODS TEST SEQUENCE AND TEST SAMPLE PLAN PRODUCT DOCUMENTATION... 7 APPENDIX A MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS SPECIFICATION... 8 APPENDIX BHYDROSTATIC STRENGTH TEST APPENDIX C DURABILITY AND FUNCTION TEST ATS PUMPS January doc Page 2

3 PREFACE This Australian Technical Specification was prepared by the Standards Australia Committee WS-031, Technical Procedures for Plumbing and Drainage Products Certification. The objective of this Australian Technical Specification is to enable product certification in accordance with the requirements of the Plumbing Code of Australia (PCA). The Conformity Assessment Body, working with and on behalf of the applicant, is to actively participate to convert the Australian Technical Specification, approved by the National Plumbing Regulators Forum (NPRF), into an Australian Standard within two (2) years of the approval date. The test protocol and information in this Specification was arranged by committee members to meet the authorization requirements given in the Plumbing Code of Australia. The word VOID set against a Clause indicates that the Clause is not used in this Australian Technical Specification. The inclusion of this word allows for the use of a common Clause numbering system for the plumbing and drainage Australian Technical Specification. The term normative has been used in this Australian Technical Specification to define the application of the appendix to which it applies. A normative appendix is an integral part of an Australian Technical Specification. ATS PUMPS January doc Page 3

4 1SCOPE Technical Specification Part 506: Pumps for general use in rainwater service applications This Australian Technical Specification sets out requirements for the materials safety, performance, quality and reliability of pumps and associated control devices that are utilised in supplying rainwater for non drinking water applications for use at continuous water operating temperatures up to 40 C and maximum operating pressures up to 1000kPa. These pumps may be for above ground (surface) or submersible applications and supplied with control equipment and associated plumbing fittings either integral or as inclusions. It is expected that the manufacturers of these pumps and associated control devices establish and maintain a certified quality management system in compliance with ISO 9001 Note: Submersible pumps utilized for borehole applications are not included under this Specification. These products require certification to WaterMark Level 2 2APPLICATION This Australian Technical Specification will be referenced in AS Appendix A sets out the means by which compliance with the Specification is demonstrated by a manufacturer for the purpose of product certification (See Appendix A). 3REFERENCED DOCUMENTS The following documents are referred to in this Specification: AS 3688 Water supply Metallic fittings and end connectors Technical specification for plumbing and drainage products Part 000 Procedures for certification of plumbing and drainage products. AS/NZS 3500 Plumbing and Drainage Part 0 Glossary of terms Part 1 Water supply Part 2 Sanitary plumbing and drainage Part 4 Heated water services Part 5 Domestic installations Household and similar appliances Safety Part 2-41: Particular requirements for pumps IEC Household and similar electrical appliances - Safety - Part 2-41: Particular requirements for pumps MP ATS PUMPS January doc Page 4

5 52 Manual of authorisation procedures for plumbing and drainage products NPRF PCA 4DEFINITIONS Plumbing Code of Australia For the purpose of this Australian Technical Specification, the definitions given in AS/NZS apply. 5MATERIALS Materials of construction of the parts in contact with the pumped rainwater and the external environment shall comply with the requirements of AS/NZS and in particular; Clause 31 Resistance to rusting and; Clause 32 Radiation, toxicity and similar hazards 6MARKING Each pump and control unit shall be durably and legibly marked with the following: (c) (d) (e) (f) (g) Manufacturer s name, brand or trademark. Model identification Country of origin WaterMark Certification Trademark. Certificate No. (h) The number of this Technical Specification, i.e., ATS NOTE: The number of the Technical Specification may be an abbreviated form ie S506 where space is limited 7PACKAGING The pump and control equipment shall be packaged in such a manner so as to avoid damage during transportation and handling. End connections shall be protected to avoid damage to threads. 8DESIGN 8.1Electrical safety The pump and associated electrical equipment shall be tested and certified to AS/NZS or IEC Automated pump controller Where included an automatic controller shall be designed so as to detect demand in the supply of water so as to start up the pump. The controller shall be tested and certified to AS/NZS or IEC ATS PUMPS January doc Page 5

6 8.3End connections 8.3.1General Where the ends are intended to be connected to pipework, pump assemblies shall be provided with threaded end connections or adaptors. All end connections shall be capable of making a watertight joint when connected and tightened in accordance with the manufacturer s instructions. 8.4Freedom from defects 8.4.1General Defects shall not affect the performance, function or safe handling of the pump and associated control devices in service Metallic components Finished metallic components shall be; (i) (j) (k) (l) free from metal folds, laps, laminations and blowholes that would clearly affect the performance of the component in service; free from pits on jointing services; clean and free from sand and swarf and free from burrs, fins and sharp edges Plastic components Finished plastic components shall be; (m) (n) (o) free from blisters and heat marks; free from chips and rough edges and sharp edges shall be removed. 9PERFORMANCE REQUIREMENTS AND TEST METHODS 9.1Hydrostatic strength test When tested in accordance with the hydrostatic strength test of Appendix B, the pump assembly shall not leak when tested at not less than 1.5 times the maximum operating pressure for minutes at ambient temperature. 9.2Durability and function test When tested in accordance with the durability and function test of Appendix C the pump, motor and any included control system shall not leak and function as specified by the manufacturer after continuous cycling for a minimum of 28 days. ATS PUMPS January doc Page 6

7 10TEST SEQUENCE AND TEST SAMPLE PLAN 10.1Test samples One pump sample typical of the range to be certified shall be selected. This pump shall be used for testing of the performance requirements of Clauses 9.1 to 9.2 and the other requirements of Clause Test sequence The same sample shall be utilised for all performance tests of Clauses 9.1 to 9.2 and testing to Clause 9.1 shall be conducted prior to other tests. 11PRODUCT DOCUMENTATION 11.1GENERAL Information shall be available to aid the installer and user in the correct installation, operation and ongoing maintenance of the product and include critical data on the products use and application and any limitations. The information shall be readily available and be in plain English and supplemented by figures and diagrams as applicable. 11.2PRODUCT DATA Product data shall be available that identifies the following critical product characteristics as a minimum a) Product range and model identification b)general dimensions c) Performance curve showing flow rate against total head. d)maximum head in metres e) Minimum flow rate f) Power consumption P1 and P2 g)jointing methods and adaptation to other piping systems h)materials of construction of components in contact with the pumped liquid 11.3INSTRUCTIONS Instructions shall be provided that give full details of installation, operating and maintenance procedures for the pump including; (c) (d) (e) (f) Detailed step by step instruction. The need for special tools or training. Commissioning procedures and adjustments required. Trouble-shooting guide. Contact details for after sales service Regular maintenance requirements ATS PUMPS January doc Page 7

8 A.1 SCOPE APPENDIX A MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS SPECIFICATION (Normative) This Appendix sets out the means by which compliance with this Technical Specification can be demonstrated by a manufacturer under the WaterMark product certification scheme. A.2 RELEVANCE The long-term performance of plumbing systems is critical to the durability of building infrastructure, protection of public health and safety, and protection of the environment. A.3 PRODUCT CERTIFICATION The purpose of product certification is to provide independent assurance of the claim by the manufacturer that products comply with this Technical Specification. The certification scheme serves to indicate that the products consistently conform to the requirements of this Specification. The frequency of the sampling and testing plan as detailed in Paragraph A5, shall be used by the Conformity Assessment Body. Where a batch release testing program is required it shall be carried out by the manufacturer as detailed in paragraph A5 and table A2. A.4 DEFINITIONS A.4.1 Type test batch Schedule of units of the same type, identical dimensional characteristics, all the same nominal diameter and wall thickness, from the same compound. The batch is defined by the manufacturer. A.4.2 Sample One or more units of product drawn from a batch, selected at random without regard to quality. NOTE: The number of units of product in the sample is the sample size. A.4.3 Sampling plan A specific plan, which indicates the number of units of components or assemblies to be inspected. A.4.4 Type testing Testing performed to demonstrate that the material, component, joint or assembly is capable of conforming to the requirements given in the Technical Specification. ATS PUMPS January doc Page 8

9 A.5 TESTING A.5.1 Type Testing Table A1 sets out the requirements for Type Testing and frequency of reverification. A.5.2 Batch Release Testing Table A2 sets out the minimum sampling and testing frequency plan for a manufacturer to demonstrate compliance of product(s) to this Technical Specification on an ongoing basis. However where the manufacturer can demonstrate adequate process control to the Conformity Assessment Body, the frequency of the sampling and testing nominated by the manufacturer s quality plan and/or documented procedures shall take precedence for the purposes of WaterMark product certification. A.5.3 Retesting In the event of a batch release test failure, the products within the batch may be retested at a frequency agreed to with the Conformity Assessment Body and only those batches found to comply may be claimed and/or marked as complying with this Australian Technical Specification. TABLE A1 TYPE TESTS Characteristic Clause Requirement Test method Frequency Materials 5 Rusting/ Radiation, toxicity and similar hazards AS/NZS At any change in materials specification Markings 6 Marking Packaging 7 To avoid damage during transportation and handling 8.1 Electrical safety Review against documentation/physical examination AS/NZS or IEC At any change in design/specification Design 8.2 Automated pump controller AS/NZS or IEC End connections Clause At any change in design/specification 8.4 Freedom from defects Clause 8.4/Visual examination Performance 9.1 Hydrostatic strength test Appendix B At any change in Durability and function materials, formulation or 9.2 test for - automated Appendix C design or every five years pumps whichever occurs first ATS PUMPS January doc Page 9

10 Characteristic Clause Requirement Test method Frequency Product Documentation 11 Product data/installation instructions Documentation review Any factor that requires a change in documentation e.g. amendments to AS/NZS 3500 series of Standards TABLE A2 BATCH RELEASE TESTS Characteristic Clause Requirement Test method Frequency Materials 5 Rusting/ Radiation, toxicity and similar hazards Delivery acceptance tests or supplier s test data Each delivery batch Markings 6 Markings Visual examination 100% Performance 9.1 Hydrostatic strength test Appendix B Once per production shift ATS PUMPS January doc Page 10

11 B.1 SCOPE APPENDIX BHYDROSTATIC STRENGTH TEST (Normative) This Appendix sets out the method for determining the ability to withstand hydrostatic pressures. B.2 PRINCIPLE The pump set assembly is subjected to a hydrostatic pressure for a period of time and inspected for structural damage. B.3 APPARATUS Water supply source sufficient to maintain the required pressure. Pressure gauge. B.4PROCEDURE The procedure shall be as follows: (c) (d) (e) (f) (g) Mount the pump set assembly in a suitable jig and connect the water supply to the inlet of mains water supply. Block the other end/s with suitable plugs that contain fittings in order to de air the device. Supply water to the device and purge all the air from the device. Slowly increase the pressure until it reaches the test pressure Maintain this pressure for the test duration. Release the pressure. Record the test pressure, temperature and duration at this pressure. Inspect the pump set assembly for any leaks or structural damage. B.5TEST REPORT The following shall be reported: Manufacturer, model, type and size of pump and any components. Any leakage or structural damage. (c) Reference to this test method, ie. ATS , Appendix B. ATS PUMPS January doc Page 11

12 APPENDIX C DURABILITY AND FUNCTION TEST C.1SCOPE This Appendix sets out the method for assessing the basic functionality of the pump set and durability. C.2PRINCIPLE The pump set assembly is subjected to a number of starts in its normal manner for a minimum of 28 days in order to determine durability. The pump set is tested for basic functionality and leakage prior to testing and after testing. C.3APPARATUS (c) Water supply source sufficient to maintain the required pressure. Pressure gauge. Monitoring equipment to check during the test and record the total number of starts. C.4PROCEDURE The procedure shall be as follows: (c) (d) (e) (f) (g) (h) (i) Conduct a hydrostatic test in accordance with Appendix B Mount the pump set assembly in a suitable jig and connect the water supply to the inlet of pump. Check basic functionality of the pump set by; Open valve on the outlet of the pump set to simulate household demand. Monitor the pressure when the pump activates and leave running for one minute before closing outlet valve. Simulate demand a further five times and monitor functionality. Compare with manufacturers specification. If the pump set has loss of prime protection assess this by closing inlet water supply and running pump dry then open water supply and instigating household demand by opening outlet valve. Providing successful functionality check instigate testing by; Simulating demand and once pump has activated leave running for the run time as identified in Table C1 then shut down demand. Leave in idle position for the remaining time as calculated for the kw rating of the motor and starts per hour as identified in Table C1then instigate demand again. Repeat e) to f) for a minimum of 28 days. At the conclusion of the test inspect the pump set for any leaks or structural damage Conduct the functional test of (c) ATS PUMPS January doc Page 12

13 (j) Conduct hydrostatic test in accordance with Appendix B. kw Rating Table C1 Testing Parameters Surface Motors Motor run time (secs) -5%+0% Starts per hour (single phase) -5%+0% Up to to to Over kw Rating Submersible Motors Motor run time (secs) -5%+0% Starts per hour (single phase) -5%+0% Up to to to Over N/a 4 Starts per hour (three phase) -5% +0% Starts per hour (three phase) -5% +0% C.5TEST REPORT The following shall be reported: Manufacturer, model, type and size of pump set and components. Test duration in days and hours (c) Total number of starts conducted (d) Any leakage or structural damage. (e) Reference to this test method, ie. ATS , Appendix C. *** END OF DRAFT *** ATS PUMPS January doc Page 13