Stock Photo of a Pump
A guide for new engineers and a refresher for experienced engineers.
Dangote Fertilisers Ltd.

In this article, the startup procedures necessary for pump commissioning are listed, as well as the procedures necessary for the removal of a pump from service.

Pump Commissioning

  1. Confirm the numbering of the pump to be inspected matches sign off documentation.
  2. Certify from the quality control unit the pipe strain, soft foot, alignment and runout are all within the acceptable range.
  3. Confirm the electrical insulation resistance and leakage tests are within limits from the electrical unit.
  4. Run the motor on no-load (decoupled from the pump) for a time period of at least 12 to 24 hours depending on the original equipment manufacturer’s schedule.
  5. The lines going to the pump inlet should be flushed with demineralized water while being disconnected from the pump.
  6. The strainer on the inlet line should be cleaned.
  7. Recommended oil should be used to flush the pump and drained.
  8. Recommended oil should be filled in the pump and level should be confirmed satisfactory.
  9. Suction lines are then connected to the pump.
  10. The suction lines are to bleed off air to prevent air pockets getting through to the pump.
  11. Pump should be coupled with motor in preparation for load run.
  12. The discharge valve should be fully closed to check for maximum pump pressure/head.
  13. Upon startup of pump, the system should be checked for leaks, abnormal sound, vibration and bearing temperature.
  14. The flow should be checked (upon certification from the instrument unit that the gauge calibration has been checked).
  15. Confirm power consumption of the pump is in line with equipment data sheet.
  16. Ensure proper documentation.
  17. Should all parameters fall within range, the pump may be signed off and put in operation.

Pump Decommissioning

  1. Ensure pump number tag matches with the pump to be decommissioned as per signoff documents.
  2. Ensure the pump has been de-energized and the electrical point has been tagged out.
  3. Motor and pump unit should be decoupled.
  4. Oil should be completely drained from pump and properly disposed.
  5. Oil leveler, couplings, breathers and pump accessories should be removed and stored safe.
  6. Pump connections to pump inlet and discharge should be removed and blinded.
  7. Mechanical seal piping (if available) should be removed, tagged together and stored safely.
  8. Motor or pump driver foundation bolts should be loosed, removed and stored safely.
  9. Pump should be loosed from foundation bolts, removed and stored safely.
  10. Ensure proper documentation and sign off by necessary field engineers.