Pump Commissioning and Start-Up: Pump Commissioning Checklist

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Pre-requisites for commissioning and start-up of a Process Pump:

Before commissioning and starting up of any equipment some preparation must be done. There will be some mandatory requirements, that should be fulfilled. So Process Pump is not an exception. At the same time process pumps, being vibration prone and sensitive, the utmost care has to be exercised. So before starting up the pump set, make sure that the following requirements are met:

Filling in the lubricant in bearing bracket of Process Pump:

Fill the bearing bracket of the Process Pump with lubricating oil. The constant-level oiler is screwed into the upper tapping hole of the bearing bracket. If no constant-level oiler is provided on the bearing bracket, the oil level can be read in the middle of the oil level sight glass arranged at the side of the bearing bracket. Note that Insufficient lubricating oil in the reservoir of the constant-level oiler damages the bearings. So

Process Pumps

Bearing Bracket with constant level oiler of typical Process Pump

  1. Remove the protective cage.
  2. Unscrew the vent plug (2).
  3. Hinge down the reservoir of the constant-level oiler (1) from the bearing bracket (5) and hold it in this position.
  4. Pour in the oil through the vent plug tapping hole until oil appears in the connection elbow of the constant-level oiler (3).
  5. Fill the reservoir of the constant-level oiler (1) with oil up to the maximum level.
  6. Snap the reservoir of the constant-level oiler (1) back into the operating position.
  7. Screw the vent plug (2) back in.
  8. Fit the protective cage.
  9. After approximately 5 minutes, check the oil level in the reservoir of the constant-level oiler (1). It is important to keep the reservoir properly filled at all times, to ensure an optimum oil supply. Repeat steps 1 – 8, if necessary.
  10. To verify the correct function of the constant-level oiler (1), slowly drain the oil through the drain plug (4) until air bubbles can be seen in the oiler.
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Note that, An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil.

Shaft seal

Filling and venting the Process Pump:

Before starting up the pump set, vent the pump and suction line and fill both with the fluid to be handled.

Final check before Starting the Process Pump:

Water cooling:

Observe the cooling water quality. Also, observe the following quality data of the cooling water:

Cooling of the pump:

The casing cover, the bearing bracket and the casing support on the baseplate can be cooled. Observe the following quality data of the cooling water:

Cooling of the shaft seal:

Cooling Liquid Quantities for Process Pump Operation

Heating up/keeping warm the pump (set):

Prior to pump start-up, heat up the pump as described in the operating manual. Observe the following when heating up the pump (set) and keeping it warm:

If the pump is used for handling fluids with fluid temperatures exceeding 150 °C, make sure that the pump has been heated throughout before starting it up. The temperature difference between the pump’s surface and the fluid handled must not exceed 100 °C (100 K) when the pump is started up.

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Start-up:

  1. Fully open the shut-off valve in the suction head/suction lift line.
  2. Close or slightly open the shut-off valve in the discharge line.
  3. Switch on the motor.
  4. Immediately after the pump has reached full rotational speed, slowly open the shut-off valve in the discharge line and adjust it to comply with the duty point.
  5. When the operating temperature has been reached and/or in the event of leakage, switch off the pump set and let it cool down. Then retighten the bolts between lantern and casing.
  6. Check the coupling alignment and re-align the coupling if required.

In case of Abnormal noises, vibrations, temperatures or leakage

Checking the shaft seal

The mechanical seal only leaks slightly or invisibly (as vapor) during operation. Mechanical seals are maintenance-free.

Operating limits

Ambient temperature

Observe the specified limits for permissible ambient temperatures.

Frequency of starts

The frequency of starts is usually determined by the maximum temperature increase of the motor. This largely depends on the power reserves of the motor in steady-state operation and on the starting conditions (d.o.l., star-delta, moments of inertia, etc). If the start-ups are evenly spaced over the period indicated, the following limits can be used for orientation for a start-up with the discharge-side gate valve slightly open:

Frequency of Starts of a Process Pump

Do not re-start the pump set before the pump rotor has come to a standstill.

The density of the fluid handled

The power input of the pump increases in proportion to the density of the fluid handled. Hence always observe the information on fluid density indicated in the datasheet and make sure the power reserve of the motor is sufficient.

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Abrasive fluids

Do not exceed the maximum permissible solids content specified in the datasheet. When the pump handles fluids containing abrasive substances, increased wear of the hydraulic system and the shaft seal are to be expected. In this case, reduce the intervals commonly recommended for servicing and maintenance.

Pump Commissioning Checklist

The commissioning of Process Pumping systems is a complex process that requires a structured approach. A pump commissioning checklist validates the operation of pumps through correct installation, proper lubrication, and simulation of instrumentation and protection devices. The following checklist highlights some of the areas that need to be verified when commissioning pumping systems: