Centrifugal Pump Installation & Commissioning

1. Pre-Installation Checks:

Before installing a centrifugal pump, conduct the following checks to ensure smooth operation and prevent any potential damage:

- Pump Location: Select a location with easy access, good ventilation, and low moisture. It should be near the fluid source to minimize suction losses.

- Foundation: Ensure a solid and level foundation, typically a concrete base, to prevent vibration. Use vibration isolators if needed.

- Alignment: Confirm that the foundation and mounting base are aligned. Misalignment can lead to shaft or bearing failure.

- Check Components: Inspect the pump for any shipping damage and ensure all parts (including seals, bearings, and impellers) are in good condition.

- Piping System: Verify that the inlet and outlet piping are properly sized and aligned. Avoid any strain on the pump casing due to piping misalignment.

2. Installation Steps:

Mounting the Pump:

- Place the pump on the base plate or foundation. Securely bolt it down using appropriate fasteners.

- For larger pumps, use a leveling device to ensure the base is flat.

Suction and Discharge Piping:

- Suction Piping: Ensure the suction pipe is of adequate size to prevent cavitation (low-pressure areas that cause damage). Use short, straight runs and avoid elbows or bends near the suction flange. Include strainers if necessary.

- Discharge Piping: Install with proper supports to avoid placing stress on the pump casing. Use check valves and isolation valves where needed.

Coupling Alignment:

- If the pump is connected to a motor via a coupling, ensure both shafts are aligned axially and angularly using a dial indicator or laser alignment tool.

- Check for misalignment and correct it before operating.

Electrical Connection:

- Ensure the motor is wired according to the manufacturer’s recommendations.

- Confirm that the motor rating matches the power supply.

- Install proper motor protection devices (circuit breakers, fuses, etc.) and grounding.

Seal and Lubrication:

- Check the mechanical seals or packing glands for proper installation.

- Fill the pump bearings with the recommended lubricant.

3. Commissioning the Pump:

Once installation is complete, follow these steps for commissioning:

Pre-startup Inspection:

- Confirm that all installation procedures are completed.

- Verify the availability of a power supply and the correct motor rotation direction by briefly bumping the motor.

- Ensure all valves are properly set (suction valve open, discharge valve partially open).

Priming the Pump:

- Fill the pump casing with liquid to prevent dry running. For centrifugal pumps, this is crucial to avoid damaging the seals and impeller.

Start-Up:

- Start the pump with the discharge valve slightly closed to avoid overloading the motor.

- Gradually open the discharge valve to the desired flow rate once the pump has reached full speed.

Monitor Initial Operation:

- Observe the pump for unusual noise, vibration, or excessive temperature rise.

- Check that the motor current and voltage are within operating limits.

Performance Testing:

- Measure the pump’s flow rate, head, and power consumption to ensure it meets design specifications.

- Monitor for any leaks, pressure fluctuations, or cavitation

4. Post-Commissioning Checks:

- Maintenance Log: Record all key parameters (vibration, temperature, flow rate, pressure) for future reference.

- Routine Inspection: Check for oil leaks, motor temperature, and ensure proper lubrication of bearings during the initial few hours of operation.

Troubleshooting Common Issues:

- No Flow or Low Flow: Check suction line blockages, ensure the pump is properly primed, and verify the pump’s impeller is not damaged.

- Vibration/Noise: Check alignment, bearings, and impeller balance. Also, inspect for cavitation.

- Overheating: Check if the pump is running against a closed valve or the motor is overloaded.