Staying Safe During Pumping Station Commissioning

Martin Kealy
Apr 18
3 min read

Commissioning a pumping station is a pivotal moment in any infrastructure project — the bridge between construction completion and full operational readiness. But with this transition comes a host of safety challenges. Mechanical equipment, high-voltage systems, pressurized pipelines, and confined spaces all pose serious hazards. A well-planned, disciplined approach to safety is not only essential — it’s non-negotiable.

1. Start with a Comprehensive Commissioning & Safety Plan

Before any system is energized or pressurized, a detailed safety plan should be developed and communicated to all involved. This plan should include:

A risk assessment covering all commissioning stages.
Identification of critical hazards (e.g., electrical energization, moving parts, confined space entry).
Defined roles and responsibilities, with safety leads clearly identified.
Emergency response procedures tailored to the site and the systems.

Every person on site, from subcontractors to commissioning agents, must understand this plan and their role in it.

2. Pre-Commissioning Verifications

Safe commissioning starts long before pushing the first “Start” button. Pre-commissioning inspections must confirm that:

Electrical systems are correctly wired, grounded, and tested for insulation and continuity.
Mechanical systems — pumps, couplings, valves, and pipework — are aligned, secured, and free from obstructions.
Instrumentation and control systems are calibrated, configured, and function-tested in a safe, offline environment.

Any deviation at this stage can compromise not only system performance but personnel safety during startup.

3. Lockout/Tagout (LOTO): Zero Energy Means Zero Risk

LOTO procedures are essential for protecting workers performing maintenance or functional testing. All energy sources — electrical, hydraulic, pneumatic — must be isolated and verified before work begins.

Commissioning often involves multiple disciplines working in parallel. A clear, enforceable LOTO protocol ensures systems cannot be unintentionally energized while work is in progress.

4. Managing Confined Space Entry

Pumping stations often include underground vaults, wet wells, or sumps — all of which can qualify as confined spaces. Entry into these areas requires:

Atmospheric testing for oxygen levels and hazardous gases.
Adequate forced-air ventilation.
Use of harnesses and retrieval systems.
A trained, present attendant and a defined rescue plan.

No one should enter a confined space without proper training, authorization, and equipment.

5. Safe Hydraulic Testing and Pressurization

Hydraulic testing and initial pump operation must be approached with caution. Sudden pressurization, line failure, or water hammer events can result in serious injury.

Pressurize systems gradually, with all personnel clear of potential failure points.
Verify that pressure relief valves are installed and set correctly.
Confirm isolation valves are operating as intended before flow is introduced.

6. Coordination Is Critical

Commissioning involves a blend of trades: electrical, mechanical, controls, and civil. A lack of coordination can lead to conflicting tasks or missed hazards.

Hold daily coordination meetings to align teams.
Use structured commissioning checklists that integrate safety milestones.
Assign a central commissioning authority to ensure oversight and accountability.

7. Training and PPE: The First Line of Defense

All personnel should be trained in the specific hazards associated with their tasks. Site-specific inductions, toolbox talks, and just-in-time briefings are essential.

Ensure appropriate Personal Protective Equipment (PPE) is worn at all times — including hard hats, eye and hearing protection, gloves, and flame-resistant clothing, where required.

Final Thoughts

The commissioning phase of a pumping station is a time of heightened risk and opportunity. It’s the moment when systems come to life — and when the stakes are highest. By embedding safety into every stage of the commissioning process, teams not only protect lives but ensure a smoother, more reliable transition to operation.

Safety isn’t a box to check — it’s the foundation of successful commissioning.