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Pump Start‑Up & Shut‑Down Checklist

Operating a pump safely and efficiently starts with the right procedures. Whether you’re dealing with centrifugal pumps, positive displacement units, or specialised designs, following a clear start-up and shut-down process helps prevent damage, reduce downtime, and protect personnel. This step-by-step checklist is designed to guide operators through pre-start inspections, safe commissioning, steady-state monitoring, and controlled shutdown — ensuring your pump runs reliably from the moment it starts until the moment it stops.

Pump tag: ____ Service/fluid: ____ Operator: ____ Date/Time: ____

1) Safety & Pre‑job

  • Job brief/toolbox done; hazards identified (hot surfaces, pressure, chemicals, rotation).
  • PPE on (min: safety glasses, gloves, hearing; add chemical/thermal PPE as required).
  • Work permits in place (hot work, confined space, line break if applicable).
  • Lockout/Tagout verified removed from the pump you intend to run; isolation status confirmed for adjacent equipment.
  • Area clear; guards/couplings in place; drip trays/bunds set.

2) Pre‑Start Mechanical & System Checks

  • Suction/discharge lines correctly aligned, supported, and strain-free.
  • Suction valve fully open; strainers/filters checked/cleaned; vented of air where required.
  • Discharge valve throttled (≈10–30% open for centrifugal; fully open for PD).
  • Check check‑valves/non‑return valves free and oriented correctly.
  • Seal system set: plan water/flush/thermosyphon on and flowing; pressure per spec.
  • Cooling to bearings/jacket/heat exchanger on (if fitted).
  • Lubrication OK: oil level in sight glass, correct grade; grease points serviced per schedule.
  • Coupling alignment status known (no recent disturbance); foundation bolts tight.
  • Pump casing primed and fully vented of air (centrifugal & mag‑drive must never run dry).
  • For self‑priming or PD suction‑lift: suction lines tight; foot valve functional.
  • Relief/bypass protection available and set (mandatory for PD; recommended for thermal relief on centrifugal in dead‑headed services).
  • Instrumentation live and zeroed: suction/discharge pressure, flow, temperature, vibration, motor current.
  • Confirm correct rotation: bump/jog motor, then return to stop.

Notes by pump type

  • Centrifugal: Ensure NPSH margin adequate, vent casing/volute and top of seal chamber, recirc/min‑flow path available if low‑flow risk.
  • PD (gear, lobe, diaphragm, peristaltic): Verify discharge open, relief valve set and tested; do not throttle on discharge with a closed valve; product-compatible startup speed set.

3) Electrical/VFD Checks

  • Nameplate voltage/frequency match; MCC breakers set; interlocks healthy.
  • VFD parameters loaded: min/max speed, accel/decel (e.g., 5–20 s), current limit.
  • Start permissives satisfied (tank level, seal water, cooling, E‑stops reset).

4) Start‑Up (Normal)

Centrifugal

  • Start motor with discharge throttled (≈10–30% open), suction fully open.
  • Confirm pressure rise and stable prime within a few seconds.
  • Gradually open discharge to target flow/pressure; avoid operating near shut‑off or far left of curve.
  • If on VFD, ramp to target speed observing NPSH/anti‑cavitation limits.

Positive‑Displacement (PD)

  • Ensure discharge open and relief path active.
  • Start at low speed (or minimum air for AODD); observe pressure/flow increase.
  • Increase speed to duty; verify pressure remains below relief set point.

5) Post‑Start Checks (First 5–10 Minutes)

  • Suction/discharge pressures vs expected; record baseline: Ps = __ kPa, Pd = __ kPa, Q = __, I = __ A, T_brg = __ °C, Vib = __.
  • Flow within spec; no surging/cavitation (listen for crackle; check pressure fluctuation).
  • Mechanical seals/pump glands: leak within acceptable limits; flush rates correct.
  • No abnormal vibration/noise; coupling and base stable.
  • Bearing housings warming gradually, trending < 80 °C (or site limit) and steady.
  • No leaks at flanges, ports, drain/vent plugs.
  • For hot or viscous service: step open/step up speed gradually to temperature‑soak equipment.

6) Steady‑State Monitoring (First Hour)

  • Hold within allowable operating region (AOR); avoid minimum‑flow violations (centrifugal).
  • Motor current within nameplate/drive limit; power factor normal.
  • Temperatures steady: product, casing, bearings, seal pot.
  • Seal pot levels/pressures OK; refilled if needed.
  • Record one‑hour readings for trending (Ps, Pd, Q, I, T, Vib).

7) Normal Shut‑Down

Centrifugal

  • Gradually throttle discharge toward minimum‑flow position (or maintain min‑flow bypass).
  • If on VFD, ramp speed down to minimum.
  • Stop the motor.
  • Close discharge valve after shaft stops; keep suction open unless isolation required.
  • Maintain seal flush/cooling for post‑run soak (per OEM, e.g., 5–15 min) then shut off.

Positive‑Displacement (PD)

  • Reduce speed/air to minimum while discharge remains open.
  • Stop the drive.
  • If isolating, close suction first (to prevent backflow), then discharge; relieve trapped pressure via bleed/relief to safe location.
  • Turn off flush/cooling after any required soak.

All Pumps – After Stop

  • Zero‑energy check: pressure bled to safe state; lines labelled if pressurised.
  • Inspect for run‑down leaks, reverse rotation (watch NRV), unusual noises.
  • Record final readings and any anomalies.

8) Emergency Shut‑Down (Any Pump)

  • Hit E‑STOP or open breaker.
  • Relieve pressure using designated vents/relief to safe containment.
  • Close suction and discharge as directed by site SOP to isolate.
  • Keep clear of rotating/hot parts; notify control room/supervisor.
  • Lock/tag if equipment is unsafe; document event and readings.

9) After Maintenance / First Start (Additional Checks)

  • Shaft free to turn by hand; no rubs.
  • Impeller/rotor clearances set; seal faces/lip seals installed correctly.
  • Oil flushed/replaced; correct fill volume; breathers installed.
  • Piping re‑instated with proper alignment; strainers cleaned.
  • Bump test for rotation and phase balance; vibration probe gap set (if API/condition monitoring).
  • Controlled start with step‑ups (e.g., 30% → 60% → 100% speed) logging data at each step.

10) Storage / Standby (If Not Running Soon)

  • Short‑term: rotate shaft weekly; keep primed (centrifugal) or wetted (peristaltic elastomer).
  • Long‑term: drain/flush, preserve with inhibitor or desiccant; blank/open vents per OEM; de‑tension peristaltic shoes/rollers if specified.

Quick Rules of Thumb

  • Centrifugal: never run dry; protect from low‑flow and cavitation; start throttled, open to duty.
  • PD: never dead‑head; relief valve mandatory; start slow with discharge open.
  • Mag‑drive/sealless: absolutely no dry running; ensure circulation/venting before start.
  • AODD: use clean, dry air; install muffler heater/insulation if icing risk; regulate inlet air, not discharge.

Download pdf here: Pump Start-Up & Shut-Down Checklist.pdf

Disclaimer:
This checklist is provided as a general guide only. It is not a substitute for the manufacturer’s operating instructions, your site’s standard operating procedures (SOPs), or applicable legal and regulatory requirements. All equipment must be operated, maintained, and inspected by trained and authorised personnel. Conditions, configurations, and hazards may vary between installations. Always refer to the pump manufacturer’s manual and your organisation’s safety policies before starting, operating, or shutting down equipment. The author and distributor of this checklist accept no liability for damages, injury, or loss arising from its use.