Water Booster Pump Installation Testing and Commissioning Method Statement

Below is a precise method of statement for water pump or booster pump installation including the testing and commissioning steps.

Make sure that proper clearance is available from civil side before commencement of water pump installation works.

Ensure that the work area is clean and safe for carrying out the activities.

Also prior to start of works, it shall be ensured that the relevant shop drawings and coordination drawings are approved and issued for construction.

It shall be ensured that all electrical requirements such as cable trays, cable Trunking, entry side lugs, glands etc. are finalized and coordinated.

Make sure that material issued is as per the approved material submittals and has been inspected and approved by consultant/client.

Pump Installation Sequence and Steps

The following procedure shall be followed for the installation of water supply / water booster pumps:

Pre Installation Checks

• Ensure that the installation of the water supply pump is carried out in accordance with manufacturer’s installation recommendations and specification.
• Prior to start of installation, refer to the approved shop drawing related to the area of installation and ensure that required material is available at site as per approved material submittals.
• Ensure that the equipment and accessories are stored properly and there is no damage or deformity of any kind during transportation of material from site store to the working area.
• After inspecting the work area, ensure that it is totally ready for installation, after that the required equipment shall be moved to the place of installation.
• Visually inspect the exterior casing of the water supply pumps for any damages during transporting and transferring of the units.
• Check the equipment weight to ensure that the rigging equipment can handle that safely.
• Before installing the Water Supply Pump check whether proper space is available for servicing or not.
• If there are any services installed previously in ceiling in the same area shall be shifted to the side of the Water Supply Pump for easy future maintenance.
• The foundation of the Pumps shall be checked for dimensions, location, orientation and the level as per manufacturer’s recommendations.

Booster Pump Installation Steps

First the location of the vibration isolators shall be marked on the ground base and anchor bolts shall be installed as per sizes in the detail drawings.

Proper space for valves and piping for future maintenance shall be ensured before installing the pumps.

Install / position the water supply pumps as shown on the approved shop drawings and level the pumps by using spirit level.

After leveling the pumps tighten the base bolts of the pumps.

It shall be ensured that the pumps & motors are properly installed with no pipe strain transmitted to the pump casing.

After completion of installing the pumps the same shall be offered for client/consultant inspection.

Installation of water supply piping, valves and insulation of water supply piping shall be done as per approved method statement and as per approved shop drawings.

While installation of cable tray & trunking in the pump room, it shall be ensured that the routing does not hinder the access of various parts of the pumps.

Electrical power and control wiring and earthing shall be carried out as detailed on respective approved electrical shop drawings and as per the recommendations of manufacturer.

Valves tags and identification sign shall be provided as per project specification requirements.

Testing and Commissioning of Water Supply Booster Pump

Pre-commissioning checks prior to start-up – Mechanical Checks

Check and inspect the installation of Water Pumps is complete, verify the installation as per approved drawings.

Verify compliance to the manufacturer’s installation instructions.

Obtain installation certification from manufacturer or their authorized representative.

Check and ensure adequate clearance available for service and maintenance of water pumps and motors.

Check the installation is coordinated with other services.

Ensure the shipping bolts / chambers are removed.

Check all nuts, bolts, screws, fasteners etc. are fixed and tightened as required.

Ensure the piping is pressure tested, verify test certificates.

Check all piping connections are complete at pumps, flow meter and pressure relief line including flexible connections where applicable.

Check and ensure the domestic water piping is flushed and cleaned.

Verify and check the pump alignment is completed as per manufacturer’s instructions.

Check and verify the water level in the water tank is full.

Check and ensure safety guards are in place and secure.

Adjust desired cut-in and cut off pressure as pre project requirements.

Rotate the pump manually and ensure free and smooth rotation.

Ensure the pumps are cleaned prior to start up and all identification labels and tags are in place.

Electrical Pre-commissioning

Check that all power cabling and control wiring is complete and dressed neatly.

Also check the power isolator is fixed close to the pump motor for emergency stop and power isolation, as per approved drawings/details.

Check all terminations are complete and tight as per requirements.

Check the grounding connections are complete and tightened as required.

Ensure the overload protections are set correctly as per the pump motor load current.

Ensure all electrical identification tags and labeling works are complete.

Water Pump Testing & Commissioning Procedure

After satisfactorily installation & static checks for the domestic Water Booster Pumps, commissioning shall commence.

Ensure system is full & vented including the water tanks.

Power shall be available at the MCC & tested by electrical team as per MCC approved commissioning method statement. Record shall be available.

Start the Water Booster Pumps with the system discharge valve 50% open or as instructed by the consultant.

Establish that there is no excess vibration and the pump is running satisfactorily.

Slowly open the discharge valve to fully open while monitoring running currents.

Record the Water Booster Pumps running current, speeds, pressure & check for smooth pump operation.

Check tank float switch interlocks operates to prevent dry running of Water Booster Pumps and that the correct level/ pressure are set.

Simulate the following faults & test output with a multimeter for the following points:

Run, Trip Low Level Alarms for Water Booster Pumps & Run, Trip, Low Level Alarms and auto Status / BMS enable for the transfer pumps.

After successful commissioning of domestic water pump set, the results will be recorded on the test sheets & shall be verified & accepted by the consultant.

Functional Performance Test:

MEP contractor shall demonstrate operation of water booster pump (s) per specification including the following:

1. Activate pump start using control system command.
2. Verify pressure drop across strainer, verify strainer is clean.
3. Verify pump inlet/outlet pressure reading, compare to test and balance report, pump design conditions, and pump manufacturer’s performance data.
4. Operate pump(s) at shutoff, 50 % and 100 % flow.
5. Plot test readings on pump curve, verify specified flow is obtained.
6. Verify motor amperage per phase and voltage phase-to-phase and phase-to-ground.
7. Check and report any unusual vibration, noise, etc.

Results:

If specified equipment performance is not verified, the contractor shall ensure that corrections are made and reschedule functional performance test as soon as possible after corrective work is completed.

Reports: Submit reports of final functional performance test for acceptance by the consultant engineer.

Inspection & Testing Plan

All the works shall be inspected in accordance to the inspection & testing plan and inspection checklists.

Results of inspection & testing shall be recorded on the inspection checklist forms.

General Guidelines for Water Pump Testing & Commissioning

Following to be ensured before functional Performance Test of the pumps.

• Pump(s) in place, grouted, vibration isolation devices functional, pump alignment and rotation verified.
• Power available with motor protection, safeties, control system contactors and interlocks functional.
• Heater water/supply piping system pressure tested, cleaned, chemical water treatment completed and report submitted.
• Pressure and temperature gauges installed and functional.
• Water balance complete with design maximum flow and pressure obtained, and report submitted.

General steps for Booster Pump Testing

• Confirm that the system is completely filled with water:
• Tighten the foundation bolts properly.
• Check the suction line connection in order to avoid drawing of air into the pump.
• Open the suction valve slowly, and start the pump by opening the discharge valve.
• Observe any leakage in the pump.
• After few minutes of operation note the pressure reading at both suction and discharge sides.
• Measure the RPM / speed of the pump motor using the tachometer.
• Note down the amperes of the motor on both load and off load positions.
• Check and record the motor temperature and make sure the motor is not heating up and values are in acceptable limits.
• Contractor shall provide all suitably qualified personnel to assist as required to perform water pump functional performance tests.