Pump maintenance checklist (station inspection)
A pump maintenance checklist is a tool used by pump technicians or engineers when conducting pump inspections. pump inspection checklists guide inspectors during pump inspections to help ensure that the pumps are in good working condition. inspectors can use this digitized checklist to help prevent unscheduled disruptions by inspecting pump stations.
What does this form include?
This form contains 12 sections:
Site
- Inspect asphalt; check slope for proper drainage (no puddles)
- Inspect grounds
- Inspect fencing and gate; ensure correct operation of gate (full swing)
- Inspect fence posts and fabric for correct material (vinyl coated black or brown)
- Ensure that all debris has been removed from site
Wetwell
- Inspect interior coating (cracks, blisters, loose material, exposed concrete, etc.)
- Inspect exterior coating (coal-tar epoxy)
- Ensure that stainless steel bolts are utilized in ductile iron piping
- Inspect concrete penetrations (discharge piping, conduits, etc.)
- Ensure that all penetrations are cored and link-sealed, then finished with epoxy grout
- Check proper operation of aluminum hatch and placement per approved design
- Check and verify opening of hatch to accommodate pump extraction
- Verify all required signage has been provided (Confined Space, OSHA, etc.)
- Verify operating range of (bubbler and/or floats) per approved design
- Inspect alignment of discharge piping
- Inspect paint used on piping
- Inspect alignment of poly ladder rungs, ladder placement, and ladder mast bracket
Pumps
- Pull each pump and reset; check for ease of removal, alignment of rails and proper sealing at disconnect flange
- Inspect for any damage to paint on pump
- Inspect cord and cord placement
Valve Vault
- Inspect interior coating (cracks, blisters, loose material, exposed concrete, etc.)
- Inspect paint on all mechanical piping (cracks, blisters, loose paint)
- Inspect alignment of discharge piping
- Verify pressure gauges are in place and the correct type
- Check and verify opening of hatch
- Verify all required signage has been provided (Confined Space, OSHA, etc.)
- Ensure drain line is at grade from valve vault to wetwell
Piping
- Ensure alignment of discharge piping between wetwell and valve vault
Electrical
- Verify that seal-offs are sealed with sealing compound
- Verify that pump motor leads are a continuous run from pump to control panel
- Verify the usage of stainless steel strain reliefs on all pump and float cords
- Verify that bubbler line is sealed off in conduit
- Verify seal-offs are located in vault, and that all conduit penetrations are grouted
- Verify that there has been a signed, approved electrical inspection report
- Ensure that ground rods are accessible and have risers installed for access per specification
Control Panel
- Ensure that wiring schematic is in door pocket
- Ensure that "control" side of panel is oriented facing the wetwell
- Verify UL labeling
- Inspect enclosure for chipped paint or other damage
- Utilize mil-thickness gauge to verify proper DFT per specification
- Verify signed-off electrical inspection report from governing electrical inspector
- Verify all pilot lights are operational
- Verify all wires are labeled
- Verify all placards are in place
- Verify all wiring debris has been removed from enclosure
- General inspection of field wiring
- Conduct operation test of controls
- Pump manufacturer to supply additional motor nameplates (crew to place on interior door)
- Specialty products mounted and placed in interior of control panel
Telemetry System
- Visually verify all components have been provided and pre-wired (radio, antenna, all associated wiring, alarm points, etc.)
- Check communication link to base station
- Inspect field wiring
- Ensure that standard mast and antenna are supplied (standard anchoring method)
Operations Test - Pump System
- Ensure contractor and contractor's representatives are present during start-up (electrician, control panel manufacturer, pump manufacturer, mechanical, etc. - generator manufacturer optional)
- Verify pump rotation, reverse leads if necessary
- Throttle valves while filling force main, if applicable
- Draw-Down Test - Calculate actual GPM and compare to design specifications (check both pumps)
- Add water to system and/or simulate flow; confirm operation of liquid level control system
- Inspect sealing flange of pump for proper seal (no leaks)
- Pull pumps and extract from wetwell; ensure clearances are maintained and pumps travel smoothly
- on rail system; check pump cords for obvious obstructions
- Test "high-water" and "low-water" alarms
- Note any unusual noises/vibration
Operations Test - Generator
- Verify diesel tank is fully fueled after manufacturer's representative has performed load run
- Run generator in "manual" mode; check hertz, voltage, etc; verify operation of load bank
- Verify certified affidavit of start-up and load testing from manufacturer's representative
- Receipt of manufacturer's warranty (2-year)
- Test "auto shut-down" on overspeed circuit
- Test to see of genset meets decibel requirements of specifications
- Simulate power failure (disconnect main breaker); verify automatic start of genset
- Verify automatic transfer of power to emergency source; check for proper time delay between sequences
- Let run for ten (10) minutes
- Restore utility power source; verify automatic transfer, cool-down cycle time, and shut down
- Test load bank for proper operation
- Ensure that separate circuits are provided for battery charger and block heater
- Test block heater and battery charge for proper operation
Comments
Inspector Name and Signature
Use this template