As the industrial sector resumes operations after festive shutdowns, the focus shifts to post-start-up inspections. These inspections ensure that pump systems and fluid control equipment are operating safely, efficiently, and as intended. In this final instalment of our series, we provide a comprehensive guide to the critical checks required after start-up, empowering businesses to safeguard their machinery and optimise productivity.

The Importance of Post Start-Up Inspections

Start-up operations, even with thorough planning, can introduce unforeseen issues. Improper alignment, residual shutdown stress, or undetected wear can affect pump performance and lead to costly downtime. Conducting detailed post start-up inspections ensures early identification of such issues, minimizing risks to equipment longevity.

A Step-by-Step Guide to Post Start-Up Inspections

1. Assess Initial Performance

• Noise and Vibration Monitoring – Abnormal noises or excessive vibration can indicate problems such as misalignment, cavitation, or bearing issues.
• Pump Flow Rate – Compare the actual flow rate with design specifications to detect performance deviations.

2. Inspect Mechanical Components

Coupling Alignment: Check that couplings remain aligned after start-up. Even slight misalignment can stress shafts and seals, reducing efficiency.
Seal Integrity: Inspect mechanical seals for leaks, wear, or improper seating. A properly functioning seal is essential to maintain pressure and prevent fluid loss.

3. Evaluate Electrical Systems

Motor Current and Voltage: Measure motor electrical parameters to ensure they are within normal operating ranges.
Control Systems: Verify the functionality of automation controls, alarms, and sensors to guarantee system safety and responsiveness.

4. Monitor Fluid Dynamics

Pressure Testing: Ensure system pressures align with operational benchmarks, avoiding conditions that may compromise seals or valves.
Temperature Readings: Abnormal temperature spikes can signal issues in lubrication, cooling, or heat transfer systems.

5. System Documentation
Record all findings during post start-up inspections, noting any irregularities and corrective actions. Comprehensive documentation streamlines troubleshooting and supports predictive maintenance efforts.

 

Proactive Maintenance Post Start-Up

Routine post start-up inspections are vital, but incorporating proactive maintenance strategies enhances equipment reliability. Consider the following:
Condition Monitoring: Employ technologies like vibration analysis or thermography to track equipment health in real-time.
Spare Parts Management: Maintain an inventory of critical components such as seals, bearings, and couplings to minimize downtime during repairs.
Scheduled Audits: Partner with specialists like PCS for periodic system audits to identify and address emerging risks.

Avoiding Common Start-Up Issues

Seal Wear or Leakage: This can occur due to improper lubrication or fluid contamination during shutdown. Solution: Inspect seals thoroughly and replace them if needed.
Motor Overheating: Caused by misalignment or excessive electrical load. Solution: Monitor motor temperature and current, ensuring proper alignment and lubrication.
Pump Cavitation: Often a result of trapped air or improper priming. Solution: Bleed the system and verify fluid levels before start-up.

Why Choose PCS for Post Start-Up Excellence

Process Containment Solutions (PCS) combines decades of experience with a commitment to customer success. From seal repairs to technical consulting, we offer tailored solutions to optimise fluid control systems. Our dedication to quality aligns with ISO 45001 standards, ensuring that your equipment operates efficiently and safely.

With this series, PCS aims to empower businesses with knowledge to navigate shutdowns and start-ups successfully. If you missed parts one or two, explore shutdown procedures and cold commissioning protocols to complete your understanding.