Cold commissioning is a crucial process in restarting pump systems post shutdown. It ensures systems are inspected, tested, and optimised before returning to operational status, minimizing risks and maximizing efficiency. In this second instalment of our blog series, we outline step-by-step cold commissioning procedures for pumps, empowering industrial operators to confidently handle this critical phase.

 

Why Cold Commissioning Matters

Cold commissioning involves testing equipment in non-operational conditions to verify performance and ensure all systems are ready for operational commissioning. It provides a safety net, reducing the likelihood of catastrophic failures during live operations.

As specialists in fluid control, Process Containment Solutions (PCS) prioritises these procedures to guarantee safe, effective restarts.

 

A Step-by-Step Guide to Cold Commissioning Pumps

1. Pre-Commissioning Inspections

• Visual Examination –  Inspect pumps for signs of damage, wear, or misalignment that may have occurred during shutdown. Pay special attention to seals, bearings, and coupling alignment.
• Lubrication Checks – Verify the lubrication levels in bearings and other components. Use manufacturer-approved lubricants to avoid compatibility issues.
• Pipeline Integrity – Check associated pipelines for blockages, corrosion, or leaks. This step ensures an unobstructed flow path.

2. Testing Electrical Systems

• Motor Performance – Conduct a megger test to assess insulation resistance and verify the motor is operationally safe.
• Control Systems – Inspect and test control panels, ensuring that sensors, switches, and alarms are functional.

3. Rotational Testing

• Hand-Turning the Shaft –  Rotate the pump shaft manually to ensure free movement and detect any potential blockages or resistance.
• Coupling Alignment Verification –  Misaligned couplings can cause undue stress on bearings and seals. Use a dial indicator to measure and adjust alignment as needed.

4. System Testing

• Leak Testing – Pressurise the system to simulate operational conditions and inspect for leaks in gaskets, seals, and connections.

5. Documentation

• Record findings from each step of the commissioning process. Detailed documentation ensures transparency and provides a reference for future inspections or troubleshooting.

 

Best Practices for Cold Commissioning Success

Adhere to Manufacturer Guidelines: Always consult OEM manuals for specific recommendations tailored to your equipment.
Team Coordination: Ensure that technicians, operators, and engineers are aligned on procedures and roles.
Safety Protocols: Enforce stringent safety measures, including the use of PPE and lockout/tag-out procedures, to prevent accidents during testing.

 

 

Common Challenges and Solutions

Seal Failure: Often caused by improper lubrication or alignment. Solution: Use high-quality mechanical seals from trusted providers like PCS.
2Electrical Faults: Arise from outdated wiring or insufficient testing. Solution: Regularly update electrical components and perform rigorous pre-start tests.
Pump Cavitation: Results from incomplete priming or trapped air. Solution: Thoroughly bleed air from the system before full operation.

 

PCS: Your Partner in Commissioning Excellence

At PCS, we don’t just supply pumps, we ensure their longevity through comprehensive services, including mechanical seal repairs, technical consulting, and a preservation program that aligns with global standards like API 682. Our expertise empowers you to maximize the reliability and efficiency of your equipment.

Stay tuned for the final part of this series, where we’ll discuss post start-up inspection, ensuring your pumps remain operationally robust long after recommissioning.