Correct installation and operation are just as important as pump selection. Even the most efficient pump can fail prematurely or waste energy if not installed correctly. This section outlines best practices for installing and operating pumps to ensure reliability, safety, and long service life.
Safety First
Always follow manufacturer’s instructions, local codes, and safety regulations. Isolate power before any work on electrical connections.
Foundation & Alignment
Foundation
- Pumps should be mounted on a rigid, vibration-free foundation
- Concrete bases are preferred for permanent installations; skids or trailers are used for portable setups
- The foundation should extend at least 150 mm beyond the pump baseplate on all sides
Alignment
- Shaft alignment between pump and motor/engine is critical
- Misalignment causes vibration, seal leakage, and bearing wear
- Always perform laser alignment or dial gauge alignment after installation and again after first startup (when foundation settles)
Alignment is Critical: Misalignment is the leading cause of premature seal and bearing failure. Always re-check alignment after piping is connected and the system is pressurized.
Suction Line Installation
Keep suction piping short, straight, and oversized compared to discharge piping
Avoid high points where air can collect; slope suction lines upward toward the pump
Use eccentric reducers (flat side up) at pump suction to prevent air pockets
Install strainers or foot valves where necessary, but ensure they are cleanable and sized to minimise losses
Ensure adequate submergence at the source to prevent vortexing and air entrainment
Discharge Line Installation
Use pipework rated for pump shut-off pressure
Fit a non-return (check) valve and an isolation valve close to the pump discharge
Provide air release valves at high points to prevent air locking
Support pipework independently — never let pipe strain rest on the pump nozzles
Priming & Commissioning
Priming
- Centrifugal pumps are not self-priming (unless specifically designed)
- Fill casing and suction line before startup
- For diesel-driven dewatering sets, automatic priming systems (vacuum or diaphragm) are often included
Commissioning Checks
- Confirm rotation direction matches the arrow on the pump casing
- Start with discharge valve partially closed to reduce startup load
- Monitor suction/discharge pressures, flow, vibration, and noise
- Record baseline operating data (pressures, flow, amps/kW, temperature) for future comparison
Operating Guidelines
Operate Near BEP
- Avoid running at very low flow (recirculation → overheating, vibration)
- Avoid excessive flow (cavitation risk, motor overload)
Avoid Frequent Starts/Stops
- Too many cycles cause overheating and electrical stress (for motors)
- Use automatic level controls or VSDs to reduce cycling
Monitor Key Parameters
- Suction/discharge pressure
- Flow rate (if metered)
- Motor/engine load (amps, kW, fuel consumption)
- Bearing and seal condition
Maintain Clean Suction
- Blocked strainers reduce NPSHa, leading to cavitation
- Regularly check and clean strainers, foot valves, and intake screens
Maintenance Practices
Routine (Daily/Weekly)
- Inspect for leaks, unusual noise, or vibration
- Verify pressure/flow readings are within design range
- Check oil level in bearings (if applicable)
Scheduled (Monthly/Quarterly)
- Grease bearings as per manufacturer instructions
- Inspect mechanical seals and couplings
- For diesel sets: service oil, filters, coolant, and belts
Annual Maintenance
- Verify alignment again
- Inspect impellers for wear or fouling
- Replace worn seals, bearings, or gaskets
Safety Considerations
Always lock out/tag out electrical supply before working on pumps
Relieve system pressure before dismantling
Ensure guards are fitted over couplings and rotating shafts
For diesel pumps: handle fuel safely, ensure bunded storage, and keep fire extinguishers nearby
Provide adequate ventilation in enclosed pump rooms to prevent overheating and accumulation of exhaust gases
Common Mistakes
Undersized suction lines → cavitation and reduced pump life
Misalignment between pump and driver → bearing and seal failure
Allowing pipe strain on pump flanges → casing cracks and leaks
Running pump dry → seal destruction within minutes
Neglecting priming system → poor startup reliability
Ignoring early signs of vibration or noise → catastrophic failures
Summary
Correct installation and operation practices are essential to achieve the designed performance and efficiency of pumping systems. A strong foundation, proper alignment, well-designed suction and discharge pipework, correct priming, and disciplined operation close to BEP will ensure long service life with minimal downtime.