Commissioning Checklist: Equipment Startup
A commissioning checklist for new or newly maintained equipment. Covers pre-startup checks, functional testing, performance verification, and handover to operations.
1. Pre-Startup Checks
☐ All installation/construction work completed
☐ All tools and materials removed from the equipment area
☐ All guards, covers, and safety devices installed and secured
☐ All electrical connections tight and properly torqued
☐ All piping connections tightened and supported
☐ All valves in the correct position (suction open, discharge closed for pumps)
☐ All isolation removed (LOTO cleared) — locks and tags removed
☐ Oil/lubricant levels verified — correct type and quantity
☐ Cooling water flow verified (if applicable)
☐ Seal flush water/external supply connected (if applicable)
☐ Area cleaned — no debris, tripping hazards, or obstructions
☐ Fire extinguisher available (if required)
2. Mechanical Checks
☐ Coupling alignment verified (laser-aligned within tolerance)
☐ Rotation direction verified (bump start — check rotation arrow)
☐ Belt tension correct (if applicable)
☐ Free rotation verified — shaft turns freely by hand (if safe to do so)
☐ All fasteners torqued to specification
☐ No interference between rotating and stationary parts
3. Electrical & Instrument Checks
☐ Motor insulation resistance tested (megger test) — above minimum
☐ Phase rotation verified — correct sequence for three-phase motors
☐ All instruments calibrated — pressure, temperature, flow sensors
☐ Control system I/O tested — all inputs and outputs responding correctly
☐ Alarms and interlocks tested — verify each alarm triggers at the correct setpoint
☐ Emergency stop functional — verify E-stop shuts down the equipment
☐ Motor overload relay set to the correct FLA
4. Functional Testing (No-Load)
☐ Start equipment — no-load run for 30 minutes minimum
☐ No abnormal noise or vibration — record vibration readings
☐ Bearing temperatures stable — below 80°C
☐ Motor amperage at no-load — within expected range (typically 30–50% FLA)
☐ No oil leaks at seals, gaskets, or connections
☐ Cooling system operating — verify flow and temperature
☐ Control system operating — verify start/stop, speed control, modulation
☐ All safety devices functional — test each interlock and alarm
5. Performance Testing (Load)
☐ Gradually apply load — don't go from 0 to 100% instantly
☐ Verify flow rate and pressure/head meet design specifications
☐ Record performance data — flow, pressure, temperature, power, vibration
☐ Compare to pump/equipment performance curve — verify operation at design point
☐ Monitor for leaks under load — check all flanges, valves, and seals
☐ Verify stable operation — no oscillation, hunting, or instability
☐ Run at full load for minimum 2 hours — monitor all parameters
☐ Record baseline readings for future condition monitoring
6. Handover to Operations
☐ Operations team briefed on operation, safety, and emergency procedures
☐ Operating manual and spare parts list provided
☐ PM schedule updated in CMMS — first service scheduled
☐ Baseline condition data recorded (vibration, temperature, performance)
☐ Commissioning report completed and signed
☐ Warranty documentation filed
☐ Equipment handed over to operations — signed acceptance
Remember
Commissioning is not complete until the equipment has been proven to perform at design conditions for an extended period. Don't hand over until you're confident it's safe, functional, and reliable.