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O&M Manual Document No. Rev.No. 0 Date Issued: 18.01.2017 Page 14-0

Introduction: The Start-up procedure is prepared to ensure the requirements for starting the fuel
transfer system are fulfilled. Before starting the system it has to be checked to ensure proper
functioning of each components The testing of the system is carried out in the prescribed manner
and in compliance with the project technical specifications, design, standards and codes.


14.2.1 Fuel Pump Physical Test

14.2.A Confirm the direction of rota tion of the motor shaft as shown in the data sheet.
14.2.B Confirm the flow rate o f the fuel transfer p ump as indicated in the data sheet
by calculating the total time taken to fill the da y tank.
14.2.C Check the supply voltage is 240 V, 50 Hz, 1 Phase as per kharamaa regula tion b y using
the multimeter.
14.2.D Check the starting current of the motor is as mentioned in the data sheet b y using
the multimeter.
14.2.E Check the running current of the motor is as mentioned in the data sheet b y using
the multimeter.

14.2.2 Fuel Transfer Pump & Control Panel

14.2.2 A Pre- Functional Check:

Prior to Fuel transfer pump start-up, the Commissioning Engineer will conduct a Pre-Functional
C heck to verify that the sys tem is read y for start-up. The testing will be carried out as per the
following procedures:
1. Ensure the area is clean with enough illumination and required ventilation is available.

2. Conduct a visual check for the completion of the installation of the Control Panel and ensure
for the integrity of connections and equipment with earthing.

3. Check for the correct ratings for the components inside the Panel and check for the
tightness of the wiring.

4. Also check for the ins ulation resistance of the main power breaker MP B for P ump 1 & 2 and
record the values in the test sheet.

5. Check for the p roper earthing for the panel and pumps.

6. All the tests to be done are recorded on the test sheets.

7. All the components like fuses to be re- instated after conducting / completing the tests

O&M Manual Document No. Rev.No. 0 Date Issued: 18.01.2017 Page 14-1
Successfull y.

14.2.2 B Functional Check:

Functional check will be carried out as per the following procedures.

1. Permit to Work will be obtained prior to energizing and commencement of Live

Testing for the Panel.
2. DANGER Live Electricity warning notice and barriers to b e placed before the starting of the
testing & commissioning so that no un-authorized personnel will be allowed in the testing area and all
the circuits unable to be tested to be made safe with a padlock wherever necessar y.

3. To test the pump 1 in manual mode, select the S1 selector switch in Manual mode and select S2
selector switch to pump 1 mode. Note that P ump 1 will continue to run even when tank reaches high
level. So make sure that level of the tank is monitored during the manual operation to prevent

4. If P ump 1 gets overloaded, then the overload rela y will trip and the s ystem will shut down. But
pump 2 wont start automatically in manual cond ition.

6. Now select the S2 to pump 2 and repeat the above procedure.

8. To test the pumps in automatic mode, select the switch S1 in Auto Mode, & S2 to pump 1. In this
mod e of operation P ump 1 will start running if the fuel level in the Base Tank reaches Low level ( at
the same time solenoid valve in th e fuel suppl y line energizes & opens.) . In this condition the
pump2 wont start on failure of pump1. This option is provided to facilitate the maintenance o f any
one of the pump without interrupting the operation of the s ystem.

9. In this condition the duty of the pumps wont change in each cycles. Only pump1 will work in
auto mode.

10. Now put the S2 to pump2, repeat the above procedure.

11. When the da y tank reaches high level, the pump stops and the solenoid valve de-energizes
and flow to the Base tank stops

12. To test the s ystem in c yclic mode, select S1 to auto mode and S2 to c yclic mode.

13. If the da y tank is low level the pump1 will start automatically and continue till the Base
tanks are high level. The solenoid valve opens at low level and closes at high level.

14. In the second c ycle the pump 2 will start. In each cycle the duty of pump change. Also
in case of any fault in pump the second pump will start.

A. Once the pumps are in auto mod e, perform and verify the following operations:

O&M Manual Document No. Rev.No. 0 Date Issued: 18.01.2017 Page 14-2
1) Check the operation of solenoid valve when the tank is at low/ high level.

2) Check the operation of the pump at low/ high level of tank

3) Upon successful activation of the duty pump, the da y tank will be gradually filled with fuel until it
reaches the 2nd float switch. Observe and record the activation o f the float switch and operation of
the pump.

3) The pump stop working when the Base tank reaches high level.

B. Reco rd the result o f the above activities using the P ump Functional C heck Sheets. When the above
have been successfully performed and passed, the test forms should signed o ff by all concern

Note: After each successful unit test, the pumps will be left on Automatic Mode, unless the Engineer
or the Contractor advises the Testing and Commissio ning Team to shut down the pumps.

14.2.3 Safety Plan:

A job specific Risk Assessment shall be developed and attached with T&C Permit
Identif y all hazards related to the task
Preventive measures shall be effective and eas y to follow
RA shall be communicated to all testing team members
RA shall be followed b y all testing team membe rs
RA shall be approved byHS E

14.2.4 Other Affected Employees

All nearbyy wo rkforce shall be informed about testing b y Testing Crew Leader
Other wo rk force shall keep out from testing area b y p rovid ing barriers and signages
Other wo rk force can be permitted to enter and perform their task in the testing area
b y signing in T&C P TW with the permission of testing crew leader
Other wo rk force shall be provided Tool Box Talk b y Testing Enginee r

14.2.5 Supervision & Monitoring

Effective S upervision required all the time while testing crew is enga ged with testing activities
An experienced Testing engineer shall supervise the testing activities
He shall be authorized b y the T&C Manager
Monitoring / HS E Co verage shall be in place
Ensure the continuous HS E coverage from the contractor / subcontractor
Ensure all testing team members are comply with HSE rules and regulations

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14.2.6 Emergency Response
Emergency y response procedure o f the contractor will be communicated to the whole team involved
in testing
Emergency y contact number shall be displa yed in prominent places.
All wo rks shall be stopped in case o f emergency y.
Designated Assembly Point shall be in p lace

14.2.7 Environmental Requirements

Follow Local Environment Regulation
Follow SHs Environment P lan

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