Pump Maintenance & Start-up Checklist:
For Buildings After Extended Periods of
Turndown or Shutdown
 
 
 
 
 
Maintenance Recommendations for Buildings Post-COVID-19
COVID-19 has brought unique challenges for commercial buildings
throughout the US from reducing occupancy and/or maintenance to
complete shutdown.

In these unpresented times, Grundfos is here to offer some

recommendations when preparing to start up your pumps after long-
term reduced capacity turndown or complete building shutdown.
Included in this guide are checklists for:
1. HVAC Pumps
2. Pressure Boosting Pumps
3. Sewage Pumps

If after completing these checklists you would like additional support

from a certified pump technician to review your system or perform
maintenance, contact the Grundfos Service & Solutions team at
grundfos.us/service
 
   

Safety Disclaimer:
Carefully observe the safety instructions to ensure correct installation, operation and
maintenance of all equipment. The instructions must be known by any person installing, using or
maintaining the equipment. Safety equipment required to prevent accidents must be made
available according to local safety instructions. All local safety requirements are to be strictly
adhered to while working on any equipment. The electrical installation of the motors must be
carried out according to local regulations.

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Contents
Staying Safe ............................................................................................................................. 3
OSHA COVID-19 Training Resources ............................................................................................... 3

HVAC & Booster Pump Maintenance ...................................................................................... 4

Common Pump Issues ..................................................................................................................... 4
Mechanical Looseness .................................................................................................................. 4
Plumbing Health Concern: Legionella ........................................................................................ 4
Maintenance & Start-up Checklist: HVAC Pump ........................................................................... 5
Critical HVAC Spare Parts To Stock .............................................................................................. 6
Maintenance & Start-up Checklist: Boosting Pump ..................................................................... 7
Critical Boosting Pump Spare Parts To Stock .............................................................................. 8

Sewage Pump Maintenance ................................................................................................... 9

Maintenance & Start-up Checklist: Sewage/Sump Pumps ........................................................ 10
Critical Sump Pump Spare Parts To Stock ................................................................................. 12
 

   

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Staying Safe
The general recommendations for essential staff safety are:
 Wear personal protective equipment (PPE)
 Wash your hands regularly for at least 20 seconds
 Use a 60% alcohol based hand sanitizer when running water is not available
 Cover your nose or mouth when sneezing or coughing
 Avoid close contact — keeping a minimum of 6′ from others
 Avoid touching your face

OSHA COVID-19 Training Resources

Train all workers with reasonably anticipated occupational exposure to SARS-CoV-2 about the
where and how they can be exposed to the virus, the hazards associated with that exposure,
and appropriate workplace protocols in place to prevent or reduce the likelihood of exposure.
Training should include information about how to isolate individuals with suspected or
confirmed COVID-19 or other infectious diseases, and how to report possible cases. Training
must be offered during scheduled work times and at no cost to the employee.
Workers required to use PPE must be trained. This training includes when to use PPE; what PPE
is necessary; how to properly put it on, use, and take it off; how to properly dispose of or
disinfect, inspect for damage, and maintain PPE; and the limitations of PPE. Applicable
standards include the PPE (29 CFR 1910.132), Eye and Face Protection (29 CFR 1910.133), Hand
Protection (29 CFR 1910.138), and Respiratory Protection (29 CFR 1910.134) standards. The OSHA
website offers a variety of training videos about respiratory protection.
When the potential exists for exposure to human blood, certain body fluids, or other
potentially infectious materials, workers must receive the training required by the Bloodborne
Pathogens (BBP) standard (29 CFR 1910.1030), including information about how to recognize
tasks that may involve exposure and the methods, such as engineering controls, work practices,
and PPE, to reduce exposure. Further information on OSHA's BBP training regulations and
policies is available for employers and workers on the OSHA Bloodborne Pathogens and
Needlestick Prevention Safety and Health Topics page.
OSHA's Training and Reference Materials Library contains training and reference materials
developed by the OSHA Directorate of Training and Education as well as links to other related
sites. The materials listed for Bloodborne Pathogens, PPE, Respiratory Protection, and SARS may
provide additional material for employers to use in preparing training for their workers.
OSHA's Personal Protective Equipment Safety and Health Topics page also provides
information on training in the use of PPE.
Additional information and OSHA resources can be found here
 

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HVAC & Booster Pump Maintenance
Common Pump Issues
Mechanical Looseness
The most common mechanical issues when it comes to your HVAC and booster pumps are
categorized as mechanical looseness. Mechanical looseness is comprised of:
1. Bearing Failure
Bearings are precision parts and can be the most common and costly piece in low
performing pumps. It is important to check your bearings regularly to avoid
performance issues and downtime costs from these failures. The best way to ensure
bearings work properly is to make sure they are lubricated correctly, both in material
and application. When replacing your bearings, it’s key to use genuine OEM certified
spare parts because these are precision parts and even if the bearing fits the pump’s
shaft and housing bore, that does not ensure it’s the right bearing and won’t cause
future damage.
2. Mechanical Seal Issues
Seal issues can frequently be caused from dry running. If a pump sits dormant for an
extended period of time, the seal faces can stick together. Therefore it’s
recommended to rotate your pump and motor to ensure the motor can move
properly before full-speed start up. Additionally, seals that are stuck together could
cause cracking and lead to possible leaks.
3. Misalignment
Alignment is always a great maintenance practice and will help to ensure proper
pump operation when running. Proper alignment will prevent unnecessary wear and
tear on your pumps, preventing premature bearing or coupling failure, and
additionally help your equipment run more efficiently — keeping energy costs down.
To prolong pump alignment, check to make sure all pump equipment is bolted tightly
before each pump start.

Plumbing Health Concern: Legionella

After long periods of building turndown or shutdown, there could be stagnant water present in
your pipes, which are breeding grounds for Legionella and other bacteria. All pipes in your
building should be checked for Legionella bacteria. If Legionella isn’t found, we recommend
flushing your system with sanitizer using a dosing pump as a preventative measure. If
Legionella is detected, proper instructions for Legionella treatment of stagnant water must be
followed and it’s recommended to seek professional support for such remediation.

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Maintenance & Start-up Checklist: HVAC Pump
Use this checklist as a general guide for recommended inspection of your existing
HVAC pumps.

General Information
Inspection Date: Inspector:
Building Address:

Pump Location: Floor:

Pump & Motor Nameplate Information

Pump Model:
Pump Type:
Pump Serial Number:

Recommended HVAC Pump Maintenance Steps:

Check the pump and associated plumbing for leaks and corrosion
Verify operation of the isolation valves
Verify function of check valves
Check all critical fasteners are tight
Grease the pump and motor bearings
Change the lubricant in the bearing house (if equipped)
Evaluate pump performance gauge readings and flow meter readings
Check the integrity of the electric motor using voltage or amp readings and insulation
breakdown test
Review drive coupling wear
Test dry run protection (if equipped) and confirm the pumps have been re-primed
Inspect the conditions of the electrical panel, overload settings, alarm history, etc.*
Perform vibration analysis on the pump and motor to evaluate bearing wear
Align pump (if necessary)
Start-up pump with required initial speed — 45 H to ensure any debris between the impeller,
wear ring (or casing) is flushed out

* If in a live panel technician must have NFPA70E certification and use all required PPE for the task.
Live panel work should never be done alone.

5
 Critical HVAC Spare Parts To Stock
1. Gaskets for flanges and check valve

2. One spare mechanical seal kit, one shaft sleeve kit, and one volute gasket kit for
end-suction pumps

3. Two spare mechanical seal kits and a gasket kit for splitcase pumps

4. One coupling assembly for splitcase pumps

5. One coupling assembly for any long coupled end-suction pumps

6. One spare transducer if equipped

7. One flow switch if equipped

8. One liquid level switch if equipped

9. Fuses for control panel

10. One spare motor overload/starter for the panel

11. Bearing grease

To get genuine Grundfos OEM spare parts visit: grundfos.us/spareparts

Looking for maintenance and operation support? Grundfos has a

team of certified technicians ready to help.

Learn more at grundfos.us/service

6
Maintenance & Start-up Checklist: Boosting Pump
Use this checklist as a general guide for recommended inspection of boosting pumps.

General Information
Inspection Date: Inspector:
Building Address:

Pump Location: Floor:

Pump & Motor Nameplate Information

Pump Model:
Pump Type:
Pump Serial Number:

Recommended Boosting Pump Maintenance Steps:

Check the pump and associated plumbing for leaks and corrosion
Verify operation of the isolation valves
Verify function of check valves or PRV’s (if equipped)
Ensure all critical fasteners are tightened
Grease the pump and motor bearings
Change the lubricant in the bearing house (if equipped)
Review pump performance gauge, flowmeter and transducer readings
Check the integrity of the electric motor using voltage or amp readings and insulation breakdown test
Review drive coupling wear
Inspect the condition of the operating setpoints of the VFD’s (if equipped)
Verify system meets operating setpoints and stops, and can keep required setpoint
Test and check dry run protection (if equipped); stop function; limits function operation — both low and
high limits and make sure each pump has individually been re-primed
Inspect the diaphragm tank conditions and pressure settings (if equipped)
Test/verify that the pumps alternate and that each pump does not have an excessive run time
Inspect the conditions of the electrical panel, overload settings, alarm history, etc.*
Perform vibration analysis on the pump and motor to evaluate bearing wear if unusual noise is detected
Identify any anomalies on the suction pressure conditions
Align pump (if necessary)

* If in a live panel technician must have NFPA70E certification and use all required PPE for the task.
Live panel work should never be done alone.

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 Critical Boosting Pump Spare Parts To Stock
1. Gaskets for flanges and check valve

2. One spare mechanical seal kit, one shaft sleeve kit, and one volute gasket kit for
end-suction pumps

3. One cartridge seal kit for vertical multistage pumps

4. One spare transducer if equipped

5. One flow switch if equipped

6. One liquid level switch if equipped

7. Fuses for control panel

8. One spare motor overload/starter for the panel

9. Bearing grease

To get genuine Grundfos OEM spare parts visit: grundfos.us/spareparts

Looking for maintenance and operation support? Grundfos has a

team of certified technicians ready to help.

Learn more at grundfos.us/service

8
 Sewage Pump Maintenance
Sump pump and other sewage equipment maintenance is dangerous and requires special
precautions and certifications from technicians. Why? Because you will encounter any or all of
these dangers: slipping hazards near jagged metal, drowning hazards, flammable methane gas,
toxic carbon monoxide, oxygen deprivation, and potential electrocution. You’ll also be exposed
to biohazards like dead animals, hypodermic needles, used hygiene products, bandages, and
other products, human waste, rotted cooking fat, rats, spiders, snakes, and cock roaches.
Personnel Requirements for Technicians Include:
 Intermediate mechanical, electrical, and plumbing skills
 Confined Space Entry and Confined Space Rescue Certification. Along with training on OSHA,
CPR, and first aid
 Immunization shots for Tetanus, Hepatitis A & B, polio, and typhoid fever are mandatory
 Healthy and strong enough to sustain extended periods of time hanging, standing on ladders,
and squatting
 Tolerance to temperatures above 100°F and enough cardio vascular health to sustain breathing
low quality air
 Capable of lifting 75 lbs and strong enough to carry or drag a coworker if appropriate for an
emergency situation
 Wear a Tyvek suit, rubber boots, eye protection, disposable gloves, a gas analyzer, half mask,
disposable hat, safety glasses, and body harness
 Have the following equipment: a tripod, tunnel fan, man hoist, safe storage bucket, and battery
operated power tools only

Before performing maintenance, technicians should block-off the jobsite with caution tape and
cones if the sump is located in a place with pedestrians or employees are present; because it’s
unknown what airborne virus might be floating out of the sump or off pump. Since the health
risk is unknown, we only recommend opening sumps and performing mechanical work when
no one is around, since safety can only be guaranteed to those in PPE.
Once work is complete the entire area should be rinsed down with bleach water.
 

Looking for maintenance and operation support? Grundfos has a

team of certified technicians ready to help.

Learn more at grundfos.us/service

9
Maintenance & Start-up Checklist: Sewage/Sump Pumps
Use this checklist as a general guide for recommended inspection of sewage pumps before
start-up and where to look for common maintenance needs.
Some preventative maintenance recommendations include: Once every three months, or at a
minimum, once a year, sewage sumps should be evacuated by a transfer truck and pressure
washed. This is because pumps operating in maintained sumps are way less likely to suck up
miscellaneous items such as shoes, clothing, mop heads, and garbage. Some sumps hold more
garbage than water or sewage.
 
General Information
Inspection Date: Inspector:
Building Address:

Pump Location: Floor:

Pump & Motor Nameplate Information

Pump Model:
Pump Type:
Pump Serial Number:
 
CONFINED SPACE ENTRY
Recommended Sewage Pump Checklist:
Sumps must be pressure washed and evacuated by a transfer truck
Check the discharge piping for excessive corrosion and rot
Ensure the stools that support the volutes are stable
Look for corrosion on guide rails and related brackets
Test that the isolation valves open and close
Test there is no backflow in the check valves
Verify the floats are properly hung and secure and that all are working properly
Inspect the pump cords for swelling and verify they are securely hung
Inspect the junction box (if present) for corrosion and standing water
Pull the pumps and check the impellers and volutes for damage and ragging
Verify the pumps operate without cavitation
Check the condition of the control panel for corrosion and any external damage
Check the alarm log in the controller (if present)

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 Test and check the motor overload settings
Verify stable voltage in to the panel and out of the panel to the pumps*
Evaluate the condition of the motor by amp draw and isolation break down test
Verify the sump cover is secure

WITHOUT CONFINED SPACE ENTRY

Recommended Sump Pump Checklist:
Inspection of the condition of the control panel for corrosion and pests
Proper voltage entering the panel and exiting the panel to the pumps*
Check the motor overload settings and alarm history
Evaluation of the motors by amp draw and insulation breakdown
Open the sump and visually inspect operation of the pumps and float system
Visually inspect the condition of the pump and float cords
Listen for abnormal noise from the pumps

* If in a live panel technician must have NFPA70E certification and use all required PPE for the task.
Live panel work should never be done alone.

Looking for maintenance and operation support? Grundfos has a

team of certified technicians ready to help.

Learn more at grundfos.us/service

11
 Critical Sump Pump Spare Parts To Stock
1. Panel fuses
2. At least one transducer if the sump is equipped with transducers
3. Ideally, four floats if the sump is equipped with floats, at least one or two
4. At least one spare pump if it is equipped with submersibles
5. If it is column pumps, they should have one spare motor
6. Basic parts needed to rebuild their column pump (bearings, bushings, circlips, seals, a
shaft) in the event the pump fails — most of the time it’s the bearings and shaft.  

To get genuine Grundfos OEM spare parts visit: grundfos.us/spareparts

Looking for maintenance and operation support? Grundfos has a

team of certified technicians ready to help.

Learn more at grundfos.us/service

12
Grundfos Americas
Brookshire, TX 77423
www.grundfos.ca
www.grundfos.us

www.grundfos.mx
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