Pump Maintenance Checklist (Station Inspection)
A comprehensive pump maintenance checklist designed for technicians and engineers performing thorough pump station inspections. This structured inspection tool guides inspectors through critical evaluation procedures to verify that all pump components and systems are in optimal working condition. By systematically documenting each inspection point, this checklist helps identify potential issues early and prevents costly unscheduled disruptions to pump station operations.
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How to Use This Checklist
- Review the pump station site checklists to confirm the asphalt surface drains properly, the grounds are free of hazards or obstructing vegetation, and the fencing and gate assembly are in good condition.
- Inspect the wetwell, including the interior and exterior coatings, stainless steel bolts, concrete penetrations, hatch operation and safety signage.
- Examine the pumps, checking each pump's exterior for paint damage or corrosion, verifying power cord condition and routing, and removing and reinstalling each pump to check ease of removal, rail alignment and sealing at the disconnect flange.
- Check the valve vault and piping, confirming discharge piping alignment, pressure gauge installation, hatch access, drain line grade, and paint condition.
- Verify the electrical installation, including seal-offs, motor leads, strain reliefs, bubbler line sealing and ground rod accessibility.
- Inspect the control panel, verifying UL labeling, wiring schematic placement, pilot light operation, wire labeling and Dry Film Thickness.
- Check the telemetry system, confirming radio, antenna and wiring are pre-wired and that the communication link to the base station is operational.
- Carry out the operations test of the pump system, verifying correct rotation, throttling valves while filling the force main where applicable, completing a Draw-Down Test to compare actual GPM against design specifications, and confirming liquid level control operation.
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Standardised pump station inspections start with the right checklist
A pump station inspection verifies that every component and system is in optimal working condition. Because a station combines mechanical, electrical and control assets, an unscheduled failure can disrupt operations. This checklist documents each inspection point across site, wetwell, pumps, valve vault, piping, electrical, control panel and telemetry system, helping you identify potential issues early. It is structured for technicians and engineers conducting thorough station inspections, and includes operational tests of the pump system and generator.
Why inspection matters
Pump stations are critical assets, and disruptions are costly. By systematically documenting each inspection point, inspectors can identify potential issues early and take action before they become serious. The checklist supports this by covering the full station: site conditions, wetwell internals, pump assemblies, valve vault equipment, electrical infrastructure, control panels, telemetry systems, and operational tests. Regular inspections using this framework help prevent unscheduled disruptions and keep the station operating as designed.
What a complete pump station inspection covers
A thorough inspection moves through each area of the station in a defined order. The checklist is organised into sections: Pump Station Inspection, Site, Wetwell, Pumps, Valve Vault, Piping, Electrical, Control Panel, Telemetry System, Operations Test - Pump System, and Operations Test - Generator. This structure ensures no critical component is overlooked and that findings are recorded consistently. Within each section, you verify that installations match approved design parameters, that safety requirements are met, and that equipment operates correctly. The checklist uses a Safe / At Risk / N/A rating scale to record the condition of each item.
Site and safety
Start with the site. Inspect the asphalt surface for drainage and slope, ensuring no standing water or puddles. Check the grounds for anomalies, hazards, or obstructing vegetation. Examine the fencing and gate assembly, confirming the gate operates smoothly with full swing clearance. Verify that fence posts and fabric meet the specified material requirements. Confirm that required safety signage, such as Confined Space and OSHA signage, is properly displayed. These steps help maintain a safe work environment and secure the site.
Wetwell
Inspect the wetwell interior and exterior coatings for defects such as cracks, blisters, loose material, or exposed concrete. Confirm that stainless steel bolts are properly utilised throughout ductile iron piping connections. Check all concrete penetrations for proper installation, verifying they are cored, link-sealed, and finished with epoxy grout. Examine the aluminium hatch for proper operation and placement, and ensure its opening dimensions accommodate full pump extraction. Verify the operating range of the level control system (bubbler and/or floats) matches approved design parameters. Also inspect discharge piping alignment, paint application, and the installation of poly ladder rungs, ladder placement, and mast bracket.
Pumps
Remove and reinstall each pump to verify ease of removal, rail alignment, and proper sealing at the disconnect flange. Inspect the pump exterior for paint damage, chips, or signs of corrosion. Examine the power cord condition and verify proper routing and placement. These checks confirm that pumps are ready for reliable service and that maintenance can be performed without unnecessary difficulty.
Valve vault
Inspect the valve vault interior coating for defects and the paint condition on mechanical piping for cracks, blisters, or loose paint. Verify proper alignment of discharge piping within the vault. Confirm pressure gauges are installed and match the required type specifications. Check that the hatch opening provides adequate and safe access. Ensure required safety signage is displayed. Confirm the drain line maintains proper grade from the valve vault to the wetwell connection.
Piping
Verify proper alignment and installation of discharge piping between the wetwell and valve vault. Confirm that all seal-offs are properly sealed with approved sealing compound. Check that pump motor leads form a continuous, unbroken run from the pump to the control panel. Confirm that stainless steel strain reliefs are installed on all pump and float cords. Verify the bubbler line is properly sealed within the conduit system. Ensure seal-offs are positioned in the vault and all conduit penetrations are properly grouted.
Electrical
Verify the existence of a signed and approved electrical inspection report from the authority having jurisdiction. Ensure ground rods are fully accessible with risers installed per specification. Confirm that the current wiring schematic is placed in the door pocket of the control panel. Verify the control side of the panel is oriented to face the wetwell direction. Confirm UL labeling is present and visible on the control panel enclosure. Inspect the enclosure for physical damage. Use a mil-thickness gauge to verify Dry Film Thickness (DFT) per project specification.
Control panel
Verify the signed electrical inspection report has been obtained from the governing electrical inspector. Test all pilot lights to confirm proper operational status. Verify all wires within the panel are properly labeled and identified. Confirm all required placards and identification labels are in place. Verify all wiring debris has been completely removed from inside the enclosure. Conduct a thorough general inspection of all field wiring connections. Perform a comprehensive operation test of all control system functions. Confirm the pump manufacturer has supplied additional motor nameplates for placement on the interior door. Verify all specialty products are properly mounted and positioned inside the control panel.
Telemetry system
Visually confirm all components are provided and pre-wired, including radio, antenna, associated wiring, and alarm points. Verify the communication link to the base station is established and operational. Inspect all field wiring connections for the telemetry system. Confirm the standard mast and antenna are supplied with the proper anchoring method per specification.
Operations test - pump system
Confirm all required contractor representatives are present during start-up (electrician, control panel manufacturer, pump manufacturer, mechanical contractor; generator manufacturer optional). Verify correct pump rotation direction; reverse leads if rotation is incorrect. Throttle valves appropriately while filling the force main, if applicable to system design. Perform a Draw-Down Test: calculate actual GPM and compare results to design specifications for both pumps. Add water to the system or simulate flow; confirm proper operation of the liquid level control system.
Operations test - generator
This section covers the generator operational test. Follow the manufacturer's procedures and record results. The checklist includes items to verify that the generator starts, runs, and transfers load as intended, ensuring standby power is available when needed.
How to use this checklist
Use this checklist during pump station inspections and start-up. Work through each section in order, recording findings for every item using the Safe / At Risk / N/A rating. For items that require measurement, such as Dry Film Thickness or pump flow, record the actual values. Note any defects or deviations from specifications and take corrective action before returning the station to service. Retain the completed checklist as a record of the inspection.
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