MEC/Mechanical/TBT-MEC-007

Pump Installation and Alignment

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Pump Installation and Alignment

Toolbox Talk Record

Ref: TBT-MEC-007  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

  • Pump installation involves positioning, levelling, grouting, connecting, and aligning mechanical pumps.
  • Pumps range from small submersibles to multi-tonne centrifugal units requiring crane installation.
  • Misalignment between the pump and motor shafts causes premature bearing failure and seal leaks.
  • Laser alignment tools provide accurate readings but trained operators are needed to interpret results.
  • Lifting pumps into position requires a LOLER-compliant lift plan with rated lifting accessories.
  • Pump bases must be level, grouted, and fully cured before final alignment is attempted.
  • Rotating parts including couplings, shafts, and flywheels must be guarded before commissioning.
  • Pipework connection forces can distort pump casings if not properly supported and aligned.
  • Electrical connections to pump motors must be isolated and locked off until alignment is complete.
  • PUWER 1998 requires that all pumps are safe to operate and properly maintained once installed.

Why?

Prevent injuriesPumps involve heavy lifts, rotating machinery, and electrical connections — each creating risk of crush, entanglement, or electrocution.
Equipment reliabilityPoor alignment causes vibration, bearing damage, and premature failure, leading to costly shutdowns and repeat work.
Legal compliancePUWER 1998, LOLER 1998, and the Electricity at Work Regulations 1989 all apply to pump installation activities.
Do Don't
  • Prepare a lift plan before moving any pump that requires mechanical lifting.
  • Ensure the pump base is level, grouted, and fully cured before alignment.
  • Use laser alignment tools and trained operators for final shaft alignment.
  • Guard all rotating parts including couplings and shafts before commissioning.
  • Isolate and lock off electrical supplies until installation is fully complete.
  • Support pipework independently so it does not impose loads on the pump.
  • Check pump rotation direction before energising the motor for the first time.
  • Record alignment readings and retain them for future maintenance reference.
  • Follow the manufacturer installation manual for torque values and tolerances.
  • Wear appropriate PPE including gloves, safety boots, and eye protection.
  • DON'T lift pumps without a LOLER-compliant lift plan and rated accessories.
  • DON'T attempt final alignment before the base grout has fully cured.
  • DON'T run the pump with unguarded couplings, shafts, or rotating parts.
  • DON'T energise the motor until shaft alignment is verified and accepted.
  • DON'T allow pipework to impose strain or force on the pump casing.
  • DON'T ignore vibration during test running; it may indicate misalignment.
  • DON'T work on pump internals without confirming electrical isolation and LOTO.
  • DON'T skip the rotation check before first energisation of the motor.
  • DON'T use lifting points not specified by the pump manufacturer.
  • DON'T force bolt holes to align; reposition the pump or base instead.

See also: MEICA Safety Awareness | Motor and Drive Installation
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