1. Carry a note from your doc specifying what supplies you have to carry (needles, infusion sets, snacks, etc)
2. DO NOT REMOVE YOUR PUMP OR LET ANYONE HANDLE IT. Even if someone tells you to remove it, do not. It's a medical device and should not be removed. In the event that you get seperated from your pump, you have no basal insulin in your system.
3. Do not go through the body scanners. No matter what the TSA agents tell you, it is not clear whether these devices damage pumps. Better be safe than sorry. If a TSA agent insists you go through, ask for their supervisor. Politely stand your ground.
4. Be polite, but firm.
5. Be organized. Have all your D stuff clearly marked, with prescription labels affixed to insulin.
6. Print this from TSA's website and carry it with you - http://www.tsa.gov/traveler-information/passengers-diabetes
7. Your pump should have come with an information card about not exposing it to x-rays. Take that with you and have it ready.
8. If you are traveling with a loaner pump, make sure that it doesn't go through the x-ray machine. Request that it be hand-screened.
I have traveled quite a bit and generally don't run into too many issues. I've had the occasional TSA agent who insists my pump can go through the body scanner, and I just firmly (but politely) insist that, for my safety, it cannot. I once had to remind a TSA agent that she was not a medical professional or medical device manufacturer and should therefore not be dispensing medical advice. Once I got her supervisor over to our lane, things were fine.