Safety,Are your Generator Practises Safe?

Handling, installing, owning and maintaining a diesel generator can be a risky business whether you're the end user, the installer, the maintenance contractor or just the man in the street. Let's consider what a diesel generator is from a safety perspective, a heavy cast iron reciprocating engine running on diesel fuel oil, with a sump full of lubricating oil, a radiator full of a water/glycol mix, a rotating fan to cool this radiator, an A.C. generating alternator with A.C. power cables, a set of lead acid D.C. batteries, a power breaker and a basetank full of diesel fuel. When the generator is running it emits hot exhaust gases, noise, vibration ,creates heat in the alternator, heat in the engine expelled as hot air from the radiator and electric current.
So basically the genset can burn you electrically/ thermally and chemically, it can injure you due to the fact it is a rotating machine, it can electrocute you, suffocate you, deafen you, poison you and possibly crush you - so lets avoid all these and look at the risks.

So what are the safety factors to consider for a generator installer?

Handling

The weight and centre of gravity of the genset/associated equipment is important for mechanical handling, the lifting points are marked on most gensets, they should always be lifted at the baseframe or single lift point and never at the separate engine or alternator lifting points. A genset can quickly slide off fork toes if incorrectly handled, lifting a genset with a crane device can damage generator components if forethought is not put into the need for spreader beams etc. The use of jacks, rollers, crowbars, handling on uneven, off-level surfaces must also be taken in to account. A genset damaged during handling is no use to the customer.
Are the people carrying out the genset handling qualified, licensed or at least experienced in this work? - too many times gensets are damaged by installers that are not knowledgeable of the product or the handling method they are carrying out.

Installing.

It may be an obvious question but is everyone agreed on the genset location and orientation before the installation begins? Sets have been half way through room installation before someone realises that it needs rotated 180 degrees! Does the installation require temporary lighting, working at height, confined spaces, the use of portable tools, cartridge tools, welding operations, excavation etc? Are your installers competent in the use of their tools, are the tools suitable for the job, do they have an inspection safety certificate, do they have the necessary personal protection to prevent injuries to their heads, eyes, toes, skin, lungs and feet? If someone is injured during an installation is there a first aider on site? Is there an accident reporting procedure.
Can your installers be seen on site, do they have hi-visibilty clothing available for working at night for example?

There are several ways a fire can start during a generator installation, they usually are as a result of "hot works" i.e. welding/grinding/burning or of an electrical origin. If a fire occurs are measures in place to extinguish it, are your installers trained in the use of/differences in fire extinguishers, fire precautions, gas bottle storage and evacuation procedures?

Are your installers trained in manual handling procedures i.e. how to lift a heavy object without causing personal injury, is the weight of the object to be lifted known? There are several factor influencing manual handling - the task, the individual, the load and the environment - keeping your back straight and bending your knees will not help a 150lb man lift a 500lb object above his head to his colleague!

Working at height, for example installing an exhaust silencer can be a serious risk for site personnel, the use of scaffolding, trestles, access plant, even ladders are all subject to safe practises that can prevent fall injuries. Is the plant being used safe for the height it is being used at, has it been constructed by a competent person, is it level and secured, An injured employee is not a working employee!

Installing the fuel system during a genset installation will sooner or later result in diesel leaks or spillages, are the measures in place to contain and clean diesel spillages - to prevent diesel entering ground water for example, or posing a possible fire hazard?, working with diesel fuel can also result in skin dermatitis with some individuals, are gloves, barrier creams readily available?

Installing the electrical power cables can be quite a physical task during an installation, are your personnel qualified to understand phase rotation, glanding, lug connections, terminal torques, cable trefoiling, trench deration etc, some problems at installation carry right through to genset commission - sometimes with expensive consequences.

Commissioning

When the installation is complete and the genset is installed mechanically and electrically, the next all important step is the commissioning. This will be the first time the genset has run since it was manufactured and the new fuel system, exhaust system, electrical system and operation will be tested for the first time. When the genset runs for the first time it will be creating heat, noise, vibration, exhaust gases and A.C. current - each of these must be checked in turn, is the noise level acceptable for the environment in which the generator is working? Is the exhaust system gastight and expelling the gases satisfactorily? (i.e. no recirculation, no contamination of air conditioning units), is the full load output current carried on the load cables used without heating?, and finally is the fuel system leak-free and operational?

What are the safety factors for the Owner?

So your new genset has been installed and commissioned and you now have standby power, so what responsibilties do you have? Have you read the genset manuals, are you aware of the basic operation of the engine, how to check oil levels, the type of oil used, the coolant level, the type of coolant used, the alternator voltage regulator position, the panel operation? If you have an automatic transfer switch are you aware of its operation and how it works, where the signal wire locate on it and the genset panel? In the event of an emergency could you start/stop the generator, trip the breaker,  changeover/changeback the automatic transfer switch? If you wait until a power failure to learn about the genset you could be putting yourself and others in danger.

Do you know the fuel consumption figures for the genset? - there is nothing worse than sitting pretty during a power cut with everyone around you in darkness and then your genset runs out of fuel! And if it runs out of fuel do you know how to bleed the fuel system. Do you have a fire extinguisher/ fire blanket near the genset should the worst happen?

Do you run the genset occasionally, remember the genset has a D.C. battery just like your car and it can go flat over time, if you have a battery charger fitted to your genset always check that the A.C. supply is actually switched on. Boost charging a flat battery in an emergency can release dangerous acidic gases and sometimes result in an explosion.

Maybe you have a maintenance contractor appointed to look after the genset and believe you don't need to consider any of the above, but you won't know there is a problem with the genset until you need it and invariably your contractor will not be about when this happens. Considerations for the Owner when selecting a maintenance contractor next.

What are the safety considerations for the Maintenance provider?

The greatest risk to the operation of a genset is someone performing work on it without training, model specific information or experience. Do you have the operation and maintenance manual for this model of genset, do you know how the engine, fuel system, cooling system, lubricating system, engine interface/control module works? Do you have the manual for the alternator,understand the AVR, terminal windings, diodes, voltage sensing etc. Can you read the electrical drawing for the genset, do you know the operation of the genset panel/ automatic transfer switch, how to navigate fault menus, troubleshoot and fault-find? - If your answer to any of these is no then you should not work on a FGW genset until you can answer "yes" - you will be a risk to yourself, the genset and others.

Do you understand the warranty procedure for the genset, the service intervals, do you understand that the warranty can be invalidated if incorrect parts, fluids, procedures are used during the genset maintenance? How will you service the genset?, how will you dispose of waste oil, waste coolant, oil filters, fuel filters in an environmentally friendly way? What if the power fails during a oil change service, have you isolated the genset to prevent start-up, have you a plan to get the genset on-line as soon as possible?  Do you keep a record of services, part history, an OEM parts inventory, do you offer emergency cover etc?
Remember if you can do the job safely, professionally and efficiently you will get a good reputation, your business can only benefit from this.