Recently, I had the opportunity to visit the generator room at our corporate office—and what I observed was deeply concerning. The visit exposed multiple safety, operational, and compliance issues that not only risked operational downtime but also posed serious threats to worker safety and environmental health.
This blog shares key findings from that visit, the risks involved, and the comprehensive Standard Operating Procedure (SOP) we’ve developed to transform that space into a safe, secure, and compliant operation zone.
🚨 What I Observed on Site
Here are the critical issues I encountered during the inspection:
- No designated entry or exit to the generator room.
- Lack of ventilation and soundproofing, making it an unsafe environment for long exposure.
- Workers were not insured and were not regular employees.
- The changeover panel was exposed to the weather and mounted at a height—both electrical hazards.
- The exhaust outlet led directly to a private parking lot, risking air quality and public exposure.
- Poor housekeeping with diesel-filled drums left in the open.
- Incorrect fire extinguisher type—a DCP extinguisher was placed where a CO₂ extinguisher should be.
- Risk of battery explosion due to lack of monitoring for overheating and overcharging.
Clearly, these issues demanded immediate attention.
🛡️ Taking Action: SOP for Safe Generator Operation
To address the risks, we designed a detailed Standard Operating Procedure (SOP) tailored to the safe operation of a 315 KVA Diesel Generator. This SOP is now the baseline safety protocol for the facility.
🎯 Purpose
Ensure the generator is operated safely, efficiently, and in compliance with safety, environmental, and insurance standards.
👷 Operator Responsibilities
- Must be life and health insured.
- Must inform line supervisors before any operation or maintenance activity.
- Only trained and authorized personnel can operate the generator.
- Area must be monitored through a surveillance camera system.
✅ Pre-Operation Checklist
- Area must be clean and ventilated.
- Fuel should be properly stored.
- Fire extinguisher (CO₂ type) must be accessible.
- Battery condition and charging levels must be checked.
- Communication with supervisors must be logged.
- Surveillance system must be functional.
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⚙️ Operating Procedure (Simplified)
- Inspect all systems (fuel, oil, coolant, battery).
- Notify supervisor and log activity.
- Start generator—let it idle to stabilize.
- Gradually engage load breakers.
- Monitor parameters and battery temperature during use.
- Shut down systematically—turn off breakers, idle, then shut off generator.
🚒 Emergency Scenarios & Actions
- Battery Explosion: Evacuate, use CO₂ extinguisher, ventilate, and report.
- Fire: Trigger emergency shutdown and use fire equipment.
- Fuel Spill: Use spill kit, isolate the area, notify HSE.
- Overheating: Shut down and inspect cooling system.
🔋 Battery Safety Tips
- Never allow overcharging or overheating.
- Keep battery area ventilated.
- Monitor voltage and temperature daily.
- Use proper tools and follow monthly maintenance checks.
🧹 Housekeeping & Compliance
- No flammable materials near the generator.
- Fuel stored per local fire/environment codes.
- Surveillance camera must record all operational activities.
- Emergency procedures and SOP should be posted clearly.
📁 Recordkeeping Essentials
- Generator usage log
- Maintenance and battery inspection reports
- Fire extinguisher and surveillance checks
- Insurance and training documents of operators
🔄 Final Thoughts
This visit was a wake-up call—but it also presented a valuable opportunity to improve. Safety isn’t just a regulatory checkbox; it’s a culture we need to live by.
If your organization operates diesel generators or similar high-risk equipment, consider taking a fresh look at your systems, your people, and your procedures.
The right SOP doesn’t just protect your equipment—it protects lives.
Need help designing a generator SOP for your own facility? I’d be happy to share a customizable version of the SOP, audit checklist, or training log—just reach out!
More detail information on OSHA
