Industrial Generator Safety: 9 Essential Tips

Your industrial generator is one of your most valuable assets during a power outage. It provides a reliable backup power source to keep your operations flowing without disruption. The right size generator will be capable of running all your critical business

systems, including equipment, tools, computers, lighting, phones, security systems, and much more. You’ll have access to the power you need until the main grid is restored.

However, generators are powerful equipment requiring careful handling to maintain the safety of your property, employees, and customers. Keep these essential tips in mind to operate your generator safely and reduce your risk of potential hazards.

1. Ensure the Proper Installation of Unit

A generator should be installed outside with plenty of clearance between it and any doors, windows, or vents. Adequate airflow is necessary to keep exhaust fumes from entering your building. Additionally, your generator should be installed on a raised concrete pad to safeguard it against flooding water.

Industrial standby systems are permanently installed and connected to your site’s electrical system. To prevent electric shock, this job must be left to a professional. Our technicians at Valley Power Systems have the necessary knowledge and skills to ensure the power system is installed properly the first time.

2. Install Carbon Monoxide (CO) Detectors

Generators release a dangerous gas called carbon monoxide (CO). This colorless, odorless, tasteless gas is virtually undetectable and extremely deadly in high concentrations. While your generator should come with an integrated CO sensor, it’s possible that the sensor could fail. For additional protection, we recommend having CO detectors installed at your site as well. Your detectors will alert you to abnormal levels of carbon monoxide so that you can take prompt action to protect everyone in the building.

3. Use Hearing Protection Devices

It’s natural for generators to emit some level of noise during production. An industrial diesel generator can produce over 115 dB, which can cause hearing damage with prolonged exposure. Anyone working around the generator should be properly secured with hearing protection equipment, such as approved noise-reducing earmuffs. You should also consider installing a sound-attenuating enclosure to keep noise at bay.

If your unit is making strange sounds or excessive noise, you should have the generator checked out by a technician. This could indicate a loose, missing, or worn part that could impact system performance.

4. Handle Fuel Safely

If you have a diesel generator, it’s important to store extra fuel on-site in case of an emergency. You should use only approved storage containers and place them in a well-ventilated area away from heat sources. Also, take extra care when refueling the generator and wait for the engine to cool down completely. If fuel accidentally spills on a hot engine, it can cause serious burns and even fires.

5. Minimize Moisture Exposure

Moisture can cause a host of problems for your industrial power system. Critical parts and components can rust and become corroded, severely impacting generator performance and reliability. Moisture exposure can also damage the electrical system, increasing the risk of electrocution, electric shock, or fire.

A generator enclosure will help protect your unit against the elements, but you should also be mindful when cleaning the generator. Never spray water directly on the unit. Instead, you can wipe it down with a soft, slightly damp cloth. If that’s not enough to clean the generator, contact our professionals at Valley Power Systems. We have the tools, equipment, and knowledge to conduct comprehensive generator cleaning without damaging the system.

6. Implement Generator Safety Training Procedures

As a business owner, you are responsible for ensuring the training of your employees. This should include generator safety. If you’re unavailable to address an issue with your system, it’s a good idea to have multiple people you can trust with the job. Only authorized, fully trained personnel should ever handle the generator.

At Valley Power Systems, we recommend incorporating generator operating procedures, safety compliance, and an emergency plan into the training. Implementing these protocols will help ensure the safety of your staff and property.

7. Invest in a Remote Monitoring System

A remote monitoring system can help you keep up with the status of your power system. Certain problems can cause safety concerns, but a remote monitoring system will be able to detect many issues with your generator before they have a chance to progress into a true hazard. Another great benefit of a remote monitoring system is that you can track generator status and adjust settings from anywhere via a smart device. If needed, you can shut down the unit until you can return to your facility to check out errors in person. Additionally, a remote monitoring system can help you be more proactive about maintenance, which will further improve the safety of your generator.

8. Keep Generator Filters Clean

Your generator filters help keep dust, dirt, and debris out of the engine. When filters become clogged, airflow is restricted, which forces the generator to work harder than necessary. This excess strain on the unit can lead to overheating, which can cause several safety risks. Generator filters should be checked in between maintenance visits to ensure cleanliness. If you clear clogs and the filter still appears dirty, it’s best to swap it out for a new one.

9. Remember Generator Maintenance

Routine maintenance is essential to maintain the safety of your system. A well-maintained generator will be less likely to pose safety risks. Neglected generators are more prone to overheating and experiencing electrical problems, increasing the risk of fire hazards. Fuel, coolant, or exhaust leaks may go undetected until it’s too late. An inefficient generator will also give off more carbon monoxide, increasing the risk of exposure. A trained generator technician from Valley Power Systems can perform a complete assessment of your system to identify repair needs and restore generator safety.

Maintenance also helps with extending your generator’s expected lifespan. A properly maintained industrial generator could last for 20 years or more. You may wonder how often your system should be maintained to reach this lifespan. It will depend on the unit’s size, age, frequency of use, and environmental conditions. In general, the first maintenance check should occur after 50 hours of service, and then every 100-200 hours after that. This may increase as your generator ages. Valley Power Systems offers customized maintenance contracts to fit the individual needs of your unit. We’d be happy to provide a maintenance recommendation to keep your generator in prime condition year-round.

Offering Reliable Power Solutions Since 1949

Valley Power Systems has been serving the power needs of California businesses for 75 years. We take pride in offering state-of-the-art power products from today’s leading manufacturers, including:

Blue Star Power Systems
Atlas Copco
Waukesha

We are your trusted resource for generator sales, installation, repair, and maintenance. Our experienced technicians can handle all your generator needs, from simple oil changes to complete engine overhauls, with a focus on maintaining the safety and reliability of your unit.

At Valley Power Systems, we know just how important it is to have an industrial generator that you can count on in an emergency. Part of this is knowing how to operate your generator safely and minimize risks. For more generator safety tips, contact our professionals at Valley Power Systems today!