05 November 2024
Raising The Bar Guidance - Diesel Generator Above 20KVA Equipment Requirements
Diesel generators above 20KVA are essential for supplying stable power on construction and highway sites, particularly in remote or off-grid locations. These high-capacity generators are used to power heavy machinery, lighting, and other equipment critical to project operations. However, due to the potential environmental impact, fuel storage requirements, noise, and exhaust emissions, large diesel generators require careful handling and stringent safety standards. The National Highways "Raising the Bar 1" guidelines provide vital safety and operational protocols to ensure the safe, compliant use of diesel generators above 20KVA on all projects.
General Minimum Requirements
The General Minimum Requirements (GMR) establish baseline safety and operational standards for all equipment, including diesel generators above 20KVA:
Daily Inspections: Diesel generators must undergo thorough pre-use inspections each day. Operators should complete a checklist to identify any potential issues, such as fuel or oil leaks, damaged components, and the functionality of the generator’s controls and emergency shutdown features.
Compliance with Legislation: Diesel generators must meet UK regulatory standards, including UKCA certification and compliance with the European Commission Machinery Directive (2006/42/EC). Additionally, they should meet environmental standards, such as compliance with Stage V emissions where applicable.
Safety Decals and High-Visibility Markings: Safety decals must be legible and visible, especially around access points, control panels, and fuel compartments. High-visibility markings should also be applied to any access steps or external connections.
Fuel Storage and Containment: Generators require secure fuel storage, with all fuel tanks fitted with secondary containment, such as a bund, to prevent spills or leaks that could lead to environmental contamination.
Noise Control Measures: Due to the high noise output of large generators, noise control measures, such as acoustic enclosures or barriers, should be in place to reduce noise pollution, especially in sensitive areas.
Equipment-Specific Safety and Compliance Standards
Given the fuel handling, emissions, and noise output, diesel generators above 20KVA require additional safety standards to ensure stable and safe operations:
Emergency Shutdown System: An emergency shutdown system must be in place and accessible to operators and nearby personnel, allowing for immediate shutdown in case of an emergency, such as fuel leaks or overheating.
Automatic Voltage and Load Monitoring: The generator should have automatic voltage and load monitoring to prevent overloads, which could damage equipment and increase the risk of fire or malfunction.
Fire Suppression System: Due to the risk of fire, especially with large fuel capacities, a fire suppression system should be installed near the generator. Fire extinguishers must also be readily accessible.
Exhaust and Emissions Management: Generators should be equipped with emissions controls to reduce harmful exhaust, with exhaust vents directed away from workers and sensitive areas. Compliance with Stage V emissions standards is strongly recommended to minimize environmental impact.
Fuel Security and Locking Mechanisms: All fuel tanks and filler caps should be securely locked to prevent unauthorized access and reduce the risk of tampering or fuel theft.
Spill Kits and Containment: Spill kits should be available at all times near the generator to contain and manage fuel spills. Fuel storage and containment should also comply with environmental protection standards.
Power Supply, Load Management, and Site Standards
The high-capacity power generation of diesel generators above 20KVA requires adherence to specific standards to prevent overload, manage fuel effectively, and ensure safe power distribution:
Controlled Load Management: Operators should manage power distribution based on the generator’s load capacity to prevent overload. Automatic load management systems are recommended to maintain safe operation.
Fuel Storage and Refuelling Safety: Fuel storage must be located away from the generator exhaust to prevent overheating. Refuelling should only occur when the generator is shut down and cooled, and operators should wear appropriate PPE during refuelling.
Proper Grounding and Earth Connections: The generator must be properly grounded to prevent electrical hazards. Earth connections should be checked daily to ensure safe, stable operation, especially in wet conditions.
Clearance from Flammable Materials: Generators must be positioned at a safe distance from flammable or combustible materials. Barriers should be in place to restrict access and protect nearby personnel from potential hazards.
Regular Oil and Filter Changes: To maintain performance and reduce emissions, operators should conduct regular oil and filter changes according to the manufacturer’s schedule, especially on projects with long operational hours.
Exclusion Zones Around Generator: Exclusion zones should be established around the generator to keep unauthorized personnel clear, especially during refuelling or maintenance, to reduce the risk of accidental contact.
Operator Competency and Requirements
The proper operation of diesel generators above 20KVA requires skilled operators who are trained in handling fuel, power loads, and safety procedures. The following standards apply:
Licensing and Certification: Operators must hold the appropriate certifications for handling fuel and large generators. Training should cover emergency shutdown procedures, load management, and refuelling safety.
Generator-Specific Training: Operators should receive training specific to the generator model, including operation under different load conditions, refuelling, and handling power surges or load imbalances.
Understanding of Load Management and Fuel Handling: Operators should understand the impact of varying loads on generator performance and efficiency, particularly during peak usage periods.
Safe System of Work: Operators must be briefed on the site’s Safe System of Work (SSoW) and sign onto the Plant, Vehicle, and People Management Plan (PVPMP) for each specific worksite.
Emergency Procedures: Operators must be trained in emergency shutdown and containment procedures, including using fire extinguishers and spill kits to handle any fuel or oil spills effectively.
Desirable Features
Additional features are recommended to improve safety, efficiency, and environmental compliance for diesel generators above 20KVA:
Automatic Load Monitoring System: An automatic load monitoring system helps operators manage power loads, preventing overloads and ensuring efficient power distribution.
Stage V Emission Compliance: For projects emphasizing environmental goals, Stage V-compliant engines are recommended to reduce emissions, especially in urban or environmentally sensitive areas.
Acoustic Enclosure or Noise Reduction Barriers: Acoustic enclosures or noise barriers reduce noise pollution, making it more suitable for operation in noise-sensitive areas or near residential zones.
Fuel Level and Usage Monitoring: A fuel monitoring system provides real-time feedback on fuel levels, helping operators plan refuelling schedules and avoid unnecessary downtime.
Automatic Shutdown on Overheat or Overload: An automatic shutdown feature that activates in case of overheating or overload conditions helps prevent potential hazards and reduces wear on the generator.
Remote Monitoring Capability: Remote monitoring allows operators to oversee generator performance, fuel levels, and load distribution from a distance, providing flexibility in managing multiple machines on a large site.
Hazard Identification and Mitigation
Operating a diesel generator above 20KVA involves specific hazards, and hazard mitigation is essential for safe operation:
Fuel and Fire Hazards: The large fuel capacity poses fire and spill risks. Secure fuel storage, spill containment kits, and fire extinguishers help mitigate these hazards.
Overload and Electrical Hazards: High-capacity generators are at risk of overload, especially during peak loads. Automatic load monitoring and proper grounding help prevent overloads and reduce electrical risks.
Noise and Vibration Exposure: Diesel generators generate significant noise and vibrations. Operators should use hearing protection, and acoustic enclosures are recommended to minimize noise impact.
Emissions and Air Quality Concerns: Generators produce exhaust emissions that affect air quality. Emissions management systems and compliance with Stage V standards help reduce environmental impact.
Unauthorized Access and Fuel Theft: Secure locking mechanisms for fuel tanks and filler caps prevent unauthorized access and potential tampering or fuel theft.
Oil and Hydraulic Fluid Leaks: Regular maintenance, such as oil changes and filter checks, helps prevent leaks, reducing the risk of environmental contamination.
Summary
The Diesel Generator Above 20KVA is a critical power source for construction and highway projects, particularly in remote or off-grid locations. However, due to the high-capacity fuel, emissions, and potential noise pollution, strict adherence to National Highways' "Raising the Bar 1" guidelines is essential. By following protocols for daily inspections, load management, refuelling safety, and emissions control, operators and site managers can ensure the safe and effective operation of diesel generators. Additional features, such as acoustic enclosures, automatic load monitoring, and remote monitoring, further enhance operational safety, efficiency, and environmental responsibility.
This article provides a comprehensive overview of the safety standards, operator requirements, and hazard management strategies for diesel generators above 20KVA, ensuring compliance with National Highways’ standards for safe and efficient project execution.