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[summary:protected] => The CPWR Toolbox Talk on Working Around Vehicles in the Work Zone addresses methods to avoid being struck-by a vehicle on a construction site. The resource includes a case example, steps to prevent a related injury, and questions for discussion. It includes a graphic that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish.
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[summary:protected] => The CPWR Toolbox Talk on Spray-painting and Sanding Nano-Enabled Paint addresses how to reduce exposure to nano titanium dioxide when spraying, sanding, or disturbing nano-enabled paint. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish.
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[title:protected] => Welding Fumes: An Interdisciplinary Annotated Bibliography
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[keywords:protected] => welding, welder, bibliography
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[summary:protected] => This document is part of a series of annotated, interdisciplinary bibliographies of academic research on major topics in construction occupational safety and health, from Asbestos to Training.
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[title:protected] => Mistakeproofing The Design of Construction Processes Using Inventive Problem Solving (TRIZ)
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[summary:protected] => This study set out to investigate and document how the principles and practices of so-called
mistakeproofing may be applied to improve safety and health performance—aspects of productand
process quality—specifically in the construction industry.
Mistakeproofing (translated from the Japanese word poka yoke, a concept integral to the Toyota
Production System, defined as Lean) has been successfully used in numerous other industry
sectors. It can be used likewise in the construction industry.
A strength of Lean is its conceptual clarity on principles and the associated systems thinking it
promotes. In addition, supporting the principles are numerous tools and methods (such as
mistakeproofing), to be applied judiciously in any given system’s context and, when used in
combination, leveraging one-another.
The research defined the Lean principles of mistakeproofing, and also the principles of TRIZ
(Theory of Inventive Problem Solving) used for concept generation. Thirty examples, collected
by reading the literature and interviewing industry practitioners, were catalogued based on the
mistakeproofing and TRIZ principles they illustrate.
The need to mistakeproof everyday products and processes (tasks and work methods) may seem
obvious (or hopefully will appear obvious in hindsight), but mistakeproofing is by no means a
common practice. By defining the principles and offering examples, this report aims to
encourage broader awareness and use of it. Knowledgeable and purposeful use of
mistakeproofing principles and their practical application will lead to improved industry
performance in construction, as it has in other industries.
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[title:protected] => A Tree Feller Dies When Struck By a Tree Limb While Felling a Fire-Damaged Tree
[total_pages:protected] => 9
[billed_pages:protected] => 9
[publication_number:protected] => California Case Report: 17CA004
[part_of:protected] =>
[keywords:protected] => tree, feller, fatality, struck, struck-by,
[comments:protected] =>
[summary:protected] => A 21-year-old male tree feller, working from a bucket truck as part of a small tree-felling crew, died when struck by a large tree limb he had just cut. The 80 to 90-foot, fire-damaged oak tree was located below a county road that ran along the steep bank of a creek ravine. The crew had been directed not to fell the tree into the ravine because of environmental and cultural concerns. The crew had been directed to take the tree down in small sections. However, after the supervisor left, the victim decided that they should attempt to bring most of the tree down in two large sections. The crew used a rigging line, pulled by a mini-excavator, to attempt to direct the cut sections to fall uphill towards the road. Neither section fell in the direction intended; the second section fell uphill against the bucket truck, fatally crushing the victim.
The California Fatality Assessment and Control Evaluation Program (CA/FACE) concluded that organizations involved in tree-felling operations should take the following steps to prevent similar incidents:
- Tree-felling contractors should ensure that each crew includes, and is led by, a person with substantial experience in tree felling.
- Tree-felling contractors should ensure that all supervisors are certified in tree-felling safety by an organization such as the Tree Care Industry Association (TCIA) or the International Society of Arboriculture (ISA). In addition, government agencies, utilities, and other project customers should include bid language requiring that all supervisors be certified in tree-felling safety by one of these organizations.
- Tree-felling crews should always be able to readily communicate with their supervisor and medical emergency services. If cell phone reception is not reliable, the employer should issue the crew a satellite phone.
When the trench collapsed, co-workers called 911 and attempted unsuccessfully to locate and dig the worker out. When emergency responders arrived, their first task before commencing rescue and recovery efforts was to shore up the trench to prevent risk of additional collapse and injuries (see Figure 2). Emergency responders spent several hours recovering the worker’s body.
Key factors identified in this investigation included an inadequate trench protective system; no ladder available for entry or egress; and a spoils pile being placed too close to the edge of the trench. Underlying contributing factors were the lack of oversight by a competent person; and insufficient employee training on recognizing and reporting hazards. 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=> d001538 [type:protected] => document [display_type:protected] => HTML w/ PPT [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => sharretta [priority_id:protected] => 1 [title:protected] => 2-hr Generator Safety Awareness Module 1 - Fixed Industrial Generators [total_pages:protected] => 51 [billed_pages:protected] => 51 [publication_number:protected] => [part_of:protected] => [keywords:protected] => operating engineer, generator, training, awareness, safety, hazmat, hazard, disaster response [comments:protected] => [summary:protected] => Developed by the International Union of Operating Engineers, this PowerPoint is one module out of three, all of which are part of a 2-hour Generator Safety Awareness Program. This presentation covers hazards specific to the use of fixed generators, and also provides helpful information to ensure that workers and others using such equipment remain safe. 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Topics We Will Cover
Test Yourself
- How often do you inspect the generator?
- How often do you test run the generator?
- How long should you test run the generator?
- Name two relevant OSHA standards.
- Name two safety hazards when testing a generator.
- For fixed generators, what is the ready position?
- Which of the following have relevance in the inspection and test run of a generator?
- Personal protective equipment
- Asbestos precautions
- Hearing protection
- Lock-out / Tag-out procedures
- Cleanliness
- Log books
Objectives
KNOWLEDGE
- Understand each step of a prestart checklist
- Understand the operations and safe parameters of a fixed generator during a test run
SKILLS
- Complete each step of a prestart checklist
- Conduct a safe test run
- Place the fixed generator back into the ready position
ATTITUDES
- Be aware of the importance of weekly inspections and test runs
- Contribute to a culture of safe work practices
- Cite relevant OSHA standards and other safety considerations
Background and Rationale
Engineers and building operators should inspect and test run the back-up generator system once a week for a minimum of thirty (30) minutes.
Think about what this means:
(1) Inspect and (2) test run (3) once per week or (4) thirty minutes
What are some of the reasons ALL of these are so important? List reasons on flip chart, once complete, post for the remainder of the week so students can refer to periodically.
Possible answers:
- System readiness
- Disasters/power outages are unpredictable
- Required by code
- Life support
- Communications
- Security
- Safety
- Continuity of Operations (COOP)
- These test-runs are necessary to ensure the reliability of the emergency power system. Back-up generators should always be in a state of readiness because of the critical functions they support.
Safety Considerations
Before a test run of a generator is conducted, workers need to be aware of proper prestart safety procedures.
What do you think some of those procedures need to be? Ask the class what they think some of the proper safety procedures would be, list them on a flip chat and post them for the class to see for the rest of the course.
What OSHA standards do you think apply? Additionally, ask what standards from OSHA apply to these safe start practices. Again, post on a flip chart and post for the remainder of the class.
Some Relevant OSHA Safety Standards
29 CFR 1910 Subpart S – Safety-related Work Practices.
- 1910.331 – Scope.
- 1910.333 – Selection and use of work practices.
- 1910.334 – Use of equipment.
- 1910.335 – Safeguards for personnel protection.
- 29 CFR 1910.95: Occupational Noise Exposure.
- 29 CFR 1910.133: Eye and Face Protection.
- 29 CFR 1910.147: Lock Out / Tag Out.
Open discussion with the class on proper hearing protection standard 29 CFR 1910.95 when working around a running generator.
OSHA Safety Standards: 29 CFR 1910.133: Eye and Face Protection
Open discussion with the class on proper eye and face protection standard 29 CFR 1910.133 when working around electrical equipment.
Image on left, face shields hanging and ready for use and on the right a United States Navy Electrician's Mate wearing a face shield while checking for bad fuses on a lighting panel aboard the USS Carl Vinson (CVN 70)
Source: Wikipedia.com
29 CFR 1910.147: Lock Out / Tag Out
Open discussion with the class on the Lock-Out Tag-Out standard 29 CFR 1910.147 Provide each student with a lock-out tag-out tag and the proper way to fill out the tag.
Prestart Check
Manufacturer procedures should always be followed when conducting prestart and test runs.
Sample Checklist
-A sample of a maintenance and inspection procedures prestart checklist for generators well as a test run log
The following few pages provide a sample of a basic generator prestart and test run operational check list and should be expanded upon depending on the needs of your facilities.
Building: ______________ Generator Number: ____________
Maintenance and Inspection Procedure for Emergency Generators
Clean Around The Generators Area
Clean Generator
Check Battery and Rack for Corrosion
Check Battery Water Level
Check Charge Operation and Rate
Check Engine Radiator Level
Check Engine Oil
Check Hoses and Clamps for Leaks
Check Belts
Check for Leaks around Generator
Check Fuel Tank Level
Test Run Generator:
- Oil Pressure:______
- Generator Temperature:________
- Volts:________
- Meter Hours Start Time:______
- Meter Hours Stop Time:______
Set Controls for Generator to Start in an Emergency
List Repairs/Maintenance Required
________________________________
________________________________
________________________________Checked By: _____________________
Date: ____________
Prestart Check: Review the generator log book
- Note the reading where the hour meter stopped. Is the reading on the generator the same?
- Are there any maintenance repairs logged?
- Any unusual comments from the last test run?
- Any fuel deliveries?
- Anything that may affect the running of the generator at this time?
Show the class an actual emergency generator logbook and review the entries.
Prestart Check: Turn off the generator
Never do a prestart check with the generator in the ready position. In order to begin your prestart checklist you need to first make sure the generator does not come on while you are checking the various components.- Turn the generator from the ready position to the OFF position and tag it!
- Stay in the moment! If you are called to do another task put the generator back in the ready (or auto) setting.
- NEVER EVER leave to do something else with the generator turned off, it will be rendered useless if there were to be a power failure!
Prestart Check: Check and clean the area around the generator
- In outdoor units, trash and debris may have collected or blown in by the wind.
- Look to see that the area around the generator is free of debris. Paper and plastic can be drawn into the fan and lodged or entangled with the fan or against the radiator. This could potentially cause overheating of the engine.
- Look for objects that could be or have already been sucked into the fan.
- Check for rodent nests. Animals can cause a great deal of damage to equipment that sits unused or is outside. Check the area occasionally for nests or signs of rodent activity. Most diesel engines have warm water jacket heaters where animals love to nest.
Animals could build nests near a generator with a warm water jacket such as those in diesel generators.
This is not a generator, but it does show what happens with a squirrel’s nest in a cooling tower fan. This is the result of starting the fan.
Animals can cause a great deal of damage to equipment that sits unused or is outside of the building. Check the area occasionally for nest or signs of rodent activity.
GOOD OR BAD?
GOOD OR BAD?
GOOD OR BAD?
Prestart Check: Check battery & battery rack for corrosion
REMEMBER, batteries can be explosive! Make sure you have the proper PPE on before you continue!
What PPE would be recommended in this situation?
Safety First!
Revisit proper PPE for handling of batteries.
List examples and post.
- Splash shield
- Apron
- Gloves
- What else?
- Check the battery and rack for soundness.
- Clean the battery.
- Check the terminals
- look for corrosion or poor connections. Poor connections of the battery terminals could prevent the generator from starting in an emergency situation. Poor connections of the battery terminals could prevent the generator from starting in an emergency situation.
-Example of clean battery rack and battery with corroded battery terminals.
Prestart Check: Check battery water level
- Check to ensure that each cell has water and at the proper level. Carefully remove the caps from each cell of the battery to check for proper water level. If the level is low add distilled water to the cell.
Prestart Check: Check charge operation and rate 
- Make sure that the charger is on.
- Ventilate the area.
- Check the charging rate. Batteries will lose their charge from sitting unused for long periods of time. Most generators are equipped with battery chargers to assure that the generator has ample power to start the generator when needed.
- Make sure it is set at the proper voltage.
Prestart Check: Check engine radiator coolant level
Safety First! Practice safe work habits.
NEVER OPEN THE RADIATOR CAP WHEN THE GENERATOR IS HOT!! Remember to slowly open the radiator cap. Failure to do so could result in the person opening the cap (if the radiator is under pressure) being scalded. Make sure the generator has the proper amount of antifreeze for the winter months. After a period of time antifreeze can break down and become corrosive. Develop a preventative maintenance schedule for flushing the radiator system.
- Fluid is the lifeblood of the generator’s engine.
- Check the radiator for the proper coolant level.
- Remember to slowly open the radiator cap. Failure to do so could result in the person opening the cap (if the radiator is under pressure) being scalded.
- In the fall, check the antifreeze level for proper low temperature settings for your area. Make sure the generator has the proper amount of antifreeze for the winter months.
- Flush the radiator system annually to avoid the buildup of sludge. After a period of time antifreeze can break down and become corrosive. Develop a preventative maintenance schedule for flushing the radiator system.
NEVER OPEN THE RADIATOR CAP WHEN THE GENERATOR IS HOT!
Prestart Check: Check engine oil
- Check the oil level to see if it is in the safe operational zone. If not, check the manufacture’s specifications for the proper oil for that generator. Different generators require different oil viscosities to ensure proper lubrication during heavy load demands.
- Add oil until you reach the proper level and note the addition of oil in the generator log.
- Make sure the level is in the safe operational zone or range.
- Change the oil annually or after an extended operational period.
- It’s cheaper to change the oil than to have the engine replaced.
Prestart Check: Check hoses and clamps
Time is an enemy of rubber. Hoses may begin to show signs of dry rotting. Under operating pressures these hoses can burst sending hot fluids flying in all directions and could cause severe burns to individuals in the immediate area. Additionally, the same thing could happen during an emergency call for power while you are not there. If the hoses were to rupture while you were absent from the area, the engine could suffer irreversible damage and the unit could be out of commission for an extended period of time.
- Check for sound hose connections.
- Examine each for dry rotting or cracking.
- Check for leaks.
Prestart Check: Check fan belts
Stop! Recheck that the generator cannot come on automatically before you continue. Do not place your hand near the fan or the fan belts until you do so! Once done, check the fan belts for signs of being worn, cracked, dry rotted or stretched. If so have the belts replaced before continuing.
On the belts check for:
- Dry rot.
- Cracking.
- Looseness.
- Proper adjustment.
- Worn or frayed areas.
Prestart Check: Check for leaks around generator
- Look for any sign of fluids on the floor under the hoses and connections.
- If it is an outdoor generator check the structure for:
- Leaky roof.
- Dampers not closing.
- Good seals on doors.
Prestart Check: Check fuel tank level
- Check and ensure that the fuel tank is topped off monthly.
- Make sure that the vent line is free of obstructions.
- Make sure that the fill and vent lines are of the same size.
Here is an example of a bird’s nest in the underground fuel tanks vent.
Prestart Check: Check fuel system
If your generator has fuel separators, drain them down to ensure that there is no water and/ or sediment in them prior to starting the engine.
Fuel tanks can accumulate moisture from condensation that can be drawn into the generator’s fuel system. Fuel oil separators placed before the generator enable engineers to remove any build up of water in the system before it enters the engine.
Prestart Check: Check warning controls or lights
If your generator has warning lights, test each light to ensure it is in working condition.
Check all system indicating lights to assure that they are functioning properly.
Conducting a Test Run
Test Run: Before you start
Remove all tags from the control panel.
Test Run: Start generator
After all of the different systems of the generator have been checked, start and begin the test run of the generator.
Don the proper hearing protection when running a generator.
Test Run: Check the exhaust stack at start up
It should run clean after a few seconds.
Test Run: Check the following systems
- Oil Pressure.
- Water Temperature.
- Volts.
- Meter Hours Start Time.
→ If possible test run your generator under load conditions.
Test Run: Safety reminder
Remember when running your generator you are generating electricity!
Test Run: Transfer switches
Transfer switches when installed should transfer from commercial power to the generated power source.
Test Run: Transfer switches (Accident)
- The lugs on this transfer switch became loose from expansion and contraction, due to lack of preventive maintenance. Once the lugs start to become loose, the cables will heat up due to a poor connection. Periodically, preventive maintenance on these lugs has to be performed. “ALWAYS REMEMBER TO FOLLOW STRICT SAFETY PROCEDURES TO ENSURE THAT THE POWER SOURCE IS OFF AND DRAINED!!!”
- Melted wires (due to lack of preventive maintenance).
- Burnt lugs (due to lack of preventive maintenance).
Test Run: Completing the generator test run
- Cool down period: Once the generator has gone through a test run under simulated load conditions, the generator will enter the next phase, the cool down time. Some generators have a built in tier for cool down periods after a test run.
- Log in any changes or unusual events and findings during the test run.
Some generators have a built in tier for cool down periods after a test run.
Test Run: Reset the generator control switch
When the test run is completed, always make sure that the generator is in the ready position in the event of a power disruption or failure.
- Set generator controls back to “ready to start” so it will be ready in an emergency.
- Remove any tag that you may have placed at the control panel.
ANY QUESTIONS?
We Covered:
Background and Rationale
- Importance of weekly inspections and test runs.
Important Safety Considerations
- Relevant OSHA standards and other safety considerations.
- How to contribute to a culture of safe work practices.
Prestart Checklist
- What is involved in each step of a prestart checklist.
Conducting a Test Run
- How to conduct a safe test run.
- The operations and safe parameters of a fixed generator during a test run.
- Placing the fixed generator back into the ready position.
This publication was supported by the National Institute Of Environmental Health Sciences of the National Institutes of Health under Award Number U45ES006182. The content is solely the responsibility of the authors and does not necessarily represent the official views of the National Institutes of Health.
IUOE National Training Fund
National HAZMAT Program
1293 Airport Road
Beaver, WV 25813
(304) 253-8674
Fax (304) 253-7758
hazmat@iuoehazmat.org
www.iuoehazmat.org
Topics We Will Cover
Test Yourself
- How often do you inspect the generator?
- How often do you test run the generator?
- How long should you test run the generator?
- Name two relevant OSHA standards.
- Name two safety hazards when testing a generator.
- For fixed generators, what is the ready position?
- Which of the following have relevance in the inspection and test run of a generator?
- Personal protective equipment
- Asbestos precautions
- Hearing protection
- Lock-out / Tag-out procedures
- Cleanliness
- Log books
Objectives
KNOWLEDGE
- Understand each step of a prestart checklist
- Understand the operations and safe parameters of a fixed generator during a test run
SKILLS
- Complete each step of a prestart checklist
- Conduct a safe test run
- Place the fixed generator back into the ready position
ATTITUDES
- Be aware of the importance of weekly inspections and test runs
- Contribute to a culture of safe work practices
- Cite relevant OSHA standards and other safety considerations
Background and Rationale
Engineers and building operators should inspect and test run the back-up generator system once a week for a minimum of thirty (30) minutes.
Think about what this means:
(1) Inspect and (2) test run (3) once per week or (4) thirty minutes
What are some of the reasons ALL of these are so important? List reasons on flip chart, once complete, post for the remainder of the week so students can refer to periodically.
Possible answers:
- System readiness
- Disasters/power outages are unpredictable
- Required by code
- Life support
- Communications
- Security
- Safety
- Continuity of Operations (COOP)
- These test-runs are necessary to ensure the reliability of the emergency power system. Back-up generators should always be in a state of readiness because of the critical functions they support.
Safety Considerations
Before a test run of a generator is conducted, workers need to be aware of proper prestart safety procedures.
What do you think some of those procedures need to be? Ask the class what they think some of the proper safety procedures would be, list them on a flip chat and post them for the class to see for the rest of the course.
What OSHA standards do you think apply? Additionally, ask what standards from OSHA apply to these safe start practices. Again, post on a flip chart and post for the remainder of the class.
Some Relevant OSHA Safety Standards
29 CFR 1910 Subpart S – Safety-related Work Practices.
- 1910.331 – Scope.
- 1910.333 – Selection and use of work practices.
- 1910.334 – Use of equipment.
- 1910.335 – Safeguards for personnel protection.
- 29 CFR 1910.95: Occupational Noise Exposure.
- 29 CFR 1910.133: Eye and Face Protection.
- 29 CFR 1910.147: Lock Out / Tag Out.
Open discussion with the class on proper hearing protection standard 29 CFR 1910.95 when working around a running generator.
OSHA Safety Standards: 29 CFR 1910.133: Eye and Face Protection
Open discussion with the class on proper eye and face protection standard 29 CFR 1910.133 when working around electrical equipment.
Image on left, face shields hanging and ready for use and on the right a United States Navy Electrician's Mate wearing a face shield while checking for bad fuses on a lighting panel aboard the USS Carl Vinson (CVN 70)
Source: Wikipedia.com
29 CFR 1910.147: Lock Out / Tag Out
Open discussion with the class on the Lock-Out Tag-Out standard 29 CFR 1910.147 Provide each student with a lock-out tag-out tag and the proper way to fill out the tag.
Prestart Check
Manufacturer procedures should always be followed when conducting prestart and test runs.
Sample Checklist
-A sample of a maintenance and inspection procedures prestart checklist for generators well as a test run log
The following few pages provide a sample of a basic generator prestart and test run operational check list and should be expanded upon depending on the needs of your facilities.
Building: ______________ Generator Number: ____________
Maintenance and Inspection Procedure for Emergency Generators
Clean Around The Generators Area
Clean Generator
Check Battery and Rack for Corrosion
Check Battery Water Level
Check Charge Operation and Rate
Check Engine Radiator Level
Check Engine Oil
Check Hoses and Clamps for Leaks
Check Belts
Check for Leaks around Generator
Check Fuel Tank Level
Test Run Generator:
- Oil Pressure:______
- Generator Temperature:________
- Volts:________
- Meter Hours Start Time:______
- Meter Hours Stop Time:______
Set Controls for Generator to Start in an Emergency
List Repairs/Maintenance Required
________________________________
________________________________
________________________________Checked By: _____________________
Date: ____________
Prestart Check: Review the generator log book
- Note the reading where the hour meter stopped. Is the reading on the generator the same?
- Are there any maintenance repairs logged?
- Any unusual comments from the last test run?
- Any fuel deliveries?
- Anything that may affect the running of the generator at this time?
Show the class an actual emergency generator logbook and review the entries.
Prestart Check: Turn off the generator
Never do a prestart check with the generator in the ready position. In order to begin your prestart checklist you need to first make sure the generator does not come on while you are checking the various components.- Turn the generator from the ready position to the OFF position and tag it!
- Stay in the moment! If you are called to do another task put the generator back in the ready (or auto) setting.
- NEVER EVER leave to do something else with the generator turned off, it will be rendered useless if there were to be a power failure!
Prestart Check: Check and clean the area around the generator
- In outdoor units, trash and debris may have collected or blown in by the wind.
- Look to see that the area around the generator is free of debris. Paper and plastic can be drawn into the fan and lodged or entangled with the fan or against the radiator. This could potentially cause overheating of the engine.
- Look for objects that could be or have already been sucked into the fan.
- Check for rodent nests. Animals can cause a great deal of damage to equipment that sits unused or is outside. Check the area occasionally for nests or signs of rodent activity. Most diesel engines have warm water jacket heaters where animals love to nest.
Animals could build nests near a generator with a warm water jacket such as those in diesel generators.
This is not a generator, but it does show what happens with a squirrel’s nest in a cooling tower fan. This is the result of starting the fan.
Animals can cause a great deal of damage to equipment that sits unused or is outside of the building. Check the area occasionally for nest or signs of rodent activity.
GOOD OR BAD?
GOOD OR BAD?
GOOD OR BAD?
Prestart Check: Check battery & battery rack for corrosion
REMEMBER, batteries can be explosive! Make sure you have the proper PPE on before you continue!
What PPE would be recommended in this situation?
Safety First!
Revisit proper PPE for handling of batteries.
List examples and post.
- Splash shield
- Apron
- Gloves
- What else?
- Check the battery and rack for soundness.
- Clean the battery.
- Check the terminals
- look for corrosion or poor connections. Poor connections of the battery terminals could prevent the generator from starting in an emergency situation. Poor connections of the battery terminals could prevent the generator from starting in an emergency situation.
-Example of clean battery rack and battery with corroded battery terminals.
Prestart Check: Check battery water level
- Check to ensure that each cell has water and at the proper level. Carefully remove the caps from each cell of the battery to check for proper water level. If the level is low add distilled water to the cell.
Prestart Check: Check charge operation and rate 
- Make sure that the charger is on.
- Ventilate the area.
- Check the charging rate. Batteries will lose their charge from sitting unused for long periods of time. Most generators are equipped with battery chargers to assure that the generator has ample power to start the generator when needed.
- Make sure it is set at the proper voltage.
Prestart Check: Check engine radiator coolant level
Safety First! Practice safe work habits.
NEVER OPEN THE RADIATOR CAP WHEN THE GENERATOR IS HOT!! Remember to slowly open the radiator cap. Failure to do so could result in the person opening the cap (if the radiator is under pressure) being scalded. Make sure the generator has the proper amount of antifreeze for the winter months. After a period of time antifreeze can break down and become corrosive. Develop a preventative maintenance schedule for flushing the radiator system.
- Fluid is the lifeblood of the generator’s engine.
- Check the radiator for the proper coolant level.
- Remember to slowly open the radiator cap. Failure to do so could result in the person opening the cap (if the radiator is under pressure) being scalded.
- In the fall, check the antifreeze level for proper low temperature settings for your area. Make sure the generator has the proper amount of antifreeze for the winter months.
- Flush the radiator system annually to avoid the buildup of sludge. After a period of time antifreeze can break down and become corrosive. Develop a preventative maintenance schedule for flushing the radiator system.
NEVER OPEN THE RADIATOR CAP WHEN THE GENERATOR IS HOT!
Prestart Check: Check engine oil
- Check the oil level to see if it is in the safe operational zone. If not, check the manufacture’s specifications for the proper oil for that generator. Different generators require different oil viscosities to ensure proper lubrication during heavy load demands.
- Add oil until you reach the proper level and note the addition of oil in the generator log.
- Make sure the level is in the safe operational zone or range.
- Change the oil annually or after an extended operational period.
- It’s cheaper to change the oil than to have the engine replaced.
Prestart Check: Check hoses and clamps
Time is an enemy of rubber. Hoses may begin to show signs of dry rotting. Under operating pressures these hoses can burst sending hot fluids flying in all directions and could cause severe burns to individuals in the immediate area. Additionally, the same thing could happen during an emergency call for power while you are not there. If the hoses were to rupture while you were absent from the area, the engine could suffer irreversible damage and the unit could be out of commission for an extended period of time.
- Check for sound hose connections.
- Examine each for dry rotting or cracking.
- Check for leaks.
Prestart Check: Check fan belts
Stop! Recheck that the generator cannot come on automatically before you continue. Do not place your hand near the fan or the fan belts until you do so! Once done, check the fan belts for signs of being worn, cracked, dry rotted or stretched. If so have the belts replaced before continuing.
On the belts check for:
- Dry rot.
- Cracking.
- Looseness.
- Proper adjustment.
- Worn or frayed areas.
Prestart Check: Check for leaks around generator
- Look for any sign of fluids on the floor under the hoses and connections.
- If it is an outdoor generator check the structure for:
- Leaky roof.
- Dampers not closing.
- Good seals on doors.
Prestart Check: Check fuel tank level
- Check and ensure that the fuel tank is topped off monthly.
- Make sure that the vent line is free of obstructions.
- Make sure that the fill and vent lines are of the same size.
Here is an example of a bird’s nest in the underground fuel tanks vent.
Prestart Check: Check fuel system
If your generator has fuel separators, drain them down to ensure that there is no water and/ or sediment in them prior to starting the engine.
Fuel tanks can accumulate moisture from condensation that can be drawn into the generator’s fuel system. Fuel oil separators placed before the generator enable engineers to remove any build up of water in the system before it enters the engine.
Prestart Check: Check warning controls or lights
If your generator has warning lights, test each light to ensure it is in working condition.
Check all system indicating lights to assure that they are functioning properly.
Conducting a Test Run
Test Run: Before you start
Remove all tags from the control panel.
Test Run: Start generator
After all of the different systems of the generator have been checked, start and begin the test run of the generator.
Don the proper hearing protection when running a generator.
Test Run: Check the exhaust stack at start up
It should run clean after a few seconds.
Test Run: Check the following systems
- Oil Pressure.
- Water Temperature.
- Volts.
- Meter Hours Start Time.
→ If possible test run your generator under load conditions.
Test Run: Safety reminder
Remember when running your generator you are generating electricity!
Test Run: Transfer switches
Transfer switches when installed should transfer from commercial power to the generated power source.
Test Run: Transfer switches (Accident)
- The lugs on this transfer switch became loose from expansion and contraction, due to lack of preventive maintenance. Once the lugs start to become loose, the cables will heat up due to a poor connection. Periodically, preventive maintenance on these lugs has to be performed. “ALWAYS REMEMBER TO FOLLOW STRICT SAFETY PROCEDURES TO ENSURE THAT THE POWER SOURCE IS OFF AND DRAINED!!!”
- Burnt lugs (due to lack of preventive maintenance).
Test Run: Completing the generator test run
- Cool down period: Once the generator has gone through a test run under simulated load conditions, the generator will enter the next phase, the cool down time. Some generators have a built in tier for cool down periods after a test run.
- Log in any changes or unusual events and findings during the test run.
Some generators have a built in tier for cool down periods after a test run.
Test Run: Reset the generator control switch
When the test run is completed, always make sure that the generator is in the ready position in the event of a power disruption or failure.
- Set generator controls back to “ready to start” so it will be ready in an emergency.
- Remove any tag that you may have placed at the control panel.
ANY QUESTIONS?
We Covered:
Background and Rationale
- Importance of weekly inspections and test runs.
Important Safety Considerations
- Relevant OSHA standards and other safety considerations.
- How to contribute to a culture of safe work practices.
Prestart Checklist
- What is involved in each step of a prestart checklist.
Conducting a Test Run
- How to conduct a safe test run.
- The operations and safe parameters of a fixed generator during a test run.
- Placing the fixed generator back into the ready position.
This publication was supported by the National Institute Of Environmental Health Sciences of the National Institutes of Health under Award Number U45ES006182. The content is solely the responsibility of the authors and does not necessarily represent the official views of the National Institutes of Health.
IUOE National Training Fund
National HAZMAT Program
1293 Airport Road
Beaver, WV 25813
(304) 253-8674
Fax (304) 253-7758
hazmat@iuoehazmat.org
www.iuoehazmat.org