Diesel Generator Operation and Maintenance Management Procedures

  1. Purpose

  To ensure timely and reliable power supply during utility outages through generator management, thereby maintaining normal operation of elevators, fire protection systems, secondary water supply, and other critical functions to meet users' emergency safety power requirements.

  2. Scope

  Applies to the operational management of diesel generators under the jurisdiction of the Property Management Center.

  3. Responsibilities

  3.1 Power supply and distribution personnel are responsible for generator operation, monitoring, record-keeping, cleaning, and maintenance.

  3.2 The Engineering Supervisor is responsible for the comprehensive management, inspection, and supervision of diesel generators.

  4. Work Procedures

  4.1 Work System

  4.1.1 Remain dedicated to duties, enhance professional competence, and improve skill proficiency;

  4.1.2 Adhere to safety operating procedures and all regulations to prevent violations and accidents;

   4.1.3 Maintain alertness and sharp thinking during work; operating generators under the influence of alcohol is strictly prohibited;

  4.1.4 Conduct regular inspections, maintenance, and cleaning of generators;

  4.1.5 Maintain accurate records in the “Generator Set Operation Log” during operation;

  4.1.6 Maintain detailed records of all issues addressed during maintenance.

  4.1.7 Eating and smoking are strictly prohibited in the generator room.

  4.1.8 Regularly clean the generator room and equipment to maintain a tidy environment. Ensure battery terminals are secure and dry.

  4.2 Safety Procedures

  4.2.1 To ensure reliable generator operation during mains power outages and maintain equipment in normal standby readiness, strictly adhere to the “Operating Procedures” outlined in this document;

  4.2.2 Conduct pre-startup inspections and preparations: verify engine oil level, coolant volume, diesel fuel sufficiency for required runtime, and check fuel lines for leaks;

  4.2.3 During operation, strictly follow the generator's operating manual requirements and promptly activate cooling fans to reduce temperature;

  4.2.4 During generator operation, monitor fuel supply lines, voltage, current, frequency, temperature, and mechanical system performance;

  4.2.5 Operators must not leave their posts without authorization while the generator is running;

  4.2.6 Generators must not be operated beyond their rated capacity.

  4.2.7 Maintain cleanliness of the starter battery and periodically inspect its capacity.

  4.2.8 If a sudden drop in oil pressure is detected, immediately investigate the cause and take corrective action.

  4.3 Operational Management Procedures

  4.3.1 Non-staff personnel entering the generator room must obtain approval from the engineering supervisor and be accompanied by a designated department representative;

  4.3.2 In the event of a " mains power“ outage, power supply and distribution personnel shall promptly proceed to the generator room. The entire generator startup process must strictly adhere to the ”Operating Procedures." No load startup is permitted. Before applying load, the cooling system, lubrication system, fuel system, and air system must be thoroughly inspected. Upon confirmation of no issues, manually start the generator promptly;

  4.3.3 During load operation, complete the “Generator Set Operation Record” hourly;

  4.3.4 Firefighting equipment in the generator room must be fully functional; smoking is strictly prohibited indoors;

  4.3.5 Maintain adequate ventilation and lighting. Doors and windows must open smoothly. All trenches, openings, and access points shall be secured with metal grating to prevent entry/exit of small animals. Maintain at least two barrels of fuel in stock;

  4.3.7 Analyze operational data, promptly address potential hazards, and report major anomalies to the Engineering Supervisor and Project Department Supervisor for resolution;

  4.3.8 Perform maintenance according to the Equipment Maintenance Schedule and document all activities in the Equipment Maintenance Log;

  4.3.9 Maintain cleanliness of generators and generator rooms, ensuring no accumulated dust, water stains, or oil stains;

  4.3.10 The Engineering Supervisor is responsible for proposing purchase and disposal plans for maintenance materials, and submitting requests for outsourced repairs to the Engineering Management Department;

  4.3.11 The Engineering Supervisor is responsible for executing intermediate and major overhaul plans according to the Equipment Maintenance Schedule.

  4.4 Operating Procedures

  4.4.1 Prior to generator operation, conduct inspections of engine oil, coolant levels, fuel quantities, and other parameters;

  4.4.2 Lubrication System: Check engine oil level, maintaining it as close as possible to the upper mark on the dipstick without exceeding the maximum level (HI position);

  4.4.3 Cooling System: Check engine coolant level. Coolant should reach approximately 5cm below the radiator opening. Never check coolant level when engine is hot to avoid burns;

  4.4.4 Fuel System: Ensure fuel tank is filled with diesel and fuel lines are unobstructed;

  4.4.5 Startup Procedure:

  4.4.5.1 Starting Operation via Generator Control Panel

  Start: Turn the key from the “O” to the “I” (preheat) position to activate the preheater. Maintain this position for 7 seconds to preheat the intake air. After 7 seconds, turn the key to the ‘S’ (start) position to initiate starting. Once the engine starts, immediately release the key to return it to the “I” (ON) position. The engine must run unloaded for at least 5 minutes before applying any load.   If starting fails, do not exceed 5–7 seconds per attempt. Ensure the key fully returns to the “O” (off) position every 10 seconds. If the engine fails to start after 4 attempts, stop and consult the Diesel Engine Manual.

   4.4.5.2 Shutdown Procedures

  Normal Shutdown: To stop the unit, first lower the generator set's output circuit breaker to the “off” position (handle down). Allow the generator set to run unloaded for 5 minutes to cool down. Then turn the key back to the “O” (off) position, and the generator set will stop;

  Emergency Shutdown: Pressing the emergency stop button or turning the control knob to the “Stop” position will immediately halt the generator set. Before restarting, ensure the control knob remains in the “Stop” position, the emergency stop button is rotated clockwise to reset, and the alarm is acknowledged and cleared.