Facility Manager: Benefits to Developing a Generator Maintenance Checklist

As the facility manager, you are at times the only person who knows a backup generator is working properly. Everyone assumes that when the power goes out, the generator is just going to start up and provide whatever electricity is required to keep everything running smoothly. I come from the Healthcare industry where a generator that doesn’t kick in when needed can literally be a life or death situation. I know first hand that the time to  identify, resolve and ultimately prevent generator issues is during routine maintenance. When a generator failure occurs at a hospital it’s big news! For example, earlier this year all surgeries had to stop at a hospital because the backup generator failed during routine tests. This issue was identified during a routine test so lives were not in immediate danger.  However, whatever kind of facility you manage, people depend on the backup generator to function properly 100% of the time. So it’s mission critical that these machines are maintained properly.

Here are some ideas you can draw from to develop a generator maintenance checklist. Take what works for you, and depending on the extent of your emergency power needs, develop frequencies that make sense for your facility.

Visual Inspection:

• Look around the area where the air comes in, and remove any debris.
• Take a look at the generator itself.
• Look for fluid leaks, corrosion, torn gaskets or jackets.
• Look often enough that you will recognize when something look different.
• Use a bright flashlight like an LED to really see what is going on.

Electrical system:

• Check the batteries — make sure they are fully charged.
• Start the generator to make sure batteries perform under load.
• Clean the battery connections.
• Check specific gravity and electrolyte levels if appropriate.
• Inspect the wiring for loose connections and any cracks in the insulation.

Cooling system:

• Make sure the radiator is clean and air can flow through it unrestricted.
• Check the coolant levels.
• Assure you are using the correct coolant and in the proper concentration.

Fuel system:

• Clean or replace fuel filters per manufacturer’s recommendations.
• Inspect fuel lines for leaks.
• Test fuel periodically to ensure it is usable.
• Use fuel additives as appropriate.
• Do not store diesel fuel in the tank for more than one year.
• Record fuel consumption, and note if there are any changes in how much fuel is being used.

Run the generator:

• On a monthly basis, operate the generator for at least 30 minutes under 30% load.
• Note any unusual noises or vibrations.
• Look for leaks.
• Use an infrared thermometer to record the stack temperature.
• Look for smoke.
• Check the fuel pressure.
• Start the generator through a transfer switch to ensure the complete emergency power system is functional.
• If you have more than one transfer switch use a different one to start the generator each month.

Annually, run the generator under 100% load for an hour to ensure that it will function properly when you really need it. Remember, proper maintenance of your generator is critical to keeping your facility operating during an unexpected power loss.

Next steps:

• Check out our learning center on how best to maintain all your facility’s existing equipment.
• Subscribe to our blog to stay informed on the latest HVAC maintenance news and insight.
• Stay up to date on facility maintenance tools such as chiller tube cleaners, boiler tube cleaners, hose/pipe cleaners, descaler systems, test instruments, industrial vacuums, commercial pressure washers, and drain cleaners.

John Thompson
Goodway Blogging Team