Plant generator Safety Operating Procedures
Date：2025-12-02 15:41:14 Traffic Index：260
The Plant generator is a crucial power supply device for safety defense and production support, playing an important role. To ensure that the Plant generator can operate normally when needed, its safety operating procedures must be properly followed.
I. Advantages of Plant generator
Plant generator is a power solution whose advantages are reflected in multiple aspects such as reliability, cost-effectiveness, functionality, and security.
II. Huaquan Power is a professional Plant generator manufacturer in China
Huaquan Power is a professional Plant generator manufacturer in China, equipped with modern workshops and production bases. It has large-scale production capabilities, able to meet both bulk and urgent order demands, and has established a solid brand image in the power industry.
Huaquan Power has strong system integration capabilities, able to optimize the matching of generators and intelligent control systems according to the characteristics of different engine brands. This integration ensures that from raw material intake, production processes, to finished product testing, there is a standardized workflow, guaranteeing the consistency of product quality.
Huaquan Power Plant generators generally adopt intelligent control systems, featuring four protections (high water temperature, low oil pressure, overspeed, overcurrent), automatic start, multi-parameter display, remote monitoring, and other functions, meeting the modern factories' needs for intelligent operation and maintenance.
Huaquan Power can make technical adjustments and customizations according to the specific needs of factories, ensuring that Plant generators can still provide stable power output in special environments.
Huaquan Power offers one-stop services from pre-sales consultation, solution design, on-site installation guidance, to after-sales maintenance.
III. Introduction to the Advantages of Plant generator
1. Ensuring Production Continuity
Plant generator can prevent production interruptions: Modern factory production lines are highly automated, and a power outage can bring the entire line to a halt immediately. Restarting not only takes time but may also cause work-in-progress scrap, mold damage, and other issues, leading to significant downtime losses. Plant generator can automatically start within seconds of a power outage and supply electricity to core production lines, ensuring orders are delivered on time.
Protecting work-in-progress and processes: Many production processes require a continuous power supply. A sudden power outage can result in the scrapping of entire batches, causing serious waste of raw materials and resources.
2. Protecting Key Equipment and Data Assets of Plant generator
Using plant generator prevents hardware damage: Sudden power loss during operation of large equipment such as CNC machines, industrial robots, and central air conditioning can easily lead to mechanical jams, program errors, or spindle damage, with high repair costs.
Plant generator prevent data loss: They provide continuous power to servers and industrial control computers, preventing the loss of production parameters, order information, and quality traceability data due to power interruptions.
3. Serving as Main or Backup Power in Specific Scenarios
Main power source: In remote areas not covered by the grid or newly-built factory campuses, plant generator can serve as the primary power source for daily operations.
Peak load compensation: During periods of peak electricity usage, starting plant generator can help share the load and reduce electricity costs.
4. Ensuring Safe Maintenance and Basic Operating Environment
Ensuring life safety: They provide power for emergency lighting, fire alarm systems, smoke exhaust fans, and evacuation indicators, ensuring safe evacuation during emergencies.
Maintaining security and environment: Plant generator can ensure the normal operation of security monitoring and access control systems to prevent property theft. They also supply power to cold storage and computer room air conditioning to prevent spoilage of goods and overheating of equipment.
5. Providing High Cost-Effectiveness and Investment Returns
High return on investment: The loss from a single power outage causing production interruption, order breach, or equipment damage can far exceed the cost of purchasing a plant generator itself.
IV. Safety Operating Procedures for Plant generator
1. Basic Personnel Requirements
Certified Operation: Operators and maintenance personnel must undergo systematic training, be proficient in the plant generator’s performance and emergency procedures, and pass assessments.
Familiarity with Equipment: Read and understand the plant generator manual as well as these procedures.
Personal Protection: Wear protective gear during operation (earplugs for noise, work clothes, insulated shoes, gloves).
Condition Requirements: Operating the plant generator is strictly prohibited under the influence of alcohol, when fatigued, or when ill.
2. Safety Check Before Startup
Ensure that the plant generator room and surrounding area are clean and free from flammable or explosive materials.
Check that ventilation systems are unobstructed; do not operate in enclosed spaces to avoid carbon monoxide poisoning.
Check that fire-fighting equipment is complete and functional.
Oil Level: Check the oil level with the dipstick while the plant generator is stopped, ensuring it is within the marked range.
Coolant Level: Check the expansion tank or radiator, ensuring the level is within the specified range.
Fuel Level: Make sure there is enough fuel, and check fuel lines and connections for leaks.
Battery: Check that terminals are secure, corrosion-free, and that electrolyte levels are normal (for non-maintenance-free batteries).
Air Filter: Check the indicator and clean or replace the filter as needed.
Plant generator Body: Quickly check that mounting bolts are tight, belts are properly tensioned, and all attachments are present. Inspect all electrical wiring for security, damage, or aging.
Ensure the output circuit breaker or main switch is in the "OFF" position.
3. Safety Monitoring During Startup and Operation
Once everything is confirmed normal, set the control mode to "manual".
Press the start button; startup should generally not exceed 10 seconds. If the first attempt fails, wait 30 seconds before retrying. If three consecutive starts fail, stop the plant generator and inspect the cause.
After starting, let the plant generator run under no-load or low-load conditions for 3-5 minutes to "warm up" and monitor parameter stability.
Instrument Monitoring: Closely observe oil pressure, coolant temperature, voltage, frequency, and other key parameters to ensure they are within the specified range.
Sensory Inspection: Listen for unusual noises, observe for severe vibrations, oil or water leaks, and smell for burning odors.
Load Operation: After the plant generator stabilizes, gradually and smoothly increase the load. Sudden high-power loading is strictly prohibited.
4. Normal Shutdown and Emergency Shutdown
Gradually disconnect all loads and allow the plant generator to run idle for 3-5 minutes to evenly cool components such as the turbocharger.
Press the stop button and wait until the plant generator fully stops.
Close the fuel valve if the plant generator will be stopped for a long period.
Conduct routine post-shutdown checks and record operations.
Immediately press the red emergency stop button in any of the following situations:
- Personal injuries or threats to human safety
- Sudden drop in oil pressure with alarm activation
- Coolant temperature exceeds the red line (e.g., 105°C) or boiling occurs
- Violent abnormal knocking sound inside the plant generator
- Excessive speed ("overspeed") that cannot be controlled
- Smoke or fire from the plant generator or wiring
- Pipeline rupture with significant fuel or oil leak
5. Maintenance and Servicing Safety Procedures
Absolute Power Off: All maintenance must be performed with the plant generator completely stopped, the starting battery disconnected, and measures in place to prevent accidental startup.
Hang Warning Signs: Place "Do Not Close, Personnel Working" warning signs on switches and control panels.
Prevent Burns: Never open the radiator pressure cap when the plant generator is hot; wait until it cools below 50°C and cover the cap with a cloth, opening it slowly.
Standard Operating Procedure: Use dedicated tools and containers for filter replacement or oil/water drainage to prevent pollution and environmental hazards.
V. Q&A on plant generator
1. How to calculate the required plant generator capacity for a factory?
List all key equipment: production lines, lighting, air conditioning, servers, etc.
Calculate total operating power (kW): sum up the operating power of all equipment.
Consider starting current: the starting current of motor-type equipment (such as pumps and air compressors) is 3-7 times the operating current.
Estimation formula: Total required power ≈ (∑ equipment operating power) × 1.5~2.5 (empirical factor depending on the proportion of motor load).
Consult Huaquan Power: provide the equipment list to Huaquan Power for precise calculation.
2. What are common reasons why a plant generator fails to start?
Check in the following order:
Fuel system: is the plant generator out of fuel? Is there air in the fuel line or any blockage?
Starting system: is the battery sufficiently charged? Are the terminals corroded or loose?
Protection system: is there an alarm or protective shutdown (e.g., low oil pressure, high water temperature) that has not been reset?
Control system: are any fuses blown? Is the emergency stop button not reset?
3. Why do plant generator need regular load test runs?
To verify actual performance: check if it can output stably at rated power.
To remove carbon deposits: long-term light load operation can form carbon deposits in diesel engines; regular load operation can clear them and extend engine life.
VI. Application Scenarios for plant generator
1. As a Backup Power Source
This is the standard configuration for plant generator within a factory, aimed at immediately taking over critical loads during grid failures to minimize losses and ensure production continuity.
Automated Production Lines: Prevent the entire production line from suddenly halting, which could make restarting difficult, cause loss of process parameters, and result in huge production downtime losses.
Process Industries: In sectors like chemicals, metallurgy, and food processing, power outages could trigger uncontrolled chemical reactions, furnace freezing, or the spoilage of entire batches of raw materials.
Ensuring Order Fulfillment: Avoid the risk of failing to deliver orders on time due to production interruptions, which could lead to contract breaches.
2. Protecting Critical Equipment and Data of plant generator
Precision Equipment: CNC machines and industrial robots may experience mechanical jams, program errors, or data loss if there's a sudden power outage.
3. Safety and Environmental Maintenance with plant generator
Life Safety Systems: Supply power for emergency lighting, evacuation indicators, fire alarm systems, and smoke exhaust fans to ensure safe evacuation of personnel.
Security Systems: Maintain the operation of monitoring and access control systems to prevent the factory from being in a safety "vacuum" during power outages.
Maintaining Basic Environmental Conditions: Supply power to data center air conditioning, production workshop ventilation systems, and laboratory temperature and humidity control equipment.
Cold Chain Systems: Provide continuous power for cold storage and refrigeration rooms to prevent spoilage of food, pharmaceuticals, or chemical raw materials.
Public Utility Dependence: Supply power to water pumping stations and wastewater treatment systems.
4. As a Primary Power Source
In certain situations, plant generator serve as the sole or main power source for daily operations.
Areas Without Grid Coverage: In remote areas, emerging industrial zones, or mining sites where the grid has not yet reached, plant generator act as "mobile power stations."
Areas with Extremely Unstable Grids: In regions with frequent power interruptions and severe voltage fluctuations, using plant generator as a stable power source is more reliable than depending on the grid.
5. As a Supplementary Power Source
This application is not intended for power outages but as a proactive energy management strategy to save electricity costs.
Peak Load Compensation: Many regions include "demand charges" in electricity bills, which are based on the highest power consumption during a period.
During peak electricity usage in factories (e.g., when multiple high-power devices start simultaneously), proactively starting the plant generator to handle part of the load can keep the total power drawn from the grid at a lower level, thereby reducing overall electricity costs.
Plant generator have evolved from passive emergency equipment into critical infrastructure that ensures production resilience, asset safety, and operational efficiency.
More information about plant generator: http://sinogens.com/
