Best Practices for Standby Generator Operations and

Maintenance
Table of Contents
 Introduction
 Description of Technology
 Key Components
 Safety Issues
 Maintenance of Technology
 Maintenance Checklist
 Performance Monitoring
 O&M Cost
 Additional Support
 Sources of Information

Introduction
Standby generators are self-contained systems that provide electricity when
power from the primary source, usually the local electric grid, is unavailable.
When the grid experiences an outage, an automatic transfer switch (ATS)
signals the standby generator to start and begin providing power. When the grid
is again available, the load and power are transferred back to the grid, and the
ATS signals the generator to stop.

Standby generators are usually internal combustion engines coupled with an

electric generator and can be powered by diesel fuel, propane, natural gas, or
other liquid fuels. These generators typically operate for a limited amount of time
and are not meant for extended use. Executing the necessary operations and
maintenance (O&M) on this system is crucial for optimized efficiency and
preparation for power outages.

The purpose of this equipment O&M Best Practice is to provide an overview of

system components, maintenance requirements, and best practices to assure
the safe and efficient operation of standby generators. Neglecting proper
maintenance of standby generators could result in premature system failure and
lack of power during an outage. Support organizations should budget and plan
for routine maintenance of standby generators to assure reliable operation.

Description of Technology
Standby generators are sized according to their electrical output (expressed in
kilowatts [kW]) and are classified in one of three categories: residential,
commercial, or industrial. Residential generators are typically operated on a
single electric phase, while commercial and industrial generators are usually
three-phase devices. Standby generators are considered distinct from
emergency generators in that the latter typically serve very specific loads and
are usually required by code for life-health-safety reasons.

According to the NFPA 110 Standard for Emergency and Standby Power
Systems (NFPA 2019) developed by the National Fire Protection Association
(NFPA), there are two levels of emergency power supply systems.

 Level 1 – where failure of the equipment to perform could result in loss of

human life or serious injuries.
 Level 2 – where failure of the emergency power supply system to perform
is less critical to human life and safety.

The balance of this guide will focus on commercial standby generators (Level 2
systems, according to the NFPA 110 Standard) because they are most
commonly used for building-level standby generation.

Standby generators can be mobile (on wheels/skid-mounted), or they can be

stationary with fixed mountings. According to the National Electrical Code
(NFPA 2020), all stationary generators that are integrated into a building’s
electrical system are required to be hardwired and contain an ATS for safety
purposes.

Standby generators can operate on a variety of fuels and some on multiple

fuels. The most common fuels are diesel, natural gas, gasoline, and propane.
There are some generators capable of burning jet fuel, dual fuels (diesel and
natural gas/propane), as well as different chemistries of biofuels. Figure 1 shows
a typical standby generator installation housed in its own containment area.
Figure 1. Typical standby generator installation within containment area
(Source: Shutterstock).

Key Components
The main components of a typical engine-driven standby generator are
described below and are shown in Figure 2. Each of these components or
systems must be maintained for basic operation and for the larger system to
function efficiently.

 Engine—provides mechanical energy that gets converted to electrical

energy. The engine’s type and size determine the generator’s fuel use
and power output.
 Generator—converts mechanical energy into electricity.
 Fuel supply system—consists of a fuel tank and associated delivery
piping and components (e.g., diesel fuel pump, fuel filter, and a nozzle or
injectors).
 Lubrication—assures smooth operation and protects against wear;
typically housed in a sump or reservoir.
 Cooling System—consists of a cooling pump, coolant fluid, and a
radiator (heat exchanger) with a fan to dissipate the heat.
 Starting System—switches the engine and generator on (larger standby
generators use compressed air injected into the cylinders to provide
starting power).
 Exhaust System—captures and directs exhaust gases to an appropriate
location for potential treatment (i.e., emission control) and ultimate
dissipation.
 Control Panel—contains devices, including the system controller, to
manage and monitor generator operation from initial start to steady-state
operation to shut-off. Monitored generator functions include oil pressure
and coolant temperatures as well as current, voltage, and frequency.
 Air Intake System—directs and filters combustion air entering the
engine.
 Batteries—provides generator power for start-up during a power outage.
 Battery Charger—typically connected to utility power and keeps batteries
charged.

All of the above components function with a system controller that monitors and
controls operation from initial start to steady-state operation to shut-off.
Depending on the generator type, location, and configuration, the entire
assembly may be housed in a factory-built enclosure, a small building, or be
built into a larger facility. Figure 2 highlights a typical standby generator, with
the major components identified.
Figure 2. Typical standby generator components. (Diesel generator is shown.)

Safety Issues
Federal, state, and local regulations will require permitting before standby
generator installation and/or operation. These permits may include emissions
certification and renewal requirements. The permitting process will require that
specific safety and environmental actions be completed before operation. The
standby generator and associated safety and environmental actions will be
subject to periodic inspection.

Whether required by local code or not, safety and environmental stewardship

must be treated with the utmost importance. An excellent reference for standby
generator operation and safety is the NFPA 110 Standard for Emergency and
Standby Power Systems (NFPA 2019).

General guidelines for safety and usage that are provided by the engine
manufacturer and the installing contractor should be followed. Installation,
repair, and maintenance should always be in accordance with the applicable
building codes and manufacturer’s instructions and recommendations. The
following guidelines are presented only as supplemental material.

 Exhaust systems must be properly installed, adequate ventilation must be

provided to assure unobstructed flow of cooling/ventilating air, and
emissions must be directed away from building air intakes as well as
areas where people may pass or gather.
 The area around the generator should be clean and free of any
combustible material that can be hazardous.
 All power supplies should be turned off/disconnected at the source before
servicing the generator, including the batteries.
 The frame of the generator should have proper grounding (earthen
ground).
 All fuel sources should be kept cool and dry. Most fuels have a resident
design life and should be monitored for degradation and actively treated
according to the supplier’s specifications.
Maintenance of Technology
Adopting a preventive and predictive maintenance program is critical to assuring
that the generator system functions properly and efficiently. Keeping the standby
generator properly maintained through active maintenance will improve system
performance, increase the operating life, and protect the asset.

Maintenance of standby generators should be conducted by qualified personnel.

Maintenance activity should be logged to confirm and document completion and
provide a foundation for trend analysis.

Maintenance Checklist
For all standby generator maintenance, it is important to follow the
manufacturer’s recommendations. Proper maintenance should only be
performed by trained and qualified personnel. The example diesel generator
checklist in Table 1 below provides recommended actions and associated
frequencies by standby generator component type. This checklist does not
supersede maintenance recommendations from the generator manufacturer, nor
is it a replacement for contracted O&M or warranty services. For maintenance
related to additional auxiliary components such as built-in engine heaters,
please refer to the equipment’s owner’s manual.

Table 1. Standby generator maintenance checklist.

Maintenance Frequency
Compone Bi-
Action Wee Mont Annu
nt Annu
kly hly ally
ally
Electric Run X
Generator generator
with no
load for
several
minutes
until
operating
temperatu
re is
achieved;
verify
control
function
and look
for
alarms,
warnings,
or
indicator
lights.
Inspect
engine,
radiator,
and
generator
for
debris, as
well as X
for loose
or broken
fittings,
hoses,
wires,
and
guards.
Run the
system
for 1 hour
under a
full
building
load
initiated
by ATS.
Record
the
system
operating
X
parameter
s (e.g.,
coolant
temperatu
re, oil
pressure,
battery
voltage,
and
generator
alternatin
g current
voltage).
Perform
load bank X
test.
 Check
fuel tank
to assure
levels are
adequate
and, if
X
present,
drain
water
from
filter
bowl.
Assure
there are
no fuel or
X
other
fluid
leaks.
Inspect
accessibl
e areas of
fuel tank
Fuel for
System damage
and
corrosion
. Verify
that
X
emergenc
y vent
compone
nts move
freely
and are
not
obstructe
d (all
tanks).
Replace
fuel X
filter(s).
Inspect
fuel hose,
replace if X
necessary
.
Lubricatio Check oil X
n System level and
inspect
 system
compone
nts for
leakage.
Sample
X
oil.
Grease
generator
bearing
X
(if
applicabl
e).
Replace
oil and
oil filter
(based on
oil
sample
X
results)
and
inspect
system
compone
nts.
Replace
engine oil
hoses if X
necessary
.
Cooling Inspect
System hoses and
belts,
replacing
if needed,
and
verify X
that the
engine
block
heater is
operating
properly.
Check
engine
X
coolant
level.
Check X
coolant
lines and
 connectio
ns.
Check
coolant
condition
with
X
kit/test
strip,
replace if
needed.
Inspect
and
adjust
belts,
verify
engine
block
heater is
operating
, check
radiator
cap
(replace
cap if
gasket is
X
cracked
or
damaged)
, clean
exterior
of
radiator,
inspect
fan
shroud,
and
inspect
system
compone
nts.
Assure
that the
generator
is in
X
Starting “Auto”
System mode for
automatic
start-up.
Clean X
 battery
connectio
ns and
apply
corrosion
inhibitor.
Check
starter
motor
and
charger
connectio
ns and
inspect
system
compone
nts.
Check
battery
electrolyt
e level X
and
specific
gravity.
Inspect
and clean
engine
X
speed
timing
sensor.
Exhaust Perform
System visible
emissions X
observati
on.
Clean
crankcase
breather
and
X
inspect
system
compone
nts.
Inspect X
exhaust
system,
muffler,
and
exhaust
 pipe.
Check
that the
generator
X
’s circuit
breaker is
closed.
Clean out
electrical
boxes,
Electrical panels,
X
System and alarm
boxes.
Inspect
wiring.
Inspect
and clean
ATS
X
contacts
and
wiring.
Inspect
air intake
Air Intake system.
X
System Replace
filter if
needed.
Record
all run Upon activity completion
hours.
Documen
t all
maintena
nce
activities
System
in log
Document
book or
ation
electronic Upon activity completion
computer
ized
maintena
nce
managem
ent
system.
Performance Monitoring
Depending on the age and type of the available control system, a standby
generator can be monitored via a building automation system (BAS) whereby
critical parameters are captured, tracked, and trended. These metrics may
include run hours, exhaust temperature and composition, and fuel rate. Without
a BAS-enabled generator, the performance should be monitored each week,
month, and year by operating the generator, recording system operating
parameters, and performing visual emissions observations. Any differences in
system operating parameters should be trended, noted, and acted upon if out of
compliance or specification.

O&M Cost
Standby generators require preventive and predictive maintenance and regular
testing to assure the highest reliability. The cost of O&M for standby generators
varies depending on the size of the generator, the operating profile, the type of
fuel used, and the maintenance plan. A survey of reported maintenance costs
found significant variability. In recent documents (NREL 2014, 2019), the
National Renewable Energy Laboratory reports maintenance costs as a function
of the generator size and being composed of both fixed cost ($/kW) and variable
($/kWh) costs. Assuming a 300 kW standby generator operating under 200
hours per year, the range of O&M costs is between $8,000 and $10,500 per
year.