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Generator (Genset) Risk Assessment

Generator (Genset) Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Generator (Genset) Risk Assessment

Product Overview

Identify and control organisational risks associated with Generator (Genset) ownership, installation and operation using this management-level Risk Assessment, focused on planning, governance and systems rather than task-by-task work instructions. This comprehensive document supports WHS Risk Management, demonstrates executive Due Diligence, and helps protect your business from regulatory enforcement and operational liability under the WHS Act.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, Legal Compliance and WHS Duties: Assessment of PCBU obligations, officer due diligence, consultation requirements, and alignment of generator use with organisational WHS policies and risk criteria.
  • Procurement, Design and Specification of Generators: Management of selection, sizing and specification of gensets, including compliance with Australian Standards, safety features, emission controls and suitability for the intended environment and load profile.
  • Installation, Commissioning and Electrical Integration: Controls for fixed and temporary installations, earthing and bonding, changeover arrangements, isolation points, and coordination with electrical engineering and authorised electrical contractors.
  • Fuel Management, Storage and Environmental Controls: Assessment of diesel, petrol and gas fuel systems, bunding, spill prevention, ventilation, hazardous area classification, and environmental protection measures.
  • Training, Competency and Authorisation: Requirements for operator training, competency verification, licensing where applicable, and formal authorisation to start, stop, test and manage generators under normal and emergency conditions.
  • Procedures for Routine Operation and Emergency Use: Development of documented start-up, shutdown, load transfer and emergency operation procedures, including communication protocols and escalation pathways during power loss events.
  • Inspection, Testing, Maintenance and Reliability Management: Preventive maintenance scheduling, periodic functional testing, condition monitoring, and management of critical spares to minimise unplanned outages and safety-critical failures.
  • Portable Generator Management, Transport and Storage: Risk controls for mobile and hire gensets, including securing during transport, load connection arrangements, refuelling practices, and temporary site placement to control fumes, noise and ignition sources.
  • Noise, Vibration and Occupational Hygiene Controls: Assessment of exposure to noise, exhaust fumes, heat and vibration, and implementation of engineering controls, PPE requirements and restricted zones to protect workers and neighbours.
  • Emergency Preparedness, Testing and Business Continuity: Integration of generator capabilities with emergency response plans, black-start and load-shedding strategies, and regular scenario testing to support business continuity objectives.
  • Documentation, Labelling and Information Management: Management of manuals, single-line diagrams, operating instructions, safety signage, fuel and isolation labelling, and record-keeping for inspections, tests and maintenance.
  • Contractor, Hire and Third-Party Interface Management: Controls for engaging electricians, fuel suppliers, hire companies and service providers, including scope definition, competency checks and interface risk management.
  • Monitoring, Audit and Continuous Improvement: Processes for performance monitoring, incident and near-miss review, internal audit, corrective actions and periodic review of generator-related risks and controls.

Who is this for?

This Risk Assessment is designed for Business Owners, Officers, Facility Managers, Electrical Engineers and Safety Managers responsible for planning, procuring, installing and managing Generator (Genset) systems across their operations.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, Legal Compliance and WHS Duties
  • • Lack of clear WHS governance for generator (genset) activities, including unclear PCBU and officer responsibilities under WHS Act 2011
  • • Failure to identify and comply with applicable Australian WHS legislation, regulations, codes of practice and Australian Standards relating to generators and electrical installations
  • • No documented policy or procedure for emergency and backup generator use, testing and maintenance across the organisation
  • • Poor integration of generator risks into the overall WHS management system and risk register
  • • Inadequate consultation with workers, health and safety representatives (HSRs), contractors and building management regarding generator risks and controls
  • • Inadequate due diligence by officers in ensuring resources and systems are in place to manage generator-related risks
  • • Lack of formal review of generator-related incidents, near misses and changes in legislation, technology or operations
2. Procurement, Design and Specification of Generators
  • • Selection of generators (fixed or portable) that are not fit for purpose in terms of power rating, duty cycle, environment, or emergency backup requirements
  • • Procurement driven solely by price without adequate consideration of safety features (RCDs, guards, emergency stops, noise attenuation, emission controls, fuel type and containment)
  • • Lack of engineering assessment of emergency and backup power needs for critical systems (e.g. life safety, fire systems, ICT, medical equipment)
  • • Importing or purchasing non-compliant or unapproved generator units and accessories that do not meet Australian Standards or local electrical safety requirements
  • • Inadequate specification of controls for carbon monoxide (CO), fuel storage, noise, vibration, manual handling and transport in procurement documents
  • • Poor integration between building electrical design and generator systems (e.g. unsafe changeover arrangements, risk of backfeed into grid, inadequately rated switchgear)
  • • Failure to specify standardised models or systems, leading to multiple brands and configurations that increase training and maintenance complexity
3. Installation, Commissioning and Integration with Electrical Systems
  • • Inadequate oversight of electrical design and installation leading to unsafe connections, risk of electric shock, fire, or backfeed to incoming supply
  • • Generators installed in locations with poor ventilation, inadequate exhaust routing or proximity to air intakes, creating carbon monoxide and fume hazards
  • • Insufficient structural support and anchoring of fixed generators, increasing risk during vibration, severe weather or seismic events
  • • Improper segregation of fuel storage from ignition sources and occupied spaces, increasing fire and explosion risk
  • • Lack of clearly labelled and tested changeover systems for emergency and backup generator operation, causing confusion and unsafe switching during outages
  • • Inadequate earthing and bonding arrangements for portable generator setups and temporary backup systems
  • • Absence of formal commissioning process, including performance testing under load, failover tests and verification of safety interlocks
4. Fuel Management, Storage and Environmental Controls
  • • Inadequate systems for safe storage and handling of petrol and diesel for generators, leading to fire, explosion or environmental spills
  • • Lack of controls over decanting and transfer of fuel into portable generators or day tanks
  • • Insufficient segregation between fuel storage areas and workplaces, emergency exits, ignition sources or public areas
  • • No clear responsibilities or procedures for inspecting tanks, hoses, valves and spill containment systems
  • • Failure to manage fuel quality, age and contamination, resulting in generator failure during critical backup events
  • • Poor record keeping of fuel deliveries, usage, inspections and spill incidents
  • • Inadequate emergency response procedures and equipment for fuel leaks, fires and exposure incidents
5. Training, Competency and Authorisation
  • • Untrained or inadequately trained personnel operating, transporting or maintaining generators, particularly petrol-driven portable units and emergency backup generators
  • • No formal competency requirements for key roles such as authorised operators, maintainers, supervisors and electricians responsible for generator systems
  • • Reliance on informal or on-the-job instruction without structured learning, supervision or competency assessment
  • • Lack of refresher training on emergency generator operation and manual changeover processes, leading to poor performance during real power outages
  • • Insufficient training on specific risks such as electrical hazards, CO exposure, noise, manual handling, fuel hazards and confined spaces around some plant rooms
  • • Contractors working on or with generators without verification of competencies and licences
6. Procedures for Routine Operation and Emergency Use
  • • Absence of clear, documented procedures for starting, operating and shutting down generators during planned use and emergencies
  • • Confusion in roles and responsibilities during power failures, leading to delayed or unsafe activation of backup generators
  • • Reliance on verbal instructions or single individuals with critical knowledge of generator systems
  • • Non-standardised procedures between sites, resulting in inconsistent responses to power outages and emergency generator operation
  • • Lack of documented triggers and decision-making criteria for when to deploy portable generators or switch to backup power in different scenarios
  • • Failure to consider after-hours, remote or lone-worker scenarios in generator operation procedures
7. Inspection, Testing, Maintenance and Reliability Management
  • • Lack of systematic preventative maintenance leading to failure of generators during real emergencies
  • • Irregular or undocumented periodical testing of backup power systems, including automatic start and changeover functions
  • • Dependence on reactive repairs rather than planned maintenance, increasing downtime and risk of catastrophic failure
  • • Failure to test under load conditions representative of real operation, masking underlying capacity or cooling issues
  • • Inadequate inspection of safety features such as emergency stops, guards, ventilation, exhausts, spill containment and electrical protection devices
  • • Poor management of third-party service providers, leading to inconsistent standards, missed tasks or incomplete reporting
8. Portable Generator Management, Transport and Storage
  • • Uncontrolled acquisition and use of portable petrol generators outside established systems and standards
  • • Improper transport of portable generators and fuel in vehicles, increasing risk of spills, fumes, fire or manual handling injuries
  • • Inadequate storage arrangements for portable units, leading to exposure to weather, tampering, theft or deterioration
  • • Use of portable generators in enclosed or partially enclosed spaces, including garages, workshops, tents or near building air intakes, causing CO exposure
  • • Improvised and unsafe connection of portable generators to building wiring or equipment (e.g. “backfeeding” via power outlets)
  • • Failure to inspect portable units after transport, hire or loan before redeployment to work sites
9. Noise, Vibration and Occupational Hygiene Controls
  • • Excessive noise from generator operation affecting workers, nearby tenants or the public, leading to hearing loss or nuisance complaints
  • • Vibration from fixed or portable generators causing equipment damage, structural issues or ergonomic discomfort
  • • Exposure to diesel or petrol exhaust, including CO, nitrogen oxides and particulates, for workers operating or working near generators
  • • Inadequate consideration of noise and exhaust impacts during backup generator testing, especially during night-time or in sensitive locations
  • • Lack of monitoring or assessment of exposure levels to noise and exhaust in high-risk areas such as enclosed plant rooms or loading docks
10. Emergency Preparedness, Testing and Business Continuity
  • • Inadequate planning for the role of generators in emergency response and business continuity, leading to critical service failures during outages
  • • Lack of coordination between WHS, IT, clinical or operational teams and facilities regarding priority loads and backup power duration
  • • Failure to routinely test emergency generator start-up, changeover and load transfer as part of emergency drills
  • • Insufficient contingency planning for generator failure, fuel shortage or prolonged outages beyond expected backup duration
  • • Poor communication to workers, tenants and stakeholders about generator testing, outages and expected behaviour during power disruptions
11. Documentation, Labelling and Information Management
  • • Incomplete or outdated documentation for generator systems, including drawings, manuals, schematics and test records
  • • Poor labelling of generator controls, switchboards, fuel lines, isolation points and distribution circuits, leading to operator error
  • • Lack of central repository for generator-related information, causing delays or mistakes during emergencies or when engaging contractors
  • • Failure to record and track changes to generator installations, control systems or load configurations
  • • Difficulty in retrieving historical test and maintenance records needed for compliance, audits or incident investigation
12. Contractor, Hire and Third-Party Interface Management
  • • Contractors working on generators without alignment to the organisation’s WHS procedures and risk controls
  • • Hired or temporary generators brought onto site with unknown maintenance history, safety features or compliance status
  • • Poor coordination between building owners, tenants and service providers regarding responsibilities for generator operation, testing and maintenance
  • • Inadequate supervision or oversight of contractor activities, including electrical work, fuel delivery and major overhauls
  • • Lack of clarity in contracts about required certifications, reporting and response times for generator faults
13. Monitoring, Audit and Continuous Improvement
  • • No systematic monitoring of generator-related performance, incidents, near misses or compliance status
  • • Failure to detect emerging issues, such as increased start failures, nuisance trips or fuel contamination trends
  • • Weak internal audit processes that overlook generator systems or focus only on paperwork rather than functional readiness
  • • Lack of worker feedback mechanisms to identify practical problems in generator operation and management
  • • Inadequate follow-up on corrective actions from incidents, test failures or audit findings

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS/NZS 3010: Electrical installations – Generating sets
  • AS/NZS 3000 (Wiring Rules): Electrical installations – General requirements for electrical safety and design
  • AS/NZS 3012: Electrical installations – Construction and demolition sites (for temporary and site-based generator applications)
  • AS 1940: The storage and handling of flammable and combustible liquids
  • AS/NZS 2430 series: Classification of hazardous areas (for fuel and exhaust-related ignition risks)
  • Safe Work Australia – Managing Noise and Preventing Hearing Loss at Work Code of Practice: Guidance for controlling generator noise exposure
  • Safe Work Australia – Managing the Work Environment and Facilities Code of Practice: Requirements for ventilation, access, egress and environmental conditions around gensets
  • Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Framework for systematic WHS risk management and due diligence.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

$79.5

Safe Work Australia Aligned