Generator Installation SWMS

Generator installation covers the mechanical positioning, electrical connection, exhaust management and commissioning of fixed or portable generating sets used for prime, standby or emergency power on Australian commercial, industrial and construction sites. The work routinely involves crane or forklift lifting of heavy plant, connection to building main switchboards or distribution boards, fuel system pressurisation, hot exhaust management and the energisation of LV (and occasionally HV) circuits. Under WHS Regulation 2025 the activity is classified as High Risk Construction Work because it involves energised electrical installations, plant lifting and confined or restricted plant rooms, triggering the mandatory SWMS duty under regulation 299. A documented SWMS is also required because the work exposes electricians, riggers and commissioning engineers to fatal arc flash, electrocution, crush and asphyxiation hazards that must be assessed, controlled and signed off by every worker before commencement. This SWMS establishes the hazard register, hierarchy of control, isolation protocols and verification steps required to discharge the PCBU's primary duty of care under section 19 of the WHS Act.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Elimination — Where feasible, specify a pre-wired containerised generator package commissioned offsite, eliminating onsite live connection and reducing arc flash exposure to zero at the installation point.
2. 2Elimination — Conduct all electrical connection work in a fully de-energised state by isolating the main switchboard upstream and proving dead with a tested two-pole voltage detector before any conductor handling.
3. 3Substitution — Substitute manual cable lugging with factory-crimped flexible cable tails and plug-in Camlock connectors to reduce exposed conductor work time and torque-error risk at terminations.
4. 4Substitution — Replace diesel load-bank commissioning inside plant rooms with resistive load banks vented to atmosphere, substituting confined exhaust accumulation for open-air dispersal.
5. 5Engineering — Install a mechanically and electrically interlocked changeover switch or Automatic Transfer Switch compliant with AS/NZS 3010 clause 2.7 to prevent parallel back-energisation of the network.
6. 6Engineering — Provide dedicated exhaust extraction ducted to atmosphere with CO monitoring and audible alarm set to 30 ppm, achieving ventilation rates compliant with AS 1668.2 plant room requirements.
7. 7Engineering — Use spreader bars, certified lifting lugs and tagged synthetic slings rated to 2x SWL, with exclusion zone barricades during all crane lifts per AS 2550.1.
8. 8Administrative — Issue a permit-to-work and electrical access permit signed by a licensed electrical worker, with documented lock-out tag-out applied to all isolation points and key retention by the worker performing the task.
9. 9Administrative — Conduct a documented pre-start SWMS toolbox brief, verify electrical licences, high-risk work licences (DG, CN, CB), confined space tickets and review the site emergency response and rescue plan.
10. 10PPE — Issue arc-rated Category 2 (minimum 8 cal/cm²) coveralls, balaclava, face shield, Class 0 insulating gloves over-gloved with leather, AS/NZS 1337 safety glasses, AS/NZS 1270 Class 5 hearing protection and AS/NZS 2210.3 safety footwear.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

On a regional cold-storage warehouse upgrade, a 500 kVA standby diesel generator is being installed in an external acoustic enclosure adjacent to the main switchroom. At the 6:30 am pre-start brief, the site supervisor opens this SWMS on a tablet and walks the four-person crew — lead electrician, offsider, rigger and mechanical fitter — through the hazard register. The crew identifies that today's tasks include the crane offload, cable pulling to the new ATS, and exhaust flue connection through the roof penetration. Reviewing the controls, the lead electrician confirms the main switchboard will be isolated at 8 am once refrigerated stock is transferred to a hire reefer, addressing the elimination control for arc flash. The rigger flags that morning crosswinds exceed the 8 m/s lift threshold noted under the engineering controls, so the crane lift is deferred to 10 am. Each worker signs the SWMS sign-on register, recording their electrical licence or HRW ticket number. Mid-task, the mechanical fitter discovers the exhaust silencer requires hot work on the roof — a hazard not originally scoped. The supervisor pauses work, amends the SWMS to add a hot work permit and fire watch control, re-briefs the crew and obtains fresh sign-ons before the cutting work proceeds, demonstrating the SWMS as a live, controlled field document.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• AS/NZS 3000 — Electrical installations

Frequently asked questions