General Use Generator Risk Assessment

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers the selection, positioning, operation, refueling, inspection, maintenance, and shutdown of portable generators used for temporary or remote electrical power supply in workplace settings. It includes associated tasks such as connecting loads through approved cords and GFCI protection, managing fuel storage and transfer, controlling exhaust and ventilation, and using personal protective equipment. The assessment applies to workers operating or maintaining generators, supervisors overseeing generator use, and any nearby persons who may be exposed to electrical, fire, noise, vibration, or carbon monoxide hazards. Exclusions: this assessment does not cover permanent standby generator installations, internal building electrical distribution design, or electrical work performed by licensed electricians beyond generator connection and transfer-switch installation.

2. Risk Assessment Methodology

This assessment uses a task-based hazard identification approach supported by a 5x5 risk matrix and the hierarchy of controls. Each hazard is evaluated for likelihood and severity before controls are applied, then reassessed for residual risk after controls. Controls are selected in order of preference: elimination, substitution, engineering controls, administrative controls, and personal protective equipment. The assessment also considers special operating conditions such as wet weather, poor ventilation, night work, and lone work, which can increase exposure and reduce the effectiveness of controls.

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Low	Medium
Major	Low	Low	Low	Medium	High
Moderate	Low	Low	Medium	High	High
Minor	Low	Medium	High	High	Extreme
Negligible	Medium	High	High	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Electrical shock or electrocution from improper generator connection, damaged cords, exposed conductors, or use of the generator in wet conditions.

Potential Consequences: Severe electric shock, burns, cardiac arrest, fatal electrocution, damage to connected equipment, and secondary incidents caused by sudden loss of power or startled movement.

Affected Persons: Generator operators, maintenance personnel, electricians, nearby workers, and utility workers if backfeed energizes external circuits.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate direct connection to building wiring unless a qualified electrician has installed an approved transfer switch.
• Use only manufacturer-supplied cords or heavy-duty, grounded, outdoor-rated extension cords in good condition.
• Install and use GFCIs where required, especially in wet or damp locations.
• Keep the generator dry, operate under a canopy if needed, and never handle electrical components with wet hands or while standing in water.
• Ensure the generator is properly grounded and grounding connections are tight in accordance with the manufacturer’s instructions.
• Inspect cords, plugs, receptacles, and generator components before each use and remove damaged equipment from service.
• Provide electrical safety training and restrict installation or connection work to competent or qualified persons.
• Wear task-appropriate PPE, including eye protection and insulated gloves where justified by the task and electrical exposure.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

2. Carbon monoxide exposure from exhaust gases when the generator is operated in enclosed, partially enclosed, or poorly ventilated areas, or too close to openings into occupied spaces.

Potential Consequences: Headache, dizziness, nausea, fatigue, unconsciousness, permanent injury, and death from carbon monoxide poisoning.

Affected Persons: Generator operators, nearby workers, occupants of adjacent buildings, visitors, and rescue personnel entering the area.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Catastrophic	Extreme

Control Measures

• Eliminate indoor or partially enclosed generator use; operate only outdoors in well-ventilated locations.
• Position the generator away from doors, windows, vents, crawl spaces, basements, and other air intakes.
• Maintain at least 3 to 4 feet of clear space on all sides and above the generator to support ventilation.
• Use carbon monoxide awareness procedures, including symptom recognition and immediate evacuation to fresh air if symptoms occur.
• Post warning signage and restrict access to areas where exhaust could accumulate.
• Use CO alarms or monitors where site conditions or local procedures require additional warning.
• Train workers to recognize CO symptoms and to never assume open doors or windows provide adequate ventilation.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

3. Fire or explosion from fuel spills, hot surfaces, improper refueling, fuel storage near ignition sources, or vapor ignition.

Potential Consequences: Burns, property damage, equipment loss, secondary explosions, smoke inhalation, and fire spread to nearby materials or structures.

Affected Persons: Generator operators, fuel handlers, nearby workers, emergency responders, and occupants of adjacent areas.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate refueling while the generator is running; shut it down and allow it to cool before refueling.
• Store and transport fuel only in approved containers designed and marked for the fuel type.
• Keep fuel away from the generator, hot surfaces, smoking materials, lighters, matches, and other ignition sources.
• Inspect fuel lines, caps, and connections for leaks or damage before use and remove unsafe equipment from service.
• Use spill control practices and keep absorbent materials available where fuel transfer occurs.
• Locate fuel storage in a designated, ventilated area away from occupied spaces and ignition sources.
• Train workers in safe fueling procedures and fire response actions.
• Provide suitable fire extinguishers and ensure they are accessible during generator operations.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

4. Noise exposure from generator operation, especially when generators are positioned near work areas or operated for extended periods.

Potential Consequences: Temporary or permanent hearing loss, communication failure, reduced situational awareness, fatigue, and increased likelihood of errors or incidents.

Affected Persons: Generator operators, nearby workers, supervisors, and visitors in the vicinity of the generator.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary exposure by locating the generator as far from occupied work areas as practicable.
• Use engineering controls such as barriers, enclosures, or remote placement to reduce noise at the point of exposure.
• Schedule noisy generator use to minimize exposure duration and coordinate work to reduce time spent nearby.
• Post hearing protection requirements where noise levels warrant it and enforce use in designated areas.
• Select hearing protection with adequate attenuation and ensure proper fit and consistent use.
• Monitor noise exposure where generator use is prolonged or multiple noisy tools are powered simultaneously.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

5. Vibration exposure from generator operation and from powered tools supplied by the generator, contributing to hand-arm or whole-body vibration effects.

Potential Consequences: Hand-arm vibration symptoms, numbness, reduced grip strength, fatigue, discomfort, and longer-term musculoskeletal or circulatory effects.

Affected Persons: Operators of generator-mounted equipment, workers using vibrating tools, and personnel handling or transporting the generator.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Moderate	Medium

Control Measures

• Select lower-vibration equipment where practicable and avoid unnecessary use of vibrating tools.
• Maintain generator condition to reduce excessive vibration caused by worn mounts, imbalance, or mechanical defects.
• Place the generator on a stable, level surface to reduce transmitted vibration and movement.
• Limit exposure duration through task rotation and planned breaks.
• Train workers to recognize early symptoms of vibration exposure and report them promptly.
• Use anti-vibration gloves only as a supplementary measure where appropriate and not as a substitute for equipment control.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Minor	Low

6. Manual handling injuries during generator movement, loading, unloading, positioning, fuel handling, and cable management.

Potential Consequences: Sprains, strains, back injuries, crushed fingers or toes, dropped-load injuries, and fatigue-related errors.

Affected Persons: Operators, helpers, maintenance staff, and anyone assisting with transport or setup.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual lifting by using carts, dollies, forklifts, cranes, or team lifts for heavier units.
• Position the generator close to the intended work area before loading fuel or connecting loads to reduce repeated handling.
• Use mechanical aids and proper lifting techniques for transport and placement.
• Plan the route in advance to avoid uneven ground, steps, and obstructions.
• Train workers in safe manual handling, team lifting, and pinch-point awareness.
• Keep hands clear of pinch points when lowering or aligning the generator and accessories.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

7. Contact with moving parts, hot surfaces, or mechanical defects during operation, inspection, or maintenance.

Potential Consequences: Cuts, burns, entanglement, impact injuries, equipment failure, and unplanned shutdown.

Affected Persons: Operators, maintenance personnel, and nearby workers performing checks or adjustments.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate maintenance while the generator is energized or hot unless the task specifically requires live testing by authorized personnel.
• Use guards and covers on moving or hot components where provided by the manufacturer.
• Allow the generator to cool before inspection, refueling, or maintenance.
• Follow lockout/tagout or equivalent isolation procedures before servicing.
• Inspect for loose fuel lines, damaged parts, and abnormal noise or smoke before each use.
• Remove defective equipment from service until repaired by a competent person.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

8. Overloading, incorrect cord selection, or improper load management causing overheating, equipment damage, or electrical fire.

Potential Consequences: Fire, melted insulation, equipment failure, power interruption, shock hazard, and damage to connected tools or appliances.

Affected Persons: Operators, nearby workers, maintenance staff, and anyone relying on the generator for temporary power.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Select a generator rated for the intended load, including starting surge requirements.
• Use load planning to stagger equipment start-up where the generator capacity is limited.
• Use only cords and connectors rated for the intended amperage and duty cycle.
• Do not overload receptacles or bypass protective devices.
• Inspect cords for cuts, frays, abrasion, or damaged plugs before use and discard defective cords.
• Monitor generator temperature, unusual odors, and smoke; shut down immediately if abnormal conditions occur.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

5. General Control Measures

• Apply a formal pre-use inspection and defect reporting process for every generator before operation.

Check fuel lines, grounding, cords, plugs, receptacles, guards, and overall condition. Remove unsafe equipment from service immediately and tag it out until repaired. [1] [4]

• Use only manufacturer-approved operating and maintenance procedures.

Follow the owner’s manual for grounding, maintenance intervals, refueling, and connection requirements. Do not improvise connections or bypass safety devices. [1] [2]

• Control access to the generator operating area and keep non-essential persons away from hazards.

Use barriers, signage, and work planning to separate the generator from pedestrian routes, occupied work areas, and public access points. [1]

• Maintain safe fuel management practices at all times.

Store fuel in approved containers, keep it away from ignition sources, and refuel only after shutdown and cooling. Keep spill response materials available where fuel is handled. [1] [3]

• Ensure electrical protection measures are in place for all temporary power arrangements.

Use grounded cords, GFCIs, and approved equipment for wet or damp locations. Only qualified electricians should connect generators to building systems. [2] [2]

6. Emergency Preparedness

• If carbon monoxide symptoms are reported, stop generator use immediately, move affected persons to fresh air, call emergency medical services if symptoms are severe or persistent, and do not re-enter the area until it has been declared safe by trained and properly equipped personnel. [1]
• If smoke, unusual odor, sparking, or fire is observed, shut down the generator if it can be done safely, isolate the area, use the correct fire extinguisher only if trained and the fire is small and controllable, and activate the site emergency response procedure. [2] [3]
• If electric shock occurs, do not touch the victim until the power source is isolated. Call emergency services, begin first aid/CPR only when the scene is safe, and preserve the equipment for investigation. [2] [4]
• Maintain emergency access to fire extinguishers, first aid supplies, and communication devices at generator work locations, especially where the generator is remote or used during recovery operations. [4]
• Establish a shutdown and isolation procedure for severe weather, flooding, or loss of ventilation conditions that could increase electrical, fire, or carbon monoxide risk. [1] [5]

7. Training Requirements

• Generator Operating and Manufacturer Instruction Training: Workers assigned to operate or supervise portable generators must be trained on manufacturer instructions, startup and shutdown steps, load limits, grounding requirements, refueling precautions, and defect reporting. Training must emphasize that unsafe equipment is removed from service and that only authorized persons perform electrical connections. [1] [4]
  • Pre-use inspection steps
  • Safe startup and shutdown sequence
  • Load capacity and overload prevention
  • Grounding and GFCI use
  • Defect reporting and removal from service
• Electrical Safety and Backfeed Prevention Training: Workers must understand shock hazards, the prohibition on direct connection to building wiring without a properly installed transfer switch, the purpose of GFCIs, and the need to keep equipment dry. Training should also cover recognition of damaged cords and the requirement to use only grounded, heavy-duty, outdoor-rated cords. [2] [2]
  • Backfeed and utility worker hazard awareness
  • Cord inspection and replacement criteria
  • Wet-condition precautions
  • Qualified electrician requirements
• Carbon Monoxide Awareness Training: All affected workers must be trained to recognize carbon monoxide hazards, understand that CO is colorless and odorless, and know the symptoms of exposure. Training must reinforce outdoor-only use, ventilation clearance, and immediate evacuation procedures if symptoms occur. [1] [4]
  • CO symptom recognition
  • Ventilation and placement requirements
  • No indoor or enclosed-space use
  • Emergency evacuation and medical response
• Fuel Handling, Fire Prevention, and Spill Response Training: Personnel who refuel or store fuel must be trained in approved container use, shutdown and cooling requirements, ignition source control, spill prevention, and fire response. Training should include the prohibition on smoking near fuel and the need to keep fuel away from the generator and other heat sources. [3] [3]
  • Approved fuel containers
  • Cooling before refueling
  • Ignition source control
  • Spill response and extinguisher use
• Noise, Vibration, and PPE Training: Workers exposed to generator noise or vibration must be trained on hearing protection selection and use, exposure minimization, and the limitations of PPE. Training should also cover the correct use, inspection, and replacement of PPE required for electrical, fuel-handling, and maintenance tasks. [6] [7]
  • Hearing protection selection and fit
  • Vibration exposure reduction
  • PPE inspection and replacement
  • Task-specific PPE limitations

8. Monitoring and Review

Review Frequency: Annually and after any incident, near miss, equipment change, or significant change in work conditions.

Monitoring Type	Frequency	Responsible Party	Description
Pre-Use Inspection	Before each use	Generator operator or assigned competent person	Inspect the generator, cords, plugs, fuel lines, grounding, guards, and surrounding area before startup. Confirm the unit is dry, properly positioned, and free from visible defects or leaks. Remove defective equipment from service immediately.
Operational Monitoring	Continuous during operation	Generator operator and supervisor	Monitor for abnormal noise, vibration, overheating, smoke, fuel odor, exhaust accumulation, and signs of overload. Verify that ventilation clearances are maintained and that the generator remains outside enclosed or partially enclosed spaces.
Electrical Safety Check	At setup and after any relocation or weather change	Qualified electrician or competent electrical supervisor	Verify grounding, GFCI protection, cord condition, load compatibility, and safe connection arrangements. Recheck after rain, flooding, or any change in the work area that could affect electrical safety.
Fuel and Fire Safety Inspection	Daily when fuel handling occurs	Supervisor or designated fuel handler	Check fuel storage condition, container labeling, spill control readiness, and separation from ignition sources. Confirm that refueling only occurs after shutdown and cooling.
PPE and Training Compliance Review	Monthly or after task changes	Supervisor and safety representative	Confirm that required PPE is available, worn correctly, and maintained in serviceable condition. Review whether workers have current training for generator operation, electrical safety, CO awareness, and emergency response.

9. Special Circumstances

• Wet weather or flooding increases shock risk and requires stricter control of generator placement, dryness, canopy protection, and GFCI use. Operations should stop if safe dry placement cannot be maintained. [2]
• Night work reduces visibility and can increase the likelihood of trips, incorrect connections, fuel handling errors, and delayed recognition of smoke, odor, or exhaust problems. Additional lighting and supervision may be required. [3]
• Lone work increases the severity of delayed emergency response for shock, CO exposure, or fire. Lone workers should have communication checks, escalation procedures, and a means to summon help quickly. [1]
• Poor ventilation, proximity to doors or windows, and operation near occupied structures significantly increase carbon monoxide risk and may require relocation of the generator or suspension of work. [1]
• Extended runtime increases heat, noise, fatigue, and fuel-management demands. Longer operating periods require more frequent inspections, rest breaks, and monitoring of load and temperature. [3]

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually and after any incident, near miss, equipment change, or significant change in work conditions. or when significant changes occur.

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