In short. Older generators are not all treated alike. Start with an inventory of every set, its age, rating, duty and location, then match each to the applicable rule and the right option. A phased plan avoids both panic replacement and unaddressed risk.
Step 1: inventory
| Field | Why |
|---|---|
| Make, model, kVA, year | Rule category |
| Hours and duty | Retrofit or replacement value |
| Location | Local restrictions apply |
| Condition | Overhaul needs |
| Fuel options | Gas or other |
Step 2: map to rules
Use current notifications. See CPCB architecture, Delhi-NCR / CAQM and GRAP.
Step 3: choose per set
- Retrofit: RECD.
- Fuel change: dual fuel.
- Replace: decision guide.
- Reduce use: storage or load management. See DG plus BESS.
Step 4: document
Keep nameplates, approvals, test reports and maintenance records. See documentation.
Step 5: phase
- Urgent: sets facing restrictions now.
- Planned: sets near end of life.
- Monitor: low-use standby sets.
Illustrative example
A campus with six sets finds two urgent cases, three to retrofit and one to retire. Phasing the work spreads cost and keeps backup power available throughout.
A simple inventory template
| Field | Example entry |
|---|---|
| Set ID | DG-03, block B |
| Make, model, kVA | As on nameplate |
| Engine year and serial | As on engine plate |
| Hours run | Meter reading with date |
| Annual hours (average) | From logs |
| Load served | Critical, essential or deferrable |
| Compliance status | Certificate on file, yes or no |
| Condition notes | Smoke, oil use, faults |
| Preferred action | Retrofit, convert, replace, restrict, keep |
Prioritising
- Sets that serve critical loads and face restrictions: first.
- Sets with high hours and high fuel cost: second, because savings pay back quickly.
- Sets near end of life: plan replacement.
- Low-use standby sets: document, maintain, restrict use.
Backup during the work
Any modernisation step takes a set out of service. Plan temporary generation or load transfer so that the critical load is never unprotected. See rental power.
Budgeting over years
Spread the cost: urgent items this year, planned items next year, long-term replacements in a rolling plan. Keep a contingency for surprises such as finding engine damage during an inspection.
Working with the regulator and neighbours
Keep up to date with notifications, and be open about the plan. Where an approval is needed, apply early. Where a neighbour complains of smoke or noise, a documented programme shows good faith.
Keeping the plan alive
Review the plan every year. Update the inventory after each action. Track fuel use and hours, because these figures show where effort pays off.
The master engineering question
For each set, what does the rule require and what is the cheapest safe way to meet it?
What to send us
Send your generator list. Send your application details.
Questions engineers ask
Do all old sets need replacement?
Not necessarily; rules and duty vary.
What about backup during work?
Plan temporary supply. See rental power.
How do I keep records?
One file per set.
Where do I start?
The inventory.
General guidance only. Confirm current rules.