October 26, 2026
Posted by: editor
Category: RECD & Emission Control Devices

Most DG set problems that end in a sealed generator or a failed RECD do not start with a dramatic breakdown. They start with a handover where the outgoing operator says “all OK” and walks out. A well-designed RECD shift handover log stops that from happening, because it forces the outgoing shift to write down what the incoming shift actually needs to know: what ran, at what load, what the back-pressure looked like, and what is still open.

Handovers on Indian sites usually fail in three ways. There is the verbal “all OK”, where nothing is written. There is lost context: the night shift notices back-pressure creeping up but, because it is “within range”, never passes it on, and four days later it is an alarm. And there is the acknowledged-but-unreported alarm: someone presses reset, the DG keeps running, and the next shift never knows.

This guide builds the log one block at a time, with the fields, why each matters and the commonest mistake, followed by a sample, a blank layout, entry rules, thresholds and a rollout plan.

What Is an RECD Shift Handover Log (and What It Is Not)?

A shift handover log is a short, structured record that one operator completes and the next operator reads and signs at every change of shift. Its job is continuity. It answers one question: “What do I need to know about this DG set and its retrofit emission control device right now?”

Keep it separate from the records sites already hold.

Record	Purpose	Who fills it	Frequency
Shift handover log	Continuity of condition between shifts	Outgoing operator, countersigned by incoming	Every shift change
Maintenance record	What work was done, parts used, findings	Technician or service company	Per job
Event or alarm log	Automatic record of alarms and trips	Controller, BMS or annunciator	Continuous
Compliance register	Consents, test reports, certificates, inspection visits	EHS or admin	As documents arrive

The handover log points to these rather than replacing them. It records what the operator did about a controller alarm, or notes a job card number instead of rewriting the job. Your RECD maintenance guide and service schedule remain the place for planned work.

Anatomy of the Log: Building It Block by Block

The log is eight small blocks on one page. Together they should take five to eight minutes, the realistic limit for a handover that is actually done every shift.

Block 1: Header

Fields: date, shift (A/B/C or Morning/Evening/Night), outgoing operator name, incoming operator name, DG set ID, RECD serial number.

Why it matters: the header makes every page traceable. Write the date in ISO 8601 format (YYYY-MM-DD). It sorts correctly in spreadsheets and ends the 10/11 versus 11/10 confusion. Match the DG ID to the canopy asset tag and the RECD serial to the device nameplate, so DG-2 readings never get filed against DG-3.

Common mistake: writing “DG” and omitting the RECD serial. If the device is later moved, replaced or reviewed under warranty, nobody can prove which readings belong to it.

Block 2: Status at Handover

Fields: DG status (running / standby-auto / standby-manual / locked out), RECD status (normal / alarm active / bypass flagged by controller, if your design has such an indication / under maintenance), open alarms (yes or no, with reference to Block 6).

Why it matters: the incoming operator reads this first. A locked-out set or an open RECD alarm must be known before the next mains failure.

Common mistake: writing “standby” when the set was left in manual after a test. The outgoing operator should look at the mode selector before writing this line.

Block 3: Run Summary

Fields: number of starts this shift, run hours this shift (hour meter start and end readings), reason for each start, approximate load in kW for each run.

Reasons should come from a short fixed list:

Mains outage
Scheduled test run
Load test or service run
Permitted use during a restriction period (for example, an exemption category during a GRAP stage, if applicable to your site)
Other (write it in)

Why it matters: starts and run hours are the RECD’s duty data. Many filter-type designs need sustained running at adequate exhaust temperature, and frequent short light-load runs can push soot loading up. Six ten-minute starts tell an engineer something very different from one four-hour run. Over time these entries build the history described in using DG load logs to assess RECD suitability.

In Delhi NCR, CAQM directions restrict DG use during GRAP stages, so a written reason for each start is far better than memory if an inspector asks. See GRAP rules for DG sets in Delhi NCR, and confirm your position with your SPCB and consent conditions.

Common mistake: writing only the end hour-meter reading. Always write start and end.

Block 4: Readings

Fields: time of reading, load in kW (or % of rating), ΔP across the RECD (or exhaust back-pressure upstream of it), exhaust temperature at the RECD inlet where a sensor or gauge is fitted, ambient temperature, and the instrument used (panel display, handheld manometer, controller screen).

Why it matters: this is the heart of an RECD readings log. ΔP is the usual indicator of how loaded a filter or trap is, and rising back-pressure also affects the engine, as explained in how exhaust back-pressure affects a DG set. Temperature shows whether the exhaust is hot enough for any passive or catalytic action the design relies on.

The key rule: always record the load at which the reading was taken. ΔP rises with exhaust flow, which rises with load. 6 kPa at 40% load and 9 kPa at 80% may describe the same filter condition, so comparing them causes false alarms or hides real ones. The same principle applies to matching generator load in RECD comparison tests.

Agree a reference load band with your supplier, say 70–80% of rated kW, and take the logged reading inside it after a few minutes of stable running. Record light-load readings too, but mark them out of band so nobody trends them against the baseline. If no gauge is fitted, write “NF” and ask your supplier about a manometer test point.

Common mistake: a bare “8.2” with no unit and no load, which is useless a week later.

Block 5: Observations

Fields: tick boxes plus a free-text line for each of the following.

Visible smoke at start (none / light grey / dark, and for how many seconds)
Visible smoke during run
Exhaust leaks at flanges, bellows or clamps (soot streaks, ticking sound)
Soot marks on the RECD body, walls or roof near the outlet
Unusual noise or vibration from the RECD or exhaust line
Condensation drips or water at drains
Insulation or heat shield damage
Changes since last shift

Why it matters: sensors miss things. A leaking clamp before the RECD makes ΔP look healthy while dirty gas escapes. Dark smoke that lasts a minute after start deserves a look at the engine-side causes in why a generator emits black smoke, and outlet drips point to the issues in protecting an RECD from rainwater and condensation.

Common mistake: ticking “OK” from the control room. Observations must come from a physical round.

Block 6: Alarms and Actions

Fields: alarm text exactly as displayed, time raised, time acknowledged, action taken, who was informed (name and time), status at handover (open / closed).

Why it matters: an acknowledged alarm is not a resolved fault. Even where a controller logs alarms, only the shift log records the human decision and who knew, which becomes vital evidence when you record details for an RECD warranty claim. Any alarm open at handover should be read aloud and initialled by the incoming operator.

Common mistake: “alarm reset, DG running OK”. Reset is a button, not an action. Write what was checked and who decided it was safe.

Block 7: Pending Work and Permits

Fields: open lockout/tagout (LOTO) points with tag numbers, open permits to work, contractors on site (company, number of people, area), parts awaited, follow-up actions promised to the next shift.

Why it matters: if a technician has isolated the set to work on the RECD, the next shift must know it cannot be started. Follow your site’s hazardous energy control procedure, never remove another person’s lock, and add a cool-down note to any planned inspection, as the RECD stays hot long after shutdown. Name any outside firm working on the device; see whether a different service company can maintain an installed RECD for why that record matters.

Common mistake: leaving the block empty. Write “Nil” to show it was checked.

Block 8: Sign-Off

Fields: outgoing operator signature and time, incoming operator signature and time, supervisor initials (optional, daily).

Why it matters: the incoming signature confirms the log was read and open items accepted. Times show whether the set was unattended between shifts.

Common mistake: one person signing both boxes. If the incoming operator is absent, write “Incoming not present at HH:MM” and inform the supervisor.

Sample Filled-In RECD Shift Handover Log (Illustrative)

The table below is an illustrative example for one evening shift on a 500 kVA DG set (400 kW rating at 0.8 power factor) fitted with an RECD that has a ΔP gauge and an inlet temperature display. All names and numbers are invented for illustration.

Block	Field	Entry
Header	Date	2026-10-14
Header	Shift	B (14:00–22:00)
Header	Outgoing / Incoming	R. Sharma / M. Khan
Header	DG set ID / RECD serial	DG-02 / RS-XXXX-0417
Status	DG status at handover	Standby-auto
Status	RECD status	Normal, no active alarm
Status	Open alarms	No (one closed, see Alarms)
Run summary	Starts this shift	2
Run summary	Hour meter	4,312.4 to 4,315.9 h (3.5 h)
Run summary	Run 1	15:05–15:20, scheduled test, ~120 kW
Run summary	Run 2	17:40–21:00, mains outage, ~300 kW
Readings	Time / load	19:30 / ~300 kW (75%)
Readings	ΔP across RECD	8.6 kPa (panel gauge)
Readings	Inlet exhaust temperature	412 °C (controller display)
Readings	Ambient (DG room)	34 °C
Readings	Run 1 reading	4.1 kPa at ~120 kW (30%), outside reference band, not trended
Observations	Smoke at start	Light grey, about 5 s, both starts
Observations	Leaks / soot / noise	Nil
Observations	Condensation	Few drips at drain after Run 1 only
Observations	Insulation	Small tear on lagging near inlet flange, photo taken
Alarms	Alarm	“High ΔP pre-warning”, 20:10
Alarms	Action	Checked load (rose to ~330 kW briefly), gauge reading 9.2 kPa, alarm cleared at 20:25 as load dropped; informed shift engineer A. Rao at 20:15
Alarms	Status	Closed, engineer to review trend tomorrow
Pending	LOTO / permits	Nil
Pending	Contractors	Nil
Pending	Follow-ups	Lagging repair request raised; engineer review of ΔP trend
Sign-off	Outgoing	R. Sharma, 22:04
Sign-off	Incoming	M. Khan, 22:06

Note how it separates the light-load reading from the reference-band one, names who was informed about the alarm, and flags a small insulation tear early.

Blank One-Page Template Layout

Reproduce this on landscape A4 or a spreadsheet tab as your DG set shift log template.

Section	Fields (left to right)
1. Header	Date (YYYY-MM-DD) · Shift · Outgoing name · Incoming name · DG set ID · RECD serial
2. Status at handover	DG: Running / Standby-auto / Standby-manual / Locked out · RECD: Normal / Alarm / Under maintenance · Open alarms: Y / N
3. Run summary	Starts (no.) · Hour meter start · Hour meter end · Run hours · For each run: start time, stop time, reason code, approx. kW
4. Readings	Time · Load kW (% rating) · In reference band? Y/N · ΔP (unit) · Inlet temp °C · Ambient °C · Instrument
5. Observations	Smoke at start · Smoke during run · Leaks · Soot marks · Noise/vibration · Condensation · Insulation · Changes since last shift · Free text
6. Alarms and actions	Alarm text · Time raised · Time acknowledged · Action taken · Informed (name, time) · Open/Closed
7. Pending work	LOTO tags · Permits · Contractors on site · Parts awaited · Follow-ups for next shift
8. Sign-off	Outgoing signature/time · Incoming signature/time · Supervisor initials
Footer	Escalation thresholds (site-specific) · Abbreviations key · Baseline ΔP at reference load and date set

Printing thresholds and baseline in the footer means operators never hunt for them.

Rules for Consistent Entries in Your RECD Logbook Format

These rules keep the log readable by anyone, including an auditor two years later.

Units and Rounding

Print one pressure unit (kPa, mbar or mm WC) on the form and never mix units.
ΔP to one decimal in kPa; no more precision than the gauge shows.
Temperatures to the nearest °C, load to the nearest 10 kW.
24-hour clock throughout.

“Nil” Versus Blank

A blank field means “not checked”. “Nil” means “checked and nothing found”. “NF” means “not fitted”. “NR” means “not run” (for readings when the DG did not operate). Never leave a field blank on purpose.

No Overwriting

Strike through errors with a single line, write the correct value beside it, and initial and time it. No correction fluid, overwritten digits or torn-out pages. Digital logs should use version history or correction notes, never silent edits.

Abbreviations List

Keep a fixed list in the footer, for example:

Abbreviation	Meaning
ΔP	Differential pressure across the RECD
RB	Reading in reference load band
OOB	Reading out of reference band
NF	Not fitted
NR	Not run
ACK	Alarm acknowledged
LOTO	Lockout/tagout
PTW	Permit to work

Add new shorthand to the list formally, never ad hoc.

Writing Escalation Thresholds on the Log

Operators should not have to judge whether a reading is “a bit high”; the log should say when to call someone. The right figures depend on device design, engine and duty, so the thresholds below are illustrative only and must be agreed with your supplier.

Trigger (illustrative)	Action
ΔP at reference load rises more than 15% above the recorded baseline	Inform shift engineer the same shift; note in Follow-ups
ΔP at reference load rises more than 25% above baseline, or any ΔP high alarm	Inform engineer immediately; follow supplier guidance on load reduction or regeneration if your design supports it
Inlet exhaust temperature consistently below the minimum stated by your supplier during long runs	Note for engineer review of loading pattern
Dark smoke lasting more than 30 seconds after start	Inform maintenance; check engine-side causes
Any exhaust leak, soot streak or insulation damage	Raise repair request; inform engineer if near cables or combustible material
Any open alarm at handover	Incoming operator reads aloud and initials

Set the baseline after commissioning or a service, at reference load, with the date in the footer, and always compare like with like. If your RECD regenerates, ΔP will cycle, so note whether regeneration was in progress; see what to record during RECD regeneration, and DieselNet on ash in particulate filters for why some rise is permanent.

A threshold breach must never lead to bypassing or removing the RECD. That is a compliance risk that can bring sealing and penalties; solve it with your supplier.

Paper vs Digital DG Log: Which Should You Use?

There is no single right answer. Many sites run both: paper at the DG and a daily spreadsheet or CMMS entry by the supervisor.

Factor	Paper log	Spreadsheet	CMMS / BMS
Set-up cost	Very low	Low	Medium to high
Works during power or network failure	Yes	Depends on device	Depends on system
Trend charts	Manual	Easy	Often built in
Tamper evidence	Good if bound and numbered	Weak unless locked or versioned	Good with audit trail
Automatic readings	No	No	Yes, if sensors are connected
Risk of missing entries	Visible gaps	Rows can be skipped quietly	Mandatory fields can enforce
Best fit	Small sites, one or two DG sets	Mid-sized sites with a trained supervisor	Multi-site, critical facilities

Even with automatic BMS readings, keep the manual log: it captures smoke, leaks and alarm decisions.

Data Retention

Store full paper books away from the DG room; back up digital logs monthly outside the main system. Confirm retention against consent conditions, warranty terms and policy with your EHS team; at least the warranty period plus a margin is sensible.

How the Shift Log Feeds the Monthly Review and Warranty Evidence

Monthly, an engineer should summarise reference-band ΔP, run hours, starts and alarms on one sheet, asking whether ΔP is trending faster, short runs are increasing, or alarms and leaks are repeating. That summary helps during a pollution control board inspection and shows you respected the operating conditions in your RECD warranty terms and exclusions.

Illustrative Worked Example: How a Back-Pressure Log Sheet Caught a Trend

This example is illustrative. The figures are invented to show the method.

A site runs a 500 kVA DG set with a reference load band of 70–80% (280–320 kW). After the RECD’s last service, the baseline ΔP at about 300 kW was recorded as 8.0 kPa. The site’s agreed escalation threshold is a 15% rise above baseline at reference load.

Over seven days, the evening shift logged these reference-band readings:

Day	Load (kW)	ΔP (kPa)	Rise from baseline (kPa)	% rise from baseline
1	300	8.1	0.1	1.25%
2	296	8.2	0.2	2.50%
3	304	8.3	0.3	3.75%
4	300	8.6	0.6	7.50%
5	308	8.9	0.9	11.25%
6	300	9.3	1.3	16.25%
7	304	9.8	1.8	22.50%

The arithmetic is: % rise = (logged ΔP − baseline ΔP) ÷ baseline ΔP × 100.

Day 4: (8.6 − 8.0) ÷ 8.0 × 100 = 0.6 ÷ 8.0 × 100 = 7.5%
Day 5: (8.9 − 8.0) ÷ 8.0 × 100 = 0.9 ÷ 8.0 × 100 = 11.25%
Day 6: (9.3 − 8.0) ÷ 8.0 × 100 = 1.3 ÷ 8.0 × 100 = 16.25%
Day 7: (9.8 − 8.0) ÷ 8.0 × 100 = 1.8 ÷ 8.0 × 100 = 22.5%

All loads sit within 296–308 kW, so the comparison is fair. The rise accelerates: 0.3 kPa over Days 1–3, then 1.5 kPa from Day 3 (8.3) to Day 7 (9.8).

On Day 6, 16.25% crossed the printed 15% threshold and the operator called the engineer. Block 3 showed eleven starts of under 15 minutes at 25–30% load during short mains interruptions. Logged as out of band, they did not distort the trend but explained it. The supplier advised the right recovery step for that design, and the site lengthened its test runs at reference load. Without the log, the first sign would likely have been a night-time alarm during a long outage. For background on why loading pattern matters this much, see our explainer on generator load factor and duty cycle.

How to Roll Out the Generator Handover Checklist in Two Weeks

Days 1–3: Draft and Brief

Adapt the blank template to your site: DG IDs, RECD serials, pressure unit, reference load band.
Agree illustrative thresholds with your supplier and turn them into site figures.
Record a fresh baseline ΔP at reference load and write it in the footer.
Brief every operator in a 20-minute toolbox talk. Our post on RECD operator training skills to check before handover lists the competencies operators need before they can fill the log meaningfully.

Days 4–10: Trial

Run the log every shift, alongside any old register.
The supervisor reviews sheets daily, marking blanks and missing loads.
Collect feedback on confusing, slow or missing fields.

Days 11–14: Refine and Fix

Remove fields nobody uses and clarify the ones people misread.
Print the final version, numbered and bound, or lock the spreadsheet template.
Laminate a one-page quick guide for the DG room wall: the eight blocks, the abbreviations, the thresholds and the “nil versus blank” rule.
Show operators one trend the log has already revealed; seeing data used builds buy-in.

For a set idle for months, re-establish the baseline after the checks in restarting an RECD-equipped DG set after long inactivity.

FAQ

What should an RECD shift handover log include?

Header and status, run summary, ΔP and temperature with load, observations, alarms with actions, pending work and LOTO, and two signatures.

Why must load be recorded with every ΔP reading?

ΔP rises with load, so readings at different loads cannot be compared. Trend only within a fixed reference band.

Is a digital log better than a paper one?

Not always. Paper works in power failures and audits well; digital shows trends easily. Many sites use both.

What ΔP rise should trigger escalation?

It depends on design and engine. A 15% rise above baseline is an illustrative starting point; agree actual figures with your supplier.

How long should RECD logs be kept?

Check your consent conditions, warranty terms and internal policy. Keeping logs at least for the full warranty period, with a margin, is a sensible minimum.

Can the log help with a pollution control board inspection?

Yes. It shows the RECD is monitored and explains DG use in restricted periods, supporting but not replacing consents and test reports.

Need Help Setting Baselines for Your RECD?

Aceget supplies CPCB type-approved retrofit emission control devices for DG sets from 25 kVA to 2500 kVA. If you are building a handover log and need help with the right reference load band, readings to monitor or escalation figures for your device, our team can guide you. Explore our retrofit emission control device range, review our type approval certifications, or speak to our engineers about your DG set.

How to Build an RECD Shift-Handover Log