Installing a Retrofit Emission Control Device (RECD) on a diesel generator is not simply a matter of fitting equipment onto the exhaust line. The quality of the installation can influence emission-control performance, exhaust flow, maintenance requirements and the documentation needed for future verification.

“Has the installation been completed correctly and verified properly?”For facility managers and DG-set operators, the most important question after installation is therefore not just “Has the RECD been fitted?” but

A structured handover check can help identify installation problems before they become expensive operational or compliance issues.

1. Verify the Generator and RECD Details

The first step is to confirm that the equipment installed at the site matches the project documentation.

Check the DG-set rating, engine details, RECD model, serial number and applicable approval or test documentation. The capacity range mentioned in the relevant documentation should correspond with the generator for which the device has been installed.

This basic verification is important because an installation should not be considered complete simply because the physical device is present.

common RECD installation mistakes to avoidFor a broader discussion of the mistakes that can occur during planning, installation and post-installation operation, see Aceget's guide on.

2. Inspect the Exhaust Connections

The exhaust path deserves close attention after the RECD has been installed.

Flanges, joints, gaskets and connections should be properly aligned and sealed. An exhaust leak can allow gases to escape before passing through the intended emission-control path and can also create an operational or safety concern depending on the location of the leak.

A visual inspection should therefore form part of the handover process rather than assuming that every connection is correct because the installation team has completed the work.

3. Check the Physical Support Arrangement

An RECD should not simply be allowed to hang from an existing exhaust pipe without considering the structural load and support arrangement.

The installation should account for the device weight, pipe configuration, vibration and accessibility for future servicing. Supports should be positioned according to the approved installation design.

This becomes particularly important when the existing exhaust arrangement has been modified to accommodate the new equipment.

4. Confirm Exhaust Backpressure

Backpressure is one of the most important technical checks after an exhaust-side retrofit.

An installation can appear physically perfect while still creating excessive resistance in the exhaust system. The total exhaust arrangement—including piping, bends, stack configuration and the RECD—should therefore be considered when evaluating backpressure.

The measured value should be compared with the applicable engine manufacturer's specification.

Ignoring this check can turn a seemingly successful installation into a long-term performance problem. Excessive exhaust resistance may affect engine operation, fuel consumption and component stress.

5. Conduct a Proper Test Run

A physical inspection alone cannot confirm that an RECD installation is functioning correctly.

The generator should be operated and the system observed under appropriate operating conditions. The commissioning process should verify that the DG set starts and runs normally and that the RECD and its associated monitoring or control components behave as expected.

Testing under actual operating conditions can reveal issues that remain invisible while the generator is switched off.

6. Check Accessibility for Maintenance

A good installation should not only work on day one—it should remain serviceable throughout its operating life.

Before signing the final handover, check whether technicians can safely access the RECD for inspection, cleaning, servicing or component replacement.

The service path should also be considered. An installation that technically fits inside a DG room but leaves no practical route for removing the device later can create unnecessary maintenance difficulties.

This is especially important in basement DG rooms and other locations where access is already restricted.

7. Review Electrical and Monitoring Connections

Where the RECD installation includes controllers, sensors, alarms or communication systems, these interfaces should be checked during commissioning.

Confirm that:

Power connections are properly terminated.
Sensors are connected to the correct points.
Alarm indications are working.
Communication links are functioning where applicable.
The control system receives the expected signals.
Wiring is suitably protected and accessible for maintenance.

Monitoring equipment is only useful when the information it provides is reliable and available when the generator is operating.

8. Make Sure Documentation Is Complete

Documentation is an important part of an RECD project.

The handover file should contain the relevant installation records and equipment details, along with applicable test or approval documents. The paperwork should correspond to the actual equipment installed at the site.

CPCB's published RECD procedure sets out the emission-compliance testing framework and requirements associated with RECDs. Organisations should therefore refer to the applicable current regulatory documentation rather than relying solely on informal claims from a supplier.

Central Pollution Control Board (CPCB)For official regulatory information, the should be used as a primary reference.

9. Establish a Maintenance Plan Before Handover

One common mistake is treating installation as the final step.

Once the RECD is operational, the facility needs a suitable inspection and maintenance approach. Operators should understand what basic signs to monitor and when professional servicing is required.

The maintenance plan should consider the generator's operating hours, duty cycle, exhaust conditions and the requirements specified by the equipment manufacturer.

Having this plan in place from the beginning is much better than waiting for a performance issue to appear.

10. Use a Final Handover Checklist

Before the installation is officially closed, facility managers can use a simple checklist:

Equipment

Generator details verified
RECD model and serial number recorded
Applicable documentation checked

Mechanical installation

Exhaust joints inspected
Supports checked
Installation layout verified
Service access confirmed

Performance

DG set test run completed
Backpressure checked
RECD operation verified
Sensors and alarms tested

Documentation

Installation records received
Test/approval documents filed
Maintenance requirements recorded
Responsibilities for future servicing established

This final review can prevent a minor installation issue from becoming a much larger problem later.

Why Installation Quality Matters

An RECD is part of the generator's exhaust system, so its installation should be approached as an engineering activity rather than a simple equipment-mounting exercise.

CPCB's generator-set environmental guidance covers emission requirements and regulatory considerations for generator sets, making it important for operators to evaluate their equipment against the requirements applicable to their specific installation.

A correctly planned installation also reduces the likelihood of problems involving exhaust leakage, excessive backpressure, difficult maintenance access or incomplete documentation.

Final Takeaway

Installation quality, commissioning, documentation and ongoing maintenanceThe success of an RECD project depends on more than selecting the right device. all contribute to the long-term effectiveness of the system.

Before accepting an RECD installation, facility managers should verify the equipment details, exhaust connections, support arrangement, backpressure, test-run results, monitoring system and documentation.

Common RECD Installation Mistakes to AvoidFor a more detailed look at the issues that commonly occur throughout an RECD project, read. It provides a broader checklist of problems that can occur before installation, during physical fitting and after commissioning.

Taking a few additional minutes during the handover stage can save considerably more time, money and operational trouble later.

RECD Installation Quality Check: 10 Things to Verify Before Handing Over Your DG Set

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