Fuel Monitoring on CAT Backup Generators at a Hospital in Uganda
- Overpayment for fuel — consumption was calculated using inflated standard rates
- Fuel “disappears” from the tank — with no way to prove it
- Refueling and fuel drains were not recorded — there was no control tool
- To verify the data, staff had to go to the generator
- Fuel write-off based on actual consumption, not standard rates
- Every liter is accounted for — fuel consumption and tank level are measured directly
- The system automatically records refueling and fuel drains and sends alerts
- Full remote control of the generator via UNUM Genset
Hospital with Backup Diesel Generators
The medical center is located in Mbale, one of the largest cities in Uganda. Its service area covers around 10% of the country’s population — 4.6 million people.
The center includes diagnostic, surgical, pediatric, and gynecology departments. It employs 359 staff members, and the inpatient facility has a capacity of 450 beds.
Reliable power supply is critically important, as the operation of surgical rooms, intensive care units, and diagnostic equipment depends on it.
CAT D100 GC 100 kVA diesel gensets
The hospital uses CAT D100 GC C4.4 generators for backup power supply. In the event of a mains power outage, the DSE 7320MKII controller automatically starts the generator and transfers the load. Once mains power is restored, it switches the load back to the primary power source.
Fuel Consumption Control and Theft Prevention
Fuel was accounted for based on generator operating time using average consumption rates. Actual fuel consumption and tank level were not monitored. This approach created room for abuse: there was suspicion that fuel was being drained.
For the hospital, uncontrolled fuel consumption is a direct operational risk. The generators supply power to operating rooms, intensive care units, and diagnostic equipment. If fuel runs out unexpectedly, critical infrastructure will be left without power.
- Measure actual fuel consumption instead of estimating it based on engine operating hours
- Automatically record every refueling event and every fuel drain, with alerts
- Send data to a cloud-based service for remote monitoring without visits to the generator
Remote Fuel Monitoring of Generators in UNUM Genset
The DFM 250D CAN fuel flow meter measures fuel volume in the fuel line and keeps fuel consumption and engine hours counters. The DUT-E CAN fuel level sensor monitors the fuel remaining in the tank and automatically detects refueling and fuel drains.
The CANUp Genset telematics gateway receives data from fuel sensors via the J1939/S6 interface and from the DSE 7320MKII controller via Modbus RTU: voltage, frequency, current, power factor, RPM, temperature, and fluid pressure.
All data is sent to the UNUM Genset cloud-based service. The customer can monitor fuel consumption, fuel remaining, and operating parameters in real time and plan costs based on reports. The data is available for export via API.
Monitoring System Components
Monitoring System Components
Reports for 3 months (October 2025 – January 2026)
Fuel level chart for the generator tank in UNUM Genset
Fuel consumption, engine operating hours, and average consumption over the period
“At first, it was important for the customer to see fuel consumption and fuel remaining directly on the genset controller screen. A high-precision fuel level sensor and fuel flow meter were installed, and their data was transmitted to the controller via the CAN J1939 bus.
Over time, the customer needed to eliminate on-site checks. We proposed installing a telematics gateway and connecting the system to UNUM Genset — with remote access, data visualization, and analytics.”
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Online monitoring of fuel consumption and fuel levels provided full transparency into generator operation. The system records every refueling event and fuel drain and automatically alerts responsible staff. Unauthorized fuel drains stopped.
Fuel is now purchased and written off based on actual consumption rather than average operating-hour rates. The standard rates turned out to be 2.5 times higher than the real figures — the generator’s actual fuel consumption is significantly lower.
The monitoring system is planned to be installed on the remaining generators.
- Reputation and market trust. Technoton is well known in the African market as a manufacturer of reliable equipment designed to withstand harsh climate conditions. It is valued for measurement accuracy and long service life.
- Complete turnkey solution. Technoton offered a complete solution: fuel monitoring, controller integration, and a telematics service. The equipment is compatible with controllers from leading manufacturers, including DSE. The customer received a single ecosystem instead of disconnected components.”
Frequently Asked Questions About Fuel Monitoring on Generators
How can you detect fuel theft from a generator?
The DUT-E fuel level sensor records every change in tank level. The system automatically classifies events — refueling and fuel drains — and sends alerts to responsible staff. In this project, unauthorized fuel drains stopped after the system was installed.
What data can be obtained from a generator with a DSE controller?
Via the CANUp Genset telematics gateway over Modbus RTU, the system reads alternator parameters (voltage, frequency, current, power factor) and engine parameters (RPM, temperature, and fluid pressure). Together with fuel sensor data, this provides a complete picture of genset operation.
Can a generator be monitored remotely without being on site?
Yes. All data is sent to the UNUM Genset cloud-based service and is available through the web interface from anywhere in the world. In this project, the transition to remote monitoring helped save staff time and eliminate abuse.
How accurate is the fuel flow meter in measuring fuel consumption?
The DFM 250D CAN fuel flow meter directly measures the volume of fuel passing through the fuel line. In this project, it revealed that actual consumption was 2.5 times lower than the standard rate — a difference that could not be identified through operating-hour-based accounting.
Is the Technoton solution suitable for generators from other manufacturers?
Yes. Technoton equipment is compatible with controllers from leading genset manufacturers, including DSE, ComAp, and others. The CANUp gateway supports CAN J1939, Modbus RTU, and the S6 telematics interface.
