UNUM Genset: reducing travel
for remote generator management
Customer:
Machinery:
Task:
Solution:
Result:UNUM Genset: reducing travel
for remote generator management
Customer:
genset automation integrator*
Machinery:
diesel power generators 60-150 kW
Task:
remote monitoring of operations, real-time diagnostics,
fuel consumption tracking
Solution:
Result:
reduced specialist travel costs by 3 times,
maintenance costs cut by 50%
The customer
For over 15 years, our client* has been a respected player in the power generator industry, dedicated to maintenance and repair of generator units.
Recently, they expanded into the sales of reliable power solutions. Over the past few years, they have successfully sold, delivered, and installed more than 50 diesel generators and 5 gas-powered generators of various capacities.
This extensive experience has positioned them as a trusted partner for their clients, known for their reliability and expertise.
SDEC diesel generator (left) and YAMZ diesel generator (right)
In the remote settlements they serve, diesel generators play a crucial role in providing backup power, ensuring that these isolated communities have access to electricity. The fleet of generators serviced by the company includes:
- SDEC H series generators: With capacities of 60, 100, 120, and 150 kW, these generators are renowned for their durability and efficiency.
- YAMZ generators: Available in capacities of 60 and 100 kW, these generators are essential for maintaining uninterrupted power supply.
The operation of these generators is managed using control panels Smartgen HGM6210 and Deif CGC 400.
Challenges in generator maintenance, diagnostics and monitoring
Every week, a dedicated team of specialists, consisting of a mechanic and a supervisor, embarks on a mission to ensure the generators are functioning correctly.
The supervisor collects critical data on energy generation, engine runtime, fuel levels, and records any errors, while the mechanic performs thorough inspections and maintenance, typically required every 2-3 weeks.
These generators are located hundreds of kilometers from the client’s office, making each trip an all-day endeavor. Adverse weather conditions can make these journeys dangerous, with risks of getting stranded or encountering accidents.
To address these challenges, the client decided to automate the monitoring of generator operations and fuel consumption, aiming to reduce the number of trips and lower maintenance costs.
Mechanic checking the generator’s technical condition
Solution: UNUM Genset – advanced remote monitoring system
To streamline their operations, the client implemented the UNUM Genset monitoring system.
This cutting-edge solution combines onboard equipment with cloud-based software, providing a comprehensive approach to remote monitoring.
The onboard equipment includes:
- DFM D fuel flow meters: ensuring precise fuel consumption measurement.
- CANUp Genset telematic gateways: transmitting electrical parameters from controllers via the RS-485 (Modbus) interface.
Monitoring data of generator operations is available from any computer 24/7 through a browser, as well as in the UNUM Genset mobile application. User-friendly dashboards display engine parameters, electrical data, and both current and total fuel consumption. The system also generates detailed reports and maintains a fault log, providing a complete overview of generator performance.
Onboard equipment of UNUM Genset monitoring system
Dashboard parameter display
Fuel consumption and power reports
“Technoton provided the client with a comprehensive monitoring solution for generators – UNUM Genset.
By incorporating the DFM D flow meter, the system ensures direct and precise measurement of fuel consumption.
Compatible with a wide range of diesel engines and various controller brands, UNUM Genset offers unparalleled flexibility. The cloud-based software delivers real-time monitoring and detailed analysis of historical operations, allowing for thorough insights. Additionally, the system can be quickly and easily customized to meet the specific requirements of the client, ensuring an optimal fit for their operational needs.”
Maxim Damarad,
Technoton sales manager
Result: enhanced efficiency and cost savings with remote monitoring
The deployment of the UNUM Genset monitoring system has significantly improved the client’s operations. They now remotely monitor critical generator parameters such as fuel consumption, engine operation, and electricity generation in real-time.
This has reduced the frequency of physical inspections and minimized errors and malfunctions. Employee trips for generator control and maintenance have been reduced by three times, resulting in substantial cost savings and increased profitability.
“The UNUM Genset monitoring system was installed on 8 generators in the most remote areas from our office. Installation costs were recouped within a few months.
UNUM Genset allows us to assess generator efficiency by calculating fuel consumed per unit of generated energy. Remote diagnostics save time and prevent potential downtime.
We plan to extend this system to all generators serviced by our company.”
Lead specialist of client company*
*Data is hidden from public access to comply with GDPR requirements.
Details on the project can be disclosed upon signing NDA and with the consent of our partner.
