HMS Industrial IoT Blog

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3 Ways to Cut Operating Expenses for Power Generators

by Julia Sheridan | Jan 02, 2018



The key factor to successfully being able to reduce operational costs is information. By understanding when, how, and if equipment is operating, we are able to make better decisions regarding site maintenance and take actions when necessary.

Below are three examples of how access to information helps us make better decisions and reduce operating costs. For more information on how to monitor your gensets from anywhere in the world visit our site:


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Power generators are often serviced according to a pre-determined service schedule. By understanding how the generator has been operated, it is possible to plan service more dynamically.

With a remote management solution, you can check operating hours, oil pressure, battery status, coolant temperatures, generated power output, fuel level, GPS position etc.

A notification may also be generated whenever a critical level has been reached, for example if the generator has been running more than expected. We may then send a notification when the running hours exceed the service interval. 

By being able to analyze the operation of each generator remotely, you will be able to understand their health and more efficiently schedule service visits in the field.


Certain advanced remote management solutions also offer remote access functionality. This means that you can open up a secure tunnel to your power generator in the field and do configuration using your regular software tools. Just like if you connect to the control panel on site.



Just like a car that has been parked for an extended period, a generator engine that has not run in a long time is likely to have start-up problems. For back-up power generators that are not operated very often, it is important to regularly perform operational tests.

Remote test starts can be made with a remote management solution that has control capabilities and is connected to the generator controller. With a simple action such as a remote operational test, you may increase the likelihood of the generator working the day there is a power outage and the generator needs to perform. 

A well-maintained generator operates better and has lower operating costs since unplanned service visits often mean substantial expenses. 



Fuel theft can be a significant problem. In certain regions, as much as 40% of genset fuel is reported to be stolen. 

Avoiding fuel theft completely might be difficult since it is often stolen a bit at a time; during transportation, at fill-up, or at the power generator in the field. However, a remote monitoring system that connects to a fuel sensor can be used to ensure that the right amount of fuel is delivered at a refill.

By using an intelligent level sensor, it is possible to track the fuel level of the tank. The fuel sensor can be calibrated to sense a full tank and by knowing this we can verify that the tank is properly refilled. A good fuel level sensor is able to detect variations down to 3-5 liters.

An abnormal decrease in content may be detected and indicate that the fuel is being stolen. With a remote monitoring system that supports alarms, a notification is sent immediately when the theft occurs. Even if it might be hard to catch the thieves, we are at least aware that the fuel has been stolen and we can schedule a refill to ensure the generators have the fuel needed to operate. 

Tracking the level of fuel in a tank increases the awareness of what happens to the fuel on site and helps users understand when theft occurs. In some cases, where organized theft is common, this may help detect patterns and take action.



Remote Monitoring allows you to have instant access to data from equipment in the field. This creates a quicker decision making process, reduces operating expenses, and have full control 24/7 to be notified if any operational issues occur.


Read more from our White Paper

Reducing Operating Expenses with Remote Management

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