Real-life case on how fuel flow meter helped predict failures of fuel supply line elements of diesel generators of a factory in Sierra Leone - done by our HQ, Technoton.

1. Predictive maintenance of
fuel system – diesel-generator case

2. Why Technoton?
• 70 000 sensors per year production capacity.
• Over 550 partners in 140 countries worldwide.
• Technoton’s products are mounted on 500,000 vehicles
and stationary objects.

3. Fuel monitoring methods
Fuel level sensors Fuel flow meters CAN bus tools

4. Fuel flow meter – not just fuel consumption
Monitoring real fuel consumption and engine operation.
Preventing fuel theft and misuse.
Engine diagnostics based on fuel consumption rate.

5. Business case – pumping station
The station is composed of two pumps running on
diesel fuel. Pumps are suppling a local
manufacturing company with water from a nearby
river.
Customer’s request – provide a solution which
allows to ensure uninterrupted station operation.
The key to solving the task is to deploy a system,
which will give a clear information on necessity of
maintenance.

6. Scheme of monitoring system
DUT-E fuel level
sensor in tank
#1
DFM fuel flow
meter – pump
#1
DFM fuel flow
meter – pump
#2
Terminal
unitTelematics
interface
DUT-E fuel level
sensor in tank
#2

7. DFM fuel flow meter in the fuel system
Fuel supply
Fuel return
DFM fuel flow meter
Live operational data:
• Instant fuel rate in supply line;
• Instant fuel rate in return line;
• Fuel temperature;
“Fuel & time” Counters:
• total fuel consumption and by
operation modes;
• total engine operation time by
operation modes.
Diesel engine Fuel tank

8. Fuel consumption chart analysis
Instant fuel rate in supply line
Instant fuel rate in return line
Instant fuel consumption
Fuel consumption suddenly increased by 27%!
What is the reason?

9. ALARM! Service required!
Event information – Wialon/SMS/e-mail
Fuel rate/supply
decrease by 14%
Fuel rate/return
decrease by 23%
Fuel consumption
increase by 27%
Instant fuel consumption rate 63.3 L
Fuel rate/supply 143.8 L
Fuel rate/return 80.5 L

10. Customer’s potential for savings
2620 $Fuel overspending per one week!
Fuel rate have increased by 15 L/h
Fuel price was 1.04 $ per liter
15 L/h *1.04 $ *24 hours *7 days = 2620.8 $

11. Predictive maintenance curve
Normal operation
Malfunctions
Broken
Usual fuel rate
Increased
fuel rate
Engine
breaks down
Repairing costs
Time
Increased
temperature
Noise
Vibration

12. Worst scenario – engine failure example

13. Summary
• Fuel monitoring using DFM fuel flow meters and DUT-E fuel level sensors allows accurate
measurement of fuel level, consumption and engine operation time data:
1. fuel rate in feed and return fuel lines
2. fuel consumption by engine
3. engine operation time split by workload
4. fuel tank refill and drain volumes.
• Accurate fuel monitoring helps to detect and prevent fuel theft from engine fuel lines and fuel
tank, thus reducing total operational costs; and help ins establishing clear fuel accounting.
• Fuel consumption and engine operation data allows to implement predictive maintenance
approach – making service and repairs of engine before critical point is reached.

14. Phone +375 17 240 39 43
Viber/Telegram +375 44 792 67 58
sales@technoton.by
www.jv-technoton.com