The Challenge
A manufacturing facility operated three diesel generators (250 kVA, 125 kVA, 62 kVA) as backup power. Generators were set to auto-start during 'demand peak' windows and manual peak periods. No one tracked actual runtime versus grid availability.
What Became Visible
Hour-by-hour generator runtime monitoring revealed that generators were running 8–10 hours daily — but grid power was available 18+ hours daily during these same periods. The facility was running generators as load-leveling backup even when grid was stable and available. The 250 kVA generator alone consumed 120–150 liters of diesel daily (~₹18–24k/day) during periods when grid power could have been used.
What Changed
Automated DG control system implemented. Generators only auto-start when grid voltage drops below threshold (indicating actual grid failure) or during scheduled high-demand tariff windows when diesel is cost-justified.
How it worked: Grid voltage monitoring was connected to generator control. Generators no longer ran on preset schedules but only during actual grid events or during specific tariff windows where running DG was economical. Within the first month, generator runtime dropped from 260 hours to 42 hours monthly (grid failures + demand peak windows).
Results
eliminated unnecessary operation
monthly
from ₹48k to ₹8.6k
fuel + engine wear reduction
Most facilities run diesel generators on autopilot schedules without checking if grid power is available. Real-time grid status visibility eliminates fuel waste from generators running when they're not needed.
Operational Reality
Facilities running scheduled DG when grid power is available waste 40–60% of diesel budget. The fix requires grid-status monitoring and smarter control logic.