The purpose of the fuel tank automation is to automatically fill the generator fuel tank.

While the generator is running, the fuel level in the tank drops and fuel drains away. In most cases these tanks are small which causes problems. These types of generators has to be filled periodically by the technical personel but it is both time consuming and the method is costly.

By the help of the PLC and HMI based automation this process can be done fully automated.

The fuel level inside the tanks are constantly checked. The tank with the shortage of fuel is automatically filled without stopping the generator.


Both mechanical and electrical parts are consists of ex-proof proportional valves, gates, flow sensors, level sensors, temperature sensors and alarm systems.

Fuel tank instrumentation, motors and system parameters are monitored and controlled from the HMI panel.


  • The fuel is filled to the main tank. When the tank is full the capacitive sensor displays visual and sound alarm indicating the tank is full.
  • Fuel is feeded to the generator line by the fuel pump and the auxilary pump. There are pressure sensor, flow sensor and electrical valves on the fuel line.
  • There are manual and proportional valves on each generator’s line. The state (on/off) of the valves can be monitored from HMI screen.
  • Each generator’s fuel level is checked by its own capacitive sensor.
  • Fuel request is generated for the generator which is short on fuel. The valve on the main line and its own proportional valve is opened then the fuel pump starts. Filling process continues until the set level is reached. Pump stops and the valves are closed.
  • Every valves state is checked. If the valves are closed, the pump doesn’t start. First the valves are opened then the pump starts.
  • The overall fuel consumption is logged and reported hourly, daily, monthly.


System parameters, max and alarm level of the tanks, main tank temperature, motors states are set in the settings screen.


Fuel consumption counters are displayed in the data log screen. The logs are kept for 90 days. The date selection is available to browse the logs.


Main tank’s volume has to be known for logging of fuel consumption. Accordingly the length, radius, camber and space values have to be set. How many liters the tank can take is calculated in the system after the values are entered. By the differential method the fuel consumption is calculated. The height of the generator tanks is entered for the controls.