Custom Diesel Refill System Extends Generator Autonomy to 48 Hours

In 2022, Hestia delivered a custom-engineered solution to extend backup power capacity for a critical facility reliant on a diesel generator. The client required increased energy autonomy during potential outages, with a target of 48 hours of continuous runtime. To achieve this, we designed and installed an external diesel storage tank with the total capacity of 1000 liters integrated with the existing generator system.

The core of the solution was a fully automated fuel transfer mechanism — custom-built to match both the generator’s internal tank specifications and the operational logic of the external tank. This system continuously monitors fuel levels and automatically activates refueling when thresholds are met, ensuring seamless operation without manual intervention. Safety protocols, pressure regulation, and overflow protection were all incorporated into the design to comply with industrial fuel handling standards.

This project stands out for its tailored approach: instead of importing a prefabricated system, we engineered the refueling solution locally, adapting to the existing infrastructure and minimizing cost and downtime. Furthermore, the system was connected to the existing BMS system so that the operators can instantly get all the relevant information in real time. The result is a dependable, smart system that guarantees 48 hours of autonomous operation, significantly improving energy resilience for the facility.