Maximize prime power efficiency and uptime

The platform integrates with major generator controller families over Modbus, CAN, and SNMP, including Woodward, ComAp, DEIF, and most OEM-provided control systems, and custom protocol support is available for legacy units. In practice, the controller is only part of the picture: the same edge agent also reads fuel level sensors over 4-20mA, ATS panels through their auxiliary contacts and Modbus registers, power meters, and emissions monitors, so the whole generation site lands in one asset hierarchy rather than just the engines. Mixed fleets are normal and expected; a site running a ComAp-controlled unit next to two OEM-panel units feeds the same dashboards and the same alarm engine, and the fleet view does not care which brand of controller produced the reading. If a controller on your site speaks none of the supported protocols, raise it during the demo and we will tell you plainly whether it can be read.

Most multi-unit prime power sites see a 10-15% reduction in fuel consumption once load balancing is optimized across the fleet, and the mechanism is straightforward. A generator burns fuel most efficiently in a fairly narrow band of its rated load; a site that spreads a light load across too many units keeps each one below that band, paying for the inefficiency on every operating hour and wet stacking diesel engines that spend their days lightly loaded. Per-unit fuel burn tracked against load carried makes this visible: which units are running rich, how many hours the fleet spends below the efficient band, and what the per-kWh cost of each configuration actually is. From there, load distribution can favor the right units and the right unit count for the demand actually present. Savings depend on unit mix, load profile, and how far current operations sit from the efficient band.

Yes. Runtime is the foundation: every run is detected automatically from the engine-hours reading, so each start is logged with its start time, end time, and total duration without anyone keeping a paper log. The runtime report splits hours into emergency and non-emergency time, which is the split EPA reporting asks for, and when a run was recorded as routine but was in fact an outage, an override records the emergency duration with a comment while keeping the original record intact. Fuel consumption and emissions telemetry are logged continuously alongside, timestamped and exportable, and reports save to PDF for any historical period, so the year-to-date picture a regulator asks for is a date-range query rather than a reconstruction. Custom report templates can be configured for specific permits, and scheduled delivery sends the package to a distribution list every cycle automatically.

Depending on the failure mode, developing problems typically surface days to weeks before they would cause an unplanned outage. The reason is that most generator failures announce themselves in trend data long before they trip a controller alarm: coolant temperature that climbs a degree or two per week points at a fouling radiator or a weakening pump, oil pressure that sags at load faster than it used to points at bearing wear, and injector irregularities show up as uneven behavior across otherwise identical units. Threshold alarms catch the acute events; trend-based anomaly detection catches the slow drifts that thresholds miss, because the value is still inside the normal band while the direction is wrong. Either way the alert reaches the on-call engineer with the trend history attached, so service is scheduled during a planned window with the right parts, which is where the up to 40% reduction in unplanned outages comes from.

Yes. ControlCom Connect runs alongside existing SCADA and DCS systems rather than replacing them: the edge agent reads the same controllers and instrumentation over Modbus, CAN, SNMP, and OPC-UA, and the control layer keeps doing exactly what it does today. The platform adds what plant SCADA typically does not deliver for a generation fleet: cloud dashboards reachable from anywhere, native mobile apps with push and SMS alerting for the on-call rotation, per-unit runtime and fuel analytics with unlimited history, and the automated compliance reporting described above. The edge agent makes outbound-only connections, so no inbound ports are opened on the control network, and it keeps collecting and evaluating alarm thresholds locally when the internet link drops, buffering unsent readings and forwarding them when the connection returns. Operators keep their HMI; the platform becomes the layer the rest of the organization actually looks at.

Most prime power sites are fully onboarded within 2-4 weeks, including controller integration, dashboard configuration, and operator training. The first week is discovery and install: inventory the controllers, fuel instrumentation, and ATS panels on site, drop the edge agent on a small box on the site network, and point the pre-built connectors at the equipment. Live telemetry typically arrives within days; the remaining time goes into the configuration that makes the data operational, per-unit alarm thresholds and escalation paths, the fleet dashboard, runtime report setup, and the notification groups that decide who gets paged for what. Larger fleets roll out site by site on an agreed schedule, with the first site establishing the asset templates and report formats that each subsequent site inherits, so later sites onboard faster than the first. There is no per-tag licensing: plans are priced by data volume and device count, so which units and tanks to instrument is an engineering decision within the allotment of your plan, and you move up a tier only when the fleet outgrows it.