Smart Fuel Management for Remote Sites

Secure Your Fuel, Reduce Your Costs, Lower Your Emissions

RevDev has developed a low-cost, fuel management system based on new technology that can be implemented at nearly any remote site. FuelSentry is designed to reduce fuel theft and waste. It provides real-time monitoring, alerts and the ability to remotely control equipment to ensure significant cost savings. Unlike legacy fuel management systems, FuelSentry solution does not require existing network infrastructure or a satellite uplink. The system generally repays the cost of investment in fuel savings within a matter of months.

The Problem: Fuel Theft & Waste at mines and other remote sites

Remote sites incur enormous fuel costs, often running into the millions of dollars monthly. Industrial studies show that a significant percentage of remote site fuel is lost to theft, spills and waste.

High Costs

Monthly fuel expenses at remote sites can reach into the millions. Even small inefficiencies or losses quickly add up, putting major strain on operational budgets.

Systemic Theft

Employees, contractors, security guards, and truck drivers often work with suppliers to steal fuel. Losing just a few percent of the monthly supply can cost hundreds of thousands of dollars.

Supplier Fraud

Suppliers may deliver watered-down or low-grade fuel that reduces efficiency and damages equipment. Without lab testing, sites often have no reliable way to detect this fraud.

Waste & Spills

Fuel is frequently wasted through avoidable spills, overfilling, and equipment left running. These operational habits lead to large, ongoing losses every month.

A wireless fuel monitoring system that tracks delivery, storage, consumption, and equipment usage with remote dashboard control.

The Solution: Fuel Management System

FuelSentry provides an affordable, efficient solution for reducing fuel theft & monitoring fuel usage at remote sites without the need to build expensive networks or other infrastructure.

Innovative Technology

Utilizes durable but low-cost Internet of Things (IoT) sensors & a self contained remote network.

Cost-Effective

Affordable cost, fast implementation (1-2 months), and a quick ROI.

Scalable and Adaptable

The system is flexible, scalable, and cost-effective—ideal for any site or equipment, even for small operators.

Comprehensive Monitoring

Real-time data collection, remote monitoring via dashboards, automated alerts and actions.

Case Study #1: The Naran Tolgoi Gold Mine

Naran Tolgoi (Sun Hill) is an open pit, hard rock gold mine that runs on Euro 5 quality diesel. Fuel is trucked into the mine using trailers and stored in tanks at the fuel farm. It is then distributed to generator sets, haul trucks and other equipment. Site management recently caught several employees stealing large quantities of fuel. An internal investigation revealed that the problem was not a once off incident but was in fact systemic. FuelSentry was put in place, achieving significant reductions in fuel theft, leakage and wastage.

Background

Location

Naran Tolgoi Gold Mine, Mongolia

Fuel Type

Euro 5 / Type #1 diesel

Consumption

~900,000 liters / month

Fuel Cost

Nearly $1.5 million USD / month

Problem

Fuel Theft

Systemic theft by employees

Leaks

Fuel losses due to poor stores management

Supplier Fraud

Watered-down fuel deliveries

Inefficient Use

Gensets and vehicles idling while not in use.

Solution

Implementation cost

~$44,000* total. Cost depends on the number of assets that need to be integrated.

Hardware

$24,000 (multi-measurement flow-meter sensors, level and quality sensors, actuators, router).

Configuration

$20,000 for setup and configuration

Installation

Network setup (single router) and sensors on all tanks, bowsers, and fuel lines in equipment. Actuators on.

Alerts

Set for unexpected drops in fuel levels and discrepancies in fuel usage.4o mini

Servicing Cost

~$4,000 / month

RESULTS

Management caught several attempts and fuel theft within the first week of using the system. They also discovered that the fuel supplier had been watering down the supply delivered to site. Management gained the ability to remotely shut off idling vehicles and gensets.

Immediate Impact

Detected several fuel theft attempts and supplier fraud within the first week

Annual Savings

Reduced monthly fuel consumption to 778,000 liters (12% reduction)

Breakdown

Theft Deterrence: 8%, Inefficient Idling: 2%, Leakage: 2%

Savings

More than $181,000 USD per month
ROI: Achieved within the first quarter

1 router device has a range of 10-20 kilometers and can communicate with all IoT sensors within this radius, even devices located underground and inside structures.4o mini

Key Features: Cutting edge technology

Fuel management systems have been around for decades, but in the past, implementing these systems took a great deal of time and money. The systems were also not practical at remote sites where network infrastructure was lacking.

Low-Cost Remote Network

With a single router device, RevDev can develop a network at any remote site. The network extends for 10 kilometers or more in every direction, with no need for cellular, satellite or microwave uplinks.