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[Practical Guide] How to Calculate Fuel Consumption? A Simple Method for Accurate Estimation
Why Calculate Fuel Consumption?
When choosing a diesel generator set, one of the questions customers care about most is: How much fuel does it burn per hour?
Fuel consumption not only determines the operating cost of the unit but also affects budgeting and long-term maintenance planning. By mastering a simple calculation method, you can have a clear idea during the selection process.
Formula for Calculating Diesel Fuel Consumption
The fuel consumption of a diesel generator set can usually be estimated with the following formula:
Fuel Consumption (L/h) ≈ Power (kW) × Load Factor × Fuel Consumption Rate (g/kWh) ÷ 860 ÷ Diesel Density (g/ml)
Where:
Power (kW): The rated power of the generator.
Load Factor: Actual load ÷ rated power, typically 0.6–0.8.
Fuel Consumption Rate: Varies by model; standard sets are around 200–230 g/kWh, while high-efficiency sets can be as low as 195 g/kWh.
Diesel Density: About 0.84 g/ml (at normal temperature).
Example:
A 200 kW diesel generator runs at 75% load, with a fuel consumption rate of 210 g/kWh:
Actual Power = 200 × 0.75 = 150 kW
Hourly Fuel Consumption ≈ 150 × 210 ÷ 860 ÷ 0.84
Result ≈ 43.6 liters/hour
Key Factors Affecting Fuel Consumption
Beyond rated specifications, usage habits and maintenance also directly impact fuel consumption:
Low load: Running below 30% load for long periods actually increases consumption.
Poor maintenance: Clogged air filters or worn injectors reduce combustion efficiency.
Fuel quality: Poor-quality diesel with impurities burns faster and damages the engine.
Frequent cold starts: Repeated starts and stops raise consumption.
Fuel consumption is not a fixed value, but the result of combined factors including power, load, and efficiency.
By using simple formulas and practical examples, businesses can better anticipate costs before purchase, preventing unexpected operational expenses later.
Taikang Power (Yangzhou)
We provide customers with precise fuel consumption data and energy-saving solutions, helping you ensure reliable power supply while significantly reducing operating costs.
