⛽ Fuel Cost
Diesel Generator Running Cost Calculator
Calculate DG set fuel consumption and total running cost per hour, day and month.
Common sizes: 15, 25, 62.5, 125, 250 kVA
Running at 70–80% is most efficient
Current avg. India HSD price
Typical industrial load PF: 0.8
📊 DG Running Cost Breakdown
Fuel Consumption
—
Cost per Hour
—
Cost per Day
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Cost per Month
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Actual Load (kW)
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Cost per kWh
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Formula Used:
Actual Load (kW) = kVA × PF × (Load% / 100)
Fuel Consumption (L/hr) = 0.28 × Actual kW (at 75% load, typical DG)
Running Cost = Fuel Consumption × Diesel Price
Actual Load (kW) = kVA × PF × (Load% / 100)
Fuel Consumption (L/hr) = 0.28 × Actual kW (at 75% load, typical DG)
Running Cost = Fuel Consumption × Diesel Price
⚡ DG vs Grid Cost: Your DG is costing approximately
— per kWh.
Compare this to your grid tariff — if grid is cheaper, minimize DG runtime.
DG Fuel Consumption Reference
Approximate diesel consumption at 75% load (standard DG sets):
| DG Size | kW Load | L/hr (75%) |
|---|---|---|
| 25 kVA | 15 kW | ~4.2 L/hr |
| 62.5 kVA | 37.5 kW | ~10.5 L/hr |
| 125 kVA | 75 kW | ~21 L/hr |
| 250 kVA | 150 kW | ~42 L/hr |
| 500 kVA | 300 kW | ~84 L/hr |
Note: Actual consumption varies by DG brand, age and maintenance condition.
💰 Related Cost Calculators
Diesel Generator Running Cost Formula
DG running cost has two main components: fuel cost (the largest component, typically 70–80%) and maintenance cost. This calculator focuses on fuel cost which is what varies daily based on load and runtime.
Fuel Consumption (L/hr) ≈ 0.28 × kW Output
Running Cost (₹/hr) = Fuel Consumption × Diesel Price
Cost per kWh = Running Cost / kW Output
Running Cost (₹/hr) = Fuel Consumption × Diesel Price
Cost per kWh = Running Cost / kW Output
Tips to Reduce DG Running Cost
- Run the DG at 70–80% of rated load — this is the most fuel-efficient operating range
- Avoid running at below 40% load — wet stacking occurs and fuel efficiency drops sharply
- Install automatic load shedding to shed non-critical loads when on DG power
- Invest in rooftop solar + battery to reduce peak DG hours
- Keep DG air filters and injectors clean — dirty injectors increase consumption by 5–10%
- Compare your cost per kWh against grid tariff — the difference tells you the true cost of power cuts
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