⛽ 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
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Cost per Hour
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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
⚡ 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 SizekW LoadL/hr (75%)
25 kVA15 kW~4.2 L/hr
62.5 kVA37.5 kW~10.5 L/hr
125 kVA75 kW~21 L/hr
250 kVA150 kW~42 L/hr
500 kVA300 kW~84 L/hr

Note: Actual consumption varies by DG brand, age and maintenance condition.

💰 Related Cost Calculators

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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

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