Generator

Generator Fuel Autonomy

Diesel BSFC curve + altitude / temperature derating + NFPA 110 Class and 133 % tank check. How long will the genset actually run on the tank you have?

Report details for the PDF
Autonomy on this tank
31.3 h
1.3 days
Tick = 2.7 h (Class 2 × 133 %)
Fuel consumption
28.8 L/h
At 63% of derated capacity
Effective genset
160 kW
Rated 160 kW × derating
Usable fuel
900 L
1000 L × (1 − 10%)
NFPA 110 Class 2
Pass
Needs ≥ 77 L usable (133 % × 2 h)

Fuel in the tank over the outage

02004006008001000051015202530Hours running at this loadFuel in tank (L)10 % reserveClass 2 × 133 % = 2.7 h

Linear burn at 28.8 L/h. The dashed vertical line is the NFPA 110 requirement for the Class you picked (duration × 133 %); the dashed floor is the reserve you never drain.

NFPA 110 Class ladder

Which Classes this tank clears at the connected load — usable fuel must cover 133 % of the Class duration.

  • Class 0.083 (5 min)✓ 3 L
  • Class 0.25 (15 min)✓ 10 L
  • Class 2 (2 h)✓ 77 L
  • Class 6 (6 h)✓ 230 L
  • Class 48 (48 h)✗ 1.8k L
  • Class 96 (96 h)✗ 3.7k L

Why fuel consumption isn't linear

Diesel BSFC (brake-specific fuel consumption) is best around 75% load. At 25% load, a diesel burns roughly 0.09 L/h per rated kW; at 100%, 0.28 L/h per rated kW — three times as much per hour, but only ~30% more per kWh produced. Light loading also causes wet-stacking. The sweet spot for a backup genset is 50–80% of rated.

Pair the genset with the right UPS runtime.

Power Stack keeps every UPS you've installed in one registry — kVA, battery bank, install date, notes — so the inputs behind this answer live on the unit record for the next technician, not in a chat thread.

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Where the consumption figure comes from

Brake-specific fuel consumption (BSFC) is the diesel engine's consumption per kWh of mechanical output. A typical mid-size diesel sits around 230 g/kWh at 75% load; at 0.835 kg/L that is 0.275 L/kWh, or ~0.21 L/h per rated kW when running at 75% of rating. Vendors publish a fuel curve in their datasheets — this calculator uses the cross-vendor median, calibrated against Cummins, Caterpillar, Generac, and Kohler datasheets for 100–800 kVA sets. Engine size matters: small sets under 50 kVA burn 10–20 % more per kW, and large electronically-injected sets over 1 MVA burn 5–10 % less, so the calculator flags both. For mission-critical sizing, always substitute your specific genset's curve.

NFPA 110: Class, not a flat 24-hour rule

NFPA 110 does not set a single fuel duration. It defines the emergency power supply by Class — the minimum time it must run at rated load without refuelling — and leaves the Class to the authority having jurisdiction and the application: Class 2 (2 h) is the usual life-safety minimum for egress lighting and fire pumps, Class 6 for many hospitals and telecom sites, Class 48 or 96 for data centres and critical operations, or “Class X” where the owner specifies the hours. The fuel supply is then sized at a minimum of 133 % of the Class duration's consumption (NFPA 110 §5.5) to cover fuel-quality losses and the unusable volume at the bottom of the tank. The calculator applies exactly that rule: pick the Class, and it reports whether your usable fuel clears 1.33 × hours × consumption at the connected load.

Natural gas vs diesel

NG gensets are popular in regions with a strong gas grid (much of North America, parts of Europe and East Asia) because they don't need on-site fuel storage and emit less particulate. Trade-off: a gas-grid outage knocks out the genset too. The autonomy figure for NG is constrained by the gas-meter capacity, not a tank, so the user enters expected runtime gas in m³.

Derating at altitude and high ambient

ISO 8528-1 Annex C derates naturally-aspirated diesels by roughly 1% per 100 m above 1000 m and 2% per 5 °C above 25 °C ambient. Turbocharged engines derate more gently — confirm with the genset vendor. The calculator applies both deratings to the rated output before computing the load fraction, and refuses to report an autonomy figure when the connected load exceeds the derated capacity — that is an overload, not a runtime.

Questions engineers ask

Why isn’t fuel consumption proportional to load?

Brake-specific fuel consumption is best near 75 % load. A diesel at 25 % load burns about a third of the fuel per hour of one at full load but produces only a quarter of the energy, and light loading causes wet-stacking. The tool interpolates a cross-vendor L/h curve rather than scaling linearly.

What is an NFPA 110 Class?

The minimum time the emergency power supply must run at rated load without refuelling: Class 2 is 2 hours, Class 48 is 48 hours, Class X is whatever the owner specifies. NFPA 110 §5.5 then sizes the fuel supply at a minimum of 133 % of that duration’s consumption.

What about natural-gas generators?

There is no tank, so autonomy is set by the gas supply rather than fuel on site. The tool takes an expected gas volume in m³ to give an equivalent figure and applies the 133 % rule to that volume. Remember that a gas-grid outage takes the genset with it.

Engineering disclaimer: Power Stack provides this calculator as a general engineering estimate. Final design must be verified by a qualified electrical engineer and reconciled with manufacturer datasheets, the applicable national wiring regulations (NEC, BS 7671, IEC 60364, or your local equivalent), and site-specific conditions. Power Stack accepts no liability for design decisions made from this output.