When managing critical power systems, accurate planning is essential—especially when it comes to fuel. At LEL Critical, we provide a variety of tools to support your power decisions, including our Diesel Generator Fuel Consumption Chart, designed to help you estimate fuel needs based on generator size and load.

Whether preparing for a planned outage or building an emergency backup plan, knowing how much fuel your generator will use is key to keeping operations running smoothly. Fuel planning impacts everything from budget forecasting to on-site fuel storage and delivery logistics. That’s why understanding generator fuel consumption is an essential part of facility and operations management.

Tip: For help estimating fuel costs, check the current diesel fuel prices from the U.S. Energy Information Administration.

Our Diesel Generator Fuel Consumption Chart offers a quick and easy way to estimate fuel usage based on generator size and operational load. The chart includes 25 generator sizes, ranging from 20 kW to 2250 kW, and provides estimated fuel consumption rates (in gallons per hour) at the following load levels:

• 1/4 Load
• 1/2 Load
• 3/4 Load
• Full Load

To use the chart, simply identify your generator’s size in kilowatts and cross-reference it with the expected load it will carry. For example, if you operate a 500 kW generator at half load, the chart will show the estimated gallons per hour (GPH) used in that specific condition. This allows you to plan for refueling, determine run time during extended outages, and understand operational efficiency.

Keep in mind that actual fuel consumption can vary due to factors such as engine condition, altitude, fuel quality, and ambient temperature. The chart is meant to be a helpful guideline—not an exact measure.

This resource is especially useful for:

• Facility and maintenance managers
• Electrical and mechanical engineers
• Procurement teams managing fuel budgets
• Contractors setting up temporary or standby power
• Emergency preparedness planners

Whether you manage a hospital, data center, manufacturing facility, or temporary job site, this chart can help support informed decision-making.

In addition to the generator fuel consumption chart, LEL Critical offers other free tools to help you plan and operate more effectively. These include:

• Amperage Chart: This chart estimates a generator’s output amperage based on its power rating and voltage. It serves as a helpful reference when sizing equipment or assessing load requirements.
• Generator Spec Sheets: Compare technical specifications for generators from leading brands. These downloadable sheets provide key details to help you identify the best fit for your facility’s unique needs.

All of these tools are available on our Power Resources page and are designed to support anyone responsible for power continuity, system design, or emergency readiness.