QDTB® Transformer

Diesel Power Station Calculator

Enter your continuous load and duty to size the genset units at ~75% load (with N+1), the ATS, fuel tank and enclosure — plus daily fuel OPEX and a complete BOM.

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How a diesel station is sized

Diesel gensets run best at 70–80% load. The calculator picks a standard unit (500–2000 kVA) so the running sets sit at ~75% load, adds an N+1 standby set, and sizes the ATS, fuel storage and 20/40 ft enclosure from your autonomy days.

Worked Example — Diesel Power Station

Example 1 — 1200 kW Prime Diesel Station (Containerised, N+1) · FOB $6,480
Diesel power station · prime
2500 kVA
5 × 500 kVA (4 running + 1 standby) · container
Fuel tank
21,600 L
Fuel OPEX
$6,480/day
Est. BOM (FOB)
POA
📦 Bill of Materials
EquipmentModelSpecQty
Diesel generator sets500 kVA × 54 running @ 75% load + 1 standby (N+1) · prime duty · ISO 85285
Paralleling control cabinet5 × 500 kVAsynchronising + GB load-sharing · PLC control1
ATS (grid ↔ genset)3608 Aautomatic transfer switch · mains-to-backup changeover1
Enclosure20 ft containercontainerised genset · weatherproof1
Fuel system21600 Lday tank + bulk storage + piping (3 days autonomy @ 7200 L/day)1
Power & control cablesLVgenerator leads + control wiring1
Silencer & noise attenuationdB(A)residential/urban grade exhaust silencing1
Foundation & secondarycivilconcrete plinth + earthing + protection relay1
Summary
Estimated total (FOB Qingdao, EXW) — priced equipmentPOA
📐 System diagram
G1500 kVAG2500 kVAG3500 kVAG4500 kVAATS3608 AGridutilityCritical loadprime - container
LEGENDBreaker (52)CTCT (current transformer)50/51Protection relaykWhMeter (kWh)
📏 Standard basis
TopicStandard
Genset ratingISO 8528 — reciprocating internal combustion engine driven generating sets
Chinese equivalentGB/T 2820 — 往复式内燃机驱动的交流发电机组
GeneratorIEC 60034 — rotating electrical machines
Genset classificationGB/T 4712 — classification of AC generating sets
🧮 How it was calculated
1. Apparent load = 1200 kW ÷ pf 0.8 = 1500 kVA
2. Unit sizing at 75% load: 1500 kVA ÷ 0.75 = 2000 kVA → standard unit 500 kVA
3. Running units = ceil(1500 ÷ 375) = 4 · +1 standby (N+1)
4. Total installed = 5 × 500 = 2500 kVA (actual load 60%)
5. Fuel = 1200 kW × 24 h × 0.25 L/kWh = 7200 L/day → tank 21600 L (3 days)
6. Fuel OPEX ≈ 7200 L/day × $0.9/L = $6480/day
📋 Design notes
Load factor: Diesel gensets run most efficiently and with least wet-stacking at 70–80% load. The unit count is sized for ~75% load per running set; N+1 adds a standby set for maintenance rotation and peak redundancy.
Duty class: Prime duty: continuous rated output, unlimited hours. Duty class affects permissible load and service interval.
Pricing basis: Genset priced per unit from the diesel-generators reference (FOB Qingdao); ATS from ats-transfer-switches. Paralleling cabinet, enclosure/container, fuel system, cabling, silencing and civil works are quoted per project (POA).
Fuel estimate: Fuel consumption assumes ~0.25 L/kWh at 75% load (typical 180–220 g/kWh, diesel density 0.84). Fuel price $0.9/L is illustrative; confirm local delivered price.
Design review: This is a preliminary sizing. A licensed engineer must verify short-circuit rating, synchronising controls, ventilation and exhaust routing, and local emissions/noise regulations.

How it was calculated

Core formulas

Apparent load = kW ÷ 0.8 (pf). Running units = ceil(kVA ÷ (0.75 × unit kVA)). Fuel ≈ 0.25 L/kWh at 75% load; tank = daily fuel × autonomy days.

Applicable standards

ISO 8528 (generating sets), GB/T 2820, IEC 60034 (generators), GB/T 4712 (classification).

Frequently asked questions

How many gensets do I need?

The calculator keeps each running set at ~75% load (best efficiency, least wet-stacking) and adds one standby set under N+1 for maintenance rotation and peak redundancy.

Containerised or machine-room?

Containerised is a factory-assembled, weatherproof 20/40 ft package that ships and commissions fast. A machine room needs civil works but suits very large or permanently-installed stations.

How is the fuel tank sized?

From ~0.25 L/kWh at 75% load: daily consumption × your autonomy days. The calculator reports both daily consumption and tank volume.

Which items are priced in the BOM?

Gensets (per-unit) and the ATS are priced from the catalogue. The paralleling cabinet, enclosure/container, fuel system, cabling, silencing and civil works are quoted per project.

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Results are engineering estimates for reference. Final design must be confirmed by a licensed local engineer against site conditions and applicable codes. Prices are FOB Qingdao (EXW) and do not include freight, duty or installation.

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