A prime-power fuel plan cannot be built by multiplying generator rating by 24 hours. Mine demand changes by shift, starting events, dewatering and camp use, while usable tank volume and access conditions constrain delivery.
Engineering scope
Owners, EPC teams and operators planning continuous prime power, remote refuelling or a diesel-storage comparison.
Bring the operating load, manufacturer fuel table, usable tank volume and delivery conditions into one annual model.
Monthly and annual fuel ranges, delivery quantity and frequency, normal and adverse autonomy, and a defined safety stock.
Build an hourly load profile first, then use the proposed engine and genset manufacturer fuel data at the relevant load points. Annual fuel is the sum of operating scenarios; refuelling is governed by usable fuel, verified hourly use and logistics margin.
01
Build a 24-hour load profile
Separate production, shift change, maintenance, night camp demand and emergency dewatering. Continuous loads, intermittent process equipment and motor starts do not create the same fuel result.
- Record hourly kW or kVA and power factor
- Separate normal, low-load and peak scenarios
- Mark crusher, pump and compressor schedules
- Model dry season, wet season and expansion separately
02
Use fuel data for the proposed model
Fuel litres per hour vary with engine, displacement, emissions configuration and load. Cite the specific bid model and data revision; without it, the result remains a planning range rather than a guarantee.
- Match the engine and genset configuration
- Use the relevant load points instead of full-load data only
- Record fuel, ambient and test conditions
- Separate estimates from guaranteed values
03
Accumulate hourly use into monthly and annual demand
Multiply hours in each operating block by fuel use at that load, then combine production days, maintenance days and seasonal scenarios. Show base, low-output and high-output cases.
- State daily, monthly and annual operating hours
- Include planned service and expected outages
- Keep production assumptions adjustable
- Reconcile the model with actual fuel and energy monthly
04
Calculate autonomy from usable tank volume
Nameplate tank volume is not all usable. Suction level, return flow, sediment space, expansion allowance and minimum level reduce available fuel.
- Separate geometric and usable volume
- Review day tank and bulk storage together
- Define high/low level and leak protection
- Confirm bunding, fire and local storage requirements
05
Set refuelling frequency from logistics risk
Average daily use supports normal delivery only. Wet-season access, supplier lead time, holidays and quality checks determine safety stock and reorder point.
- Record supplier lead time and round-trip delivery time
- Use adverse access conditions for safety days
- Define sampling, filtration and unloading procedure
- Coordinate delivery with maintenance windows
Inputs the fuel plan must retain
| Load | Hourly kW/kVA, power factor, combinations and season |
|---|---|
| Genset | Engine model, rating and litres per hour by load |
| Operation | Production days, service days, annual hours and expansion |
| Storage | Bulk tank, day tank, usable volume, levels and transfer rate |
| Logistics | Lead time, route, wet-season interruption, minimum delivery |
| Reconciliation | Fuel received, meter energy, running hours and stock variance |
Three common calculation errors
Rating multiplied by 24 hours
The plant rarely runs at full rating all day, so this distorts purchasing and hides low-load operation.
Autonomy based on nameplate tank volume
Minimum level and unusable volume make actual autonomy shorter.
Deliveries based on average daily use
The average does not cover road closure, lead-time change or abnormal demand.
Information required before review
- At least one representative hourly load profile is available
- Fuel data matches the proposed engine and genset revision
- Base, low-output, high-output and wet-season cases are separated
- Usable tank volume and level limits are confirmed
- Delivery route, lead time and minimum quantity are recorded
- Monthly fuel-to-energy reconciliation is planned