Undersize a DG set and it runs overloaded, trips under HVAC surges, and ages prematurely. Oversize it and you pay rental and fuel for capacity you never use — while light loading quietly damages the engine through wet stacking. Sizing is the one decision that determines whether site power is an asset or a recurring problem.

Start with a real load profile

List every load in the camp or facility, then separate continuous loads (lighting, refrigeration, communications) from cyclic loads (HVAC, pumps, kitchens) and high-inrush loads (motors, compressors). The generator must handle peak coincident demand plus motor starting surges — not just the arithmetic sum of nameplates.

Rules of thumb from the field

• 15–45 KVA — site offices, small crew camps, tower lighting circuits
• 62.5–125 KVA — camps of 100–300 personnel with moderate HVAC
• 125–250 KVA — 200–500 person camps; the workhorse range for oil & gas sites
• 320–500 KVA — large camps, high HVAC loads, or process facilities

Target 70–80% loading at normal demand. That leaves surge headroom while keeping the engine in its efficient, healthy operating band.

Plan N+1 for anything critical

For camps where power loss stops operations — or compromises safety systems — a standby set with automatic or manual changeover is standard practice. Two smaller sets often beat one large set: partial redundancy, better load matching across day/night cycles, and easier maintenance windows.

Do not forget the fuel logistics

A 250 KVA set at 75% load consumes roughly 40–50 litres of diesel per hour. Multiply across your fleet and duration, and fuel storage plus replenishment becomes a planning item of its own — especially at remote sites where a tanker visit takes days to arrange.

Singhal Group’s power services fleet spans 89 units from 15 KVA to 500 KVA including tower lights, with load assessment, installation, and 24/7 maintenance included. Recent deployments include Vedanta and Ray Power sites across Rajasthan.

Need help with your project site? Singhal Group has supported oil & gas, renewable energy, and infrastructure projects across India since 1982. Call +91 9571799501 or email info@singhalgroup.net for a proposal within 48 hours.