The Weld Fab Welding & Fabrication Planning Desk

SHEET TWF·T-02 REV 2026-08-20 METHOD M.2026-08-20.1

Welding generator size check

Sums the welding and auxiliary loads you enter in kVA, models the worst single sequential start from entered multipliers and adds your planning margin — a planning estimate from nameplate data, not an electrical installation design.

Classification Planning estimate

InputsT-02
F-01 Generator siting

A combustion generator indoors, in an enclosed or restricted space or in a trench stops this estimate.

F-02 Rating basis

Load figures must come from the nameplate or manufacturer data before a record can be issued.

F-03 Load 1
F-03

Optional — names this row on the issued record.

F-03 Rating entry

Enter apparent power directly, or active power with its power factor.

F-03 Nameplate
kVA

Nameplate apparent power, greater than 0.

F-03 Nameplate

Manufacturer or user-supplied figure of at least 1, recorded as entered data and never inferred. Leave empty for a running-only load.

F-04
%

Added on top of the worst modelled figure; 20 is the worked-example margin.

JavaScript is off in this browser, so no live record can be issued. The worked example below walks the full method with real figures, and the blank card on this page prints as a worksheet.

R-GEN-nnn

Welding generator size check

Awaiting inputs — enter values and issue a record. Empty slots below print as a blank worksheet.

F-01Generator siting
F-02Rating basis
F-03Loads
F-04Planning margin
RECORD VOID — inputs changed since issue. Recalculate to issue a new record.

Worked example

STATIC — not a live result

A 1.6 kW welding set at power factor 0.9 with an entered 2.5× starting multiplier, plus a 0.8 kW grinder at power factor 0.8 already running, with a 20% planning margin: running total ≈ 2.7778 kVA, worst start peak ≈ 5.4444 kVA, planned figure ≈ 6.5333 kVA.

R-GEN-EX

Welding generator size check

Planning estimate

Plan around 6.53 kVA

F-01Generator sitingOpen air, outdoors
F-02Rating basisNameplate / manufacturer data
F-03.1Load 1 · Welding set1.6 kW @ PF 0.9 · start ×2.5
F-03.2Load 2 · Grinder0.8 kW @ PF 0.8
F-04Planning margin20 %
R-01Running total2.7778 kVA
R-02Peak — start of Welding set5.4444 kVA
R-03Planned figure (+20% margin)6.5333 kVA

Planning support only — verify against nameplate/manufacturer data.

RECORD VOID — inputs changed since issue. Recalculate to issue a new record.

Method

M.2026-08-20.1

Each load enters apparent power directly, or active power with a power factor over 0 and at most 1, in which case kVA = kW ÷ PF. An optional starting multiplier of at least 1 may be entered per load; it is treated as entered data, never inferred.

  • running kVA = Σ load kVA
  • start peak = starting load kVA × multiplier + Σ other running kVA — modelled one sequential start at a time, for every load with a multiplier
  • peak kVA = max(running total, every start peak)
  • planned kVA = peak × (1 + margin ÷ 100)

Worked figures: 1.6 kW ÷ 0.9 = 1.7778 kVA and 0.8 kW ÷ 0.8 = 1 kVA give a running total of 2.7778 kVA; starting the welding set at 2.5× while the grinder runs gives 1.7778 × 2.5 + 1 = 5.4444 kVA; a 20% margin lands the planned figure at 6.5333 kVA.

Up to eight load rows are modelled. The add and remove row controls need JavaScript; without it, the single rendered row still documents every field the record reads.

Limits & stop conditions

T-02
  • STOP — a combustion generator indoors, in an enclosed or restricted space, or in a trench ends the estimate; re-plan the siting in open air per the manufacturer’s instructions, or have a competent person assess the installation before any generator runs.
  • HOLD — an empty load list, missing or non-finite values, unresolved siting, or a rating basis other than nameplate/manufacturer data keeps the record unissued.
  • Start behaviour is modelled only from the multipliers you entered, one start at a time — verify starting demand against the manufacturer’s data before selecting anything.
  • Welding sets can present a very different demand while striking an arc than at idle; the nameplate and manufacturer documentation govern.
  • The estimate maps to no product and carries no commercial link in this release.

Source register

  1. S1 Welding Health and Safety Executive (HSE) updated 2025-01-14 · retrieved 2026-08-19
Bench Awaiting values