How do you calculate hydraulic power load energy cost?

Multiply the connected load in kW by runtime in hours to get kWh, then multiply by the electricity rate. At 12 kW for 8 hours, that is 96 kWh; at $0.12/kWh the total energy cost is $11.52.

What is energy cost per unit on a TBM hydraulic system?

It is the total hydraulic energy cost divided by units processed during the runtime. In the example, $11.52 spread over 1,000 units is about $0.0115 per unit, a figure you can roll into cost-per-meter or cost-per-ring.

Should I enter rated kW or average drawn kW?

Enter the average load the pumps actually draw over the runtime. TBM hydraulics cycle hard during thrust and erection then idle, so nameplate kW will overstate energy. If you only have rated power, apply a duty-cycle factor first.

What does the hourly energy cost tell me?

It is the running burn rate of the hydraulic power pack, $1.44/hr in the example. Multiply it by planned shift hours to sanity-check a budget, or compare it against downtime to value energy saved when the machine is parked.

How does electricity rate affect the result?

Linearly. Doubling the blended rate doubles total cost and cost per unit. Underground sites often pay demand charges and time-of-use premiums, so use a blended rate that already includes those, not just the energy charge.

Why is the result called blended electricity rate?

Because a real TBM site pays energy charges, demand charges, transmission, and sometimes diesel-generated backup power. Blending them into one $/kWh figure makes the per-unit cost reflect what the project is truly billed.

Tunnel Boring & Heavy Civil Equipment calculator

Hydraulic Power Load Calculator

Hydraulic Power Load energy is the electricity a tunnel boring machine's hydraulic power pack consumes to drive thrust rams, cutterhead clamping, segment erectors, and gripper shoes. On a TBM drive, hydraulics can be one of the largest controllable energy lines, and underground power is neither cheap nor unlimited. Project engineers and plant managers use this calculation to forecast energy spend per advance, allocate cost per ring or per unit produced, and check that the surface substation can carry the load. Knowing the energy cost per unit lets you build defensible cost-per-meter estimates for civil tender bids.

What this calculator does

Estimate hydraulic power load for tunnel boring and heavy civil equipment using production-ready inputs so teams can budget energy cost, compare equipment settings, or include electricity in the quote.
Use it when hydraulic power load in tunnel boring and heavy civil equipment is up for an upgrade and you want a defensible savings story.
It computes the energy used by the hydraulic power load, its total electricity cost, the cost per unit processed, and the hourly energy cost.

Formula used

Total hydraulic power load energy cost = hydraulic power load connected load × hydraulic power load runtime × blended electricity rate
Energy cost per kWh = total energy cost ÷ units processed during runtime

Inputs explained

Hydraulic power load connected load: Use the equipment nameplate, meter data, test stand reading, or utility submeter value.
Hydraulic power load runtime: Enter the expected run, test, cure, heat, cool, or operating hours for the period.
Blended electricity rate: Use the current utility bill, energy contract, or plant finance rate including demand charges if applicable.
Units processed during runtime: Use the completed units, parts, assemblies, or tests produced during the same time period.

How to use the result

Use it when budgeting a TBM drive, allocating hydraulic energy cost across rings or excavated units, or comparing the running cost of two power-pack configurations.
It uses a single connected-load figure, so it ignores duty cycle and load variation; a pump that idles between strokes draws far less than its rated kW, which can overstate energy if you enter the nameplate rather than the average drawn load.

Current U.S. benchmarks

As of Apr 2026, industrial electricity averages 8.7 cents per kWh across the U.S. (EIA), up 5.5% from a year earlier. State averages range widely, so plants should confirm against their own tariff.
Steel mill PPI stands at 348.53 (BLS, May 2026), up 6.7% from a year earlier. New factory orders are up 2.3% year over year (Census).

Common questions

How do you calculate hydraulic power load energy cost? Multiply the connected load in kW by runtime in hours to get kWh, then multiply by the electricity rate. At 12 kW for 8 hours, that is 96 kWh; at $0.12/kWh the total energy cost is $11.52.
What is energy cost per unit on a TBM hydraulic system? It is the total hydraulic energy cost divided by units processed during the runtime. In the example, $11.52 spread over 1,000 units is about $0.0115 per unit, a figure you can roll into cost-per-meter or cost-per-ring.
Should I enter rated kW or average drawn kW? Enter the average load the pumps actually draw over the runtime. TBM hydraulics cycle hard during thrust and erection then idle, so nameplate kW will overstate energy. If you only have rated power, apply a duty-cycle factor first.
What does the hourly energy cost tell me? It is the running burn rate of the hydraulic power pack, $1.44/hr in the example. Multiply it by planned shift hours to sanity-check a budget, or compare it against downtime to value energy saved when the machine is parked.
How does electricity rate affect the result? Linearly. Doubling the blended rate doubles total cost and cost per unit. Underground sites often pay demand charges and time-of-use premiums, so use a blended rate that already includes those, not just the energy charge.

Last reviewed 2026-05-12.