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Blower System Operating Cost Calculator

Stop! Is that a blower, or is it really a fan?
In common everyday language many people frequently interchange the terms "fan" and "blower". Indeed, even the WW Grainger catalog has pages of fans they call blowers. But to the process engineer, the term blower has a special meaning. A blower is a very high pressure fan that can generate over 12- 20 inches of water gauge ("w.g.) pressure. Some multi-stage centrifugal blowers can generate well over 200"w.g. For instance, a machine that generates 120" w.g. pressure can overcome the pressure of a tank of water ten feet deep, in order to bubble air up from the bottom for mixing and aeration. If your machine is not this type of high pressure blower, go to the fan page.

Stop! Is your blower positive displacement?
Positive displacement blowers can generate even higher pressure, 15 - 30 pounds per square inch (psi), or higher. If your blower is a positive displacement blower, some items in the checklist below may not apply or may be misleading for your application. Positive displacement blowers usually can be identified easily by their weighted pressure relief device, that often looks like a stack of giant washers only they are around a pipe instead of a bolt. Positive displacement blowers are fundamentally different from centrifugal blowers, and will behave (and should be treated), very differently.

Use the Blower System operating cost calculator to estimate the energy cost of any Industrial or commercial three-phase blower. Assuming that the motor is 75% loaded is usually fine for a quick estimate of blower energy usage. If a more accurate estimate is desired, have a trained technician connect a portable meter that reads out true kW, and put that in instead of estimating part load. Measuring amps alone is not a good estimating procedure for lightly loaded blowers.

If you do not have a true power meter or a meter that will give you power factor, ask your electric utility if they can help. Have their trained technician connect it using the proper safety equipment and procedures.

Your Name  
Facility Name  
Blower system  

Blower Nameplate Information

Blower Nameplate Efficiency
Use typical efficiency for older standard efficiency, 1800 rpm, Totally Enclosed Fan Cooled (Industrial duty) blower this size. This feature works 1-200 hp only.  %

Enter nameplate efficiency   %

Blower Load estimate
Enter estimated load as a percent of full load   %

Input actual true power meter data   kW

Operating schedule
  • How many hours does the equipment operate per year? hours
  • One shift = 2,000 hours per year
  • Two Shifts = 4,000 hours per year
  • Three shifts plus weekends = 8,000 per year
  • Around the clock = 8,760 hours per year

    Average Electric cost: $ /kWh
  • Wisconsin Industrial average $0.04 /kWh
  • Wisconsin Commercial average $0.06 /kWh
  • National Average industrial $0.05 /kWh

  • To calculate your average electric cost, divide your annual electric cost by your annual kWh consumption. This gives an average or "blended" rate that includes demand and energy charges



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