Compressed Air Leak Cost Calculator

Inputs

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Use measured leak flow when you have ultrasonic survey data; use orifice mode for a first-pass hole-size estimate.
Equivalent round leak diameter used for compressible-air orifice flow.
in
Gauge pressure upstream of the leak.
psi
Gauge pressure downstream of the leak. Use zero for leakage to atmosphere.
psi
Air temperature used in the ideal-gas orifice-flow estimate.
C
Orifice discharge coefficient. Sharp, irregular leaks can differ from this screening value.
Input power per delivered SCFM at the operating pressure. Use measured compressor data when available.
kW/SCFM
User-entered electricity cost. This is not a live utility-rate lookup.
$/kWh
Hours per year the compressor system is pressurized.
h/yr
Percent of operating hours that this leak is present.
%
Labor/parts estimate used only for simple payback.
$

Results

Default result
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Estimated leak flow (Q_leak)
4.937 SCFM
Caution

Choked orifice flow; downstream/upstream absolute pressure ratio 0.128.

Also computed

Wasted compressor input (P_waste) Caution 0.8887 kW

Leak SCFM multiplied by entered compressor specific power.

Annual wasted energy (E_year) 7,785 kWh/yr

Annual leak cost (Cost_year) Caution 934.20 $/yr

Annual kWh multiplied by entered electricity rate.

Monthly leak cost 77.85 $/mo

Daily leak cost 2.56 $/day

Repair payback 78.1 days

Repair cost divided by annual leak cost.

Compressed air leak cost previewLeak flow to annual energy costFree-air leakage x compressor specific power x operating hours x electric rate.estimated leak4.9 SCFMcompressor input0.89 kWannual energy7785 kWh$934/yr
Method notes 3 notes
  • Orifice mode uses ideal-gas compressible flow for dry air and switches to choked flow below the critical pressure ratio.
  • Cost uses entered compressor specific power in kW/SCFM. For best results, use measured package kW divided by delivered SCFM at the same pressure and control mode.
  • Electricity rate is user-entered. This is not a live utility tariff, demand-charge model, compressor control simulation, leak-survey report or repair quote.

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