7/22/2017 The Cost of Air Leaks in Your System

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Cost of Air Leaks
Cost of Air Leaks
Emergency Parts & Service A 1/16” leak in your compressed air system could cost you $594 annually.
Preventative Maintenance Program (Based on 100 PSIG, $0.22 per 1000 CFM, 8,760 Hours/Year - a 1/16” diameter leak could flow as much as 6.5 cfm.)

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How much do air leaks cost?
Air Service Department

x 60 =
CFM of x 24 = x 365 = Annual cost Annual cost
Diameter cubic ft.
air lost at cubic ft. cubic ft. at $0.18 per at $0.32 per
of air leak lost per
100 psig lost per day lost per year 1,000 cu. ft. * 1,000 cu. ft. *
hour

1/32" 1.62 97.2 2,332.8 851,472 $153 $272

1/16" 6.49 389.4 9,345.6 3,411,144 $614 $1,091

1/8" 26 1,560 37,440 13,665,600 $2,459 $4,372

1/4" 104 6,240 149,760 54,662,400 $9,839 $17,491

3/8" 234 14,040 336,960 122,990,400 $22,138 $39,356

1/2" 415 24,900 597,600 218,124,000 $39,262 $69,799

Value Added
3/4" 934 56,040 1,344,960 490,910,400 $88,363 $157,091

Hydraulic 1" 1,661 99,660 2,391,840 873,021,600 $157,143 $279,366

* According to Compressed Air Challenge of the U.S. Department of Energy's Office of Industrial Technologies, the total cost of 100 psig
compressed air has been calculated to be in the general range of 18 to 32 cents per 1,000 cubic foot. (Source: Best Practices for Compressed Air
Tool and Hoist Repair Systems by Compressed Air Challenge. www.compressedairchallenge.org)

Units Converter Did You Know...

A typical plant that has not been well maintained will have a leak rate equal to 10 - 30 percent of the total
compressed air production capacity.

The easiest way to identify leaks in a compressed air system is to walk the plant and listen for them.
(Especially during non-production times.)

To estimate a plant's leak load, operate the air compressor in a load/no-load (or start/stop) mode during a
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7/22/2017 The Cost of Air Leaks in Your System
To estimate a plant's leak load, operate the air compressor in a load/no-load (or start/stop) mode during a
non-production time. Record the loaded vs. unloaded times, and compare these to the compressor's
capacity.

One of the most common leak points in plants is at “abandoned” equipment. (Equipment that has air
supplied to it while not operating.) Consider adding an automated shut off valve in the supply air line, which
closes when the machine is turned off.

Ultrasonic leak detection is the best way to find leaks in your air compressor system. An acoustic detector
can recognize high frequency air turbulence associated with leaks. An ultrasonic leak detector is available for
rent from JHF. Better yet, John Henry Foster Company can perform an Ultrasonic Leak Detection Audit that
not only detects leaks - it includes tagging and documenting all findings as well. Please contact Chad
Struckmann at 636-634-1590 to learn more.

The Difference Between Predictive Products Services John Henry Foster Co.
and Preventative Maintenance 4700 LeBourget Dr.
Hydraulic Air Compressors St. Louis, MO 63134-0820 MAP
Both are necessary to ensure the efficacy of any Pneumatic Value Added 314.427.0600
machine, but when and which are the key factors to Compressors & Tools Hydraulic
take into consideration. Industrial Automation Units Converter
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