Compressed air leak cost calculator
Estimate the annual energy equivalent of a leak from free-air flow, measured specific power, pressurized hours and tariff.
Result
Inputs used
- Leak flow as free air (L/min)
- 500
- Measured specific power (kW per m³/min free air)
- 7
- Pressurized hours per year
- 6000
- Energy tariff (currency/kWh)
- 0.15
| Equivalent compressor input | 3.5 kW |
|---|---|
| Annual leak energy equivalent | 21000 kWh/year |
| Annual leak cost equivalent | 3150 currency/year |
Flow must be expressed as free air at the same reference conditions as the specific-power value. This energy equivalent is not guaranteed metered savings: compressor unloading, sequencing and pressure control determine realization.
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Formula and worked example
Equivalent compressor input kW = leak free-air flow in L/min / 1,000 × specific power in kW per m³/min. Multiply by pressurized hours and the energy tariff for the annual cost equivalent.
A leak of 500 L/min free air and specific power of 7 kW per m³/min gives 3.5 kW. At 6,000 pressurized hours/year and 0.15 currency/kWh, the equivalent is 21,000 kWh or 3,150 currency/year.
The reference conditions matter
Use free-air flow rather than pipe-volume flow at line pressure. Match the reference temperature and pressure used for flow and compressor performance. Specific power should come from measurements or applicable compressor data at the operating pressure.
The result is an energy equivalent. Actual electrical savings depend on compressor staging, unload power, controls and whether leak repair allows a compressor to slow or stop. Verify meter and pressure trends after repairs. See plant energy management for the wider measurement boundary.
Frequently asked questions
Can the tool estimate leak flow from a hole diameter?
No. It needs a measured or independently estimated free-air flow. Diameter alone leaves pressure, geometry and discharge assumptions unresolved.
Why use pressurized hours?
Air can leak whenever the affected section remains pressurized, including non-production periods.
Reference
U.S. Department of Energy: cost of compressed air explains why operating duty and compressor behavior belong in the energy assessment.
Go deeper
Cite this page: Compressed air leak cost calculator
, Shopfloor. https://shopfloor.space/tools/compressed-air-leak-calculator/