SERVICES 
Air Compressors


Cost of Air Leaks

A 1/16” leak in your compressed air system could cost you $594 annually.
(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.)


 How much do air leaks cost?
Diameter
of air leak
CFM of
air lost at 100 psig
x 60 =
cubic ft.
lost per hour
x 24 =
cubic ft.
lost per day
x 365 =
cubic ft.
lost per year
Annual cost
at $0.18 per 1,000 cu. ft. *
Annual cost
at $0.32 per 1,000 cu. ft. *
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
3/4" 934 56,040 1,344,960 490,910,400 $88,363 $157,091
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 Systems by Compressed Air Challenge. www.compressedairchallenge.org)


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 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.