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Lets Talk About Compressed Air Leakage
Did you know that leakage in compressed air distribution systems is common? In fact, in
most compressed air systems, losses due to leakage exceed 30%. Very few users realize
how costly this leakage can be.
What is the real cost of compressed air leakage?
Take for example a plant which is losing 40% of its useful system capacity or 1,600
SCFM at 100 psig.
After the leaks have been repaired, the leakage rate is reduced to 600 SCFM or 15% of
the useful system capacity, producing savings of more then one million kWh, or $43,000
annually.
Where does leakage generally occur?
Leakage can occur at a number of points in a compressed air distribution system. Some
of these are listed below:
1.
2.
3.
4.
5.
6.

Branch line connection

Automatic drain trap
Desiccant filter
Filter/regulator/lubricator assembly
Filter/regulator/coalescent filter assembly
Regulator

7.
8.
9.
10.
11.
12.

Rubber hose
Quick coupler
Isolating valve
Control valve
Coil hose
Pneumatic cylinder

Leakage in a compressed air system can be found and fixed fast and easy
A leakage detection test closely examined the air distribution systems to locate leaks and
familiarize plant personnel responsible for compressed air systems operation and
maintenance with leakage detection techniques. This test is easily carried out by your
staff using an ultrasonic leak detector. An ultrasonic leak detector is the quickest easiest
and most cost-efficient tool for finding compressed air leaks.
Where can I get more information about compressed air leak detection?
SDT North America Inc is dedicated to providing energy and cost saving solutions to
North American Industry. Call today to request free information on compressed air leak
surveys and energy saving ideas for maintenance. 1-800-667-LEAK (5325)

1-800-667-5325 Toll Free Hotline

www.sdtnorthamerica.com
Compute Your Energy Savings Potential
How much money can you save by detecting - and correcting - air leaks? Use the chart
below to determine the leak potential. The charts show the amount of air you can expect to
lose through leaks of various sizes at known plant operating pressures. Calculate how
much energy would be loose on a weekly, monthly, or annual basis. Multiply that by the
cost of electricity to determine the cost savings.
Free air (scfm) flow through orifices
Orifice Diameter

PSI

5
6
7
9
12
15
20
25
30
35
40
45
50
60
70
80
90
100
120
130

1/64
.062
.068
.073
.083
.095
.105
.123
.140
.158
.176
.194
.211
.229
.264
.300
.335
.370
.406
.476
.494

1/32
.249
.272
.293
.331
.379
.420
.491
.562
.633
.703
.774
.845
.916
1.06
1.20
1.34
1.48
1.62
1.19
1.98

1/16
.99
1.09
1.17
1.32
1.52
1.68
1.96
2.5
2.53
2.81
3.10
3.38
3.66
4.23
4.79
5.36
5.92
6.49
7.62
7.90

1/8
3.97
4.34
4.68
5.30
6.07
6.72
7.86
8.98
10.1
11.3
12.4
13.5
14.7
16.9
19.2
21.4
23.7
26.0
30.5
31.6

1/4
15.9
17.4
18.7
21.2
24.3
26.9
31.4
35.9
40.5
45.0
49.6
54.1
58.6
67.9
76.7
85.7
94.8
104
122
126

3/8
35.7
39.1
42.2
47.7
54.6
60.5
70.7
80.9
91.1
101
112
122
132
152
173
193
213
234
274
284

1/2
63.5
69.5
75.0
84.7
97.0
108
126
144
162
180
198
216
235
271
307
343
379
415
488
506

5/8
99
109
117
132
152
168
196
225
253
281
310
338
366
423
479
536
592
649
762
790

3/4
143
156
168
191
218
242
283
323
365
405
446
487
528
609
609
771
853
394
1097
1138

7/8
195
278
230
260
297
329
385
385
496
551
607
662
718
828
939
1050
1161
1272
1494
1549

Situation: Hole of 1/16 inch in diameter in a compressed air line, pressure of 90 PSIG.
The air escapes at the rate of 5.9 CFM
Cost of a Leak: The resultant leak loss can be viewed as the equivalent of 1.2 HP. If a
facility is on line all year, the cost of the leak can be tabulated, based on the electrical
costs of:
5 cents KW/Hour, at .745 KW/Hour x 1.2 HP=
.89 KW x 8,760 Hour/Year=
7,839 KW Yr x 5 cents =
Raw power cost of $391.95 per year

1-800-667-5325 Toll Free Hotline