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. Branch line connection
  2. Rubber hose
  3. Automatic drain trap
  4. Quick coupler
  5. Desiccant filter
  6. Isolating valve
  7. Filter/regulator/lubricator assembly
  8. Control valve
  9. Filter/regulator/coalescent filter assembly
  10. Coil hose
  11. Regulator
  12. 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).

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.


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

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