Compressed Air Leak Cost Calculator

Annual cost of compressed air leaks from audit data.

Number of leaks detected

Average leak size (CFM)

System pressure (psig)

Electricity rate ($/kWh)

Operating hours/year

Tab to move between fields

Annual leak cost ($)

$2,984.00

≈ 3 smartphones

Total leak flow (CFM)30

Wasted compressor power (kW)4.97

Cost per leak per year ($)$298.40

Annual CO₂ waste (lbs)25,513

Leak Percentage Estimate100%

How to Use This Calculator

Enter the system operating pressure in PSI and number of leak points identified.
Set the average leak size in equivalent orifice diameter or as a percentage of system output.
Enter your electricity rate per kWh and compressor efficiency.
Input hours of operation per year.
Review annual leak cost to justify an ultrasonic leak detection and repair program.

How the result changes with Number of leaks detected

Number of leaks detected: Total number of leaks found during an ultrasonic leak audit.
Average leak size (CFM): Average air loss per leak in CFM. Small hiss ≈ 0.5–2 CFM, medium ≈ 3–5 CFM, large ≈ 10+ CFM.
System pressure (psig): Operating pressure of the compressed air system. Higher pressure increases leak flow.
Electricity rate ($/kWh): Cost of electricity per kilowatt-hour.
Operating hours/year: Hours per year the system is pressurized. 24/7 = 8,760; single shift = 2,000; two shifts = 4,000.

Annual leak cost ($): Total yearly electricity cost wasted on generating leaked air.
Total leak flow (CFM): Combined air flow lost through all detected leaks, pressure-corrected.
Wasted compressor power (kW): Electrical power the compressor uses just to supply leaked air.
Cost per leak per year ($): Average annual cost attributed to each individual leak.
Annual CO₂ waste (lbs): Estimated CO₂ emissions from wasted electricity (EPA grid average).

Identify Input Parameters
4 parameters
Number of leaks detected = 10, Average leak size (CFM) = 3, System pressure (psig) = 100, Electricity rate ($/kWh) = 0.1 = 5 input(s) provided
Calculate Annual leak cost
Annual leak cost = wastedKw * operatingHoursPerYear * electricRateKwh
2984 = $2,984
Calculate Total leak flow
Total leak flow = totalLeakCfm * pressureFactor
30 = 30
Calculate Wasted compressor power
Wasted compressor power = wastedBhp * 0.746
4.97 = 4.97