🕳️ leakage estimator
Leakage Calculator — User Guide & Disclaimer
What This Tool Does
The Leakage Estimator calculates the percentage of compressed air being lost through system leaks, based on a simple timed load/unload test. It also estimates the actual volume of air leaking per unit time.
How to Use It
Step 1 — Isolate the System. Shut off all air-consuming equipment. No production, no intentional demand. The compressor must be the only thing connected to the system.
Step 2 — Let Pressure Stabilise. Allow the system to reach normal operating pressure before you begin timing.
Step 3 — Time the Load Cycle (T) Start your stopwatch when the compressor kicks on (loads). Stop it when the compressor unloads. Record this as T (seconds).
Step 4 — Time the Unload Cycle (t) Immediately start timing again while the compressor is unloaded/idling. Stop when it loads again. Record this as t (seconds).
Step 5 — Enter FAD Enter your compressor’s Free Air Delivery (FAD) — its rated output capacity — in any consistent volumetric unit (e.g. m³/min, CFM, L/s).
Step 6 — Read the Results
- Leakage % — the share of compressor capacity wasted on leaks
- System Leakage — actual leakage flow in the same unit as your FAD
Interpreting Results
| Leakage % | Condition |
|---|---|
| < 10% | Good — acceptable leakage |
| 10% – 20% | Fair — improvement recommended |
| 20% – 30% | Poor — remediation needed |
| > 30% | Critical — significant energy waste |
Tips for Better Accuracy
- Repeat the test 3–5 times and average the results
- Perform the test during a production shutdown, not during active shifts
- Use a digital stopwatch for precise timing
- Ensure only one compressor is running during the test
- Confirm pressure is stable and at the normal operating level before testing
Disclaimer
This leakage estimator is provided for indicative and diagnostic purposes only.
Results produced by this tool are based on a simplified mathematical model and are intended as a screening estimate only. They do not constitute a certified measurement, a formal energy audit, or a compliance assessment under ISO 11011 or any other standard.
The accuracy of results depends entirely on test conditions. The presence of any unintended air demand during testing, pressure instability, multiple compressors, or variable-speed drive operation may affect the validity of results.
This tool is not a substitute for a full, instrumented compressed air audit conducted by a qualified engineer. It should not be used as the basis for energy billing, regulatory submissions, contractual claims, or capital investment decisions without independent verification.
No warranty, expressed or implied, is made regarding the accuracy, completeness, or fitness for purpose of this tool. The publisher accepts no liability for any loss or damage arising from reliance on its output.
Always consult a certified compressed air specialist for critical assessments.