# Compressed Air Leak Cost and CO2 Calculator

> Source: https://netray.co/tools/compressed-air-leak-cost-and-co2-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Estimate how much air, electricity, money and carbon your plant's air leaks waste each year.

## Category

ehs-workforce

## Industry

Manufacturing

## Audience

- Facilities manager
- Sustainability lead
- Plant manager

## Tool

**Kind:** calculator

**Currency:** $

**Inputs:**

#### Typical leak size at 100 psig

**Key:** leak_cfm_each

**Type:** select

**Default:** 1.6

**Options:**

##### 1/64 inch orifice (about 0.4 cfm)

**Value:** 0.4

##### 1/32 inch orifice (about 1.6 cfm)

**Value:** 1.6

##### 1/16 inch orifice (about 6.3 cfm)

**Value:** 6.3

##### 1/8 inch orifice (about 25 cfm)

**Value:** 25

**Help:** Approximate flow through a sharp orifice at 100 psig, the form used in many compressed air guides.

#### Number of leaks found

**Key:** leaks

**Type:** number

**Default:** 40

**Min:** 0

**Step:** 1

**Unit:** leaks

#### Operating hours per year

**Key:** hours

**Type:** number

**Default:** 6000

**Min:** 0

**Step:** 100

**Unit:** h

#### Compressor specific power

**Key:** kw_per_cfm

**Type:** number

**Default:** 0.19

**Min:** 0.1

**Step:** 0.01

**Unit:** kW per cfm

**Help:** About 18 to 22 kW per 100 cfm is typical for a loaded rotary screw compressor.

#### Electricity price

**Key:** tariff

**Type:** number

**Default:** 0.11

**Min:** 0

**Step:** 0.01

**Unit:** $/kWh

#### Grid emission factor

**Key:** grid

**Type:** number

**Default:** 0.4

**Min:** 0

**Step:** 0.01

**Unit:** kg CO2e/kWh

**Help:** Use your location-based factor.

#### Share of leakage repaired

**Key:** fix_pct

**Type:** slider

**Default:** 80

**Min:** 0

**Max:** 100

**Step:** 5

**Unit:** %

**Outputs:**

#### Total leak flow

**Key:** lost_cfm

**Expr:** leak_cfm_each * leaks

**Format:** decimal

**Description:** Combined flow lost through all leaks in cfm.

#### Wasted electricity per year

**Key:** kwh

**Expr:** lost_cfm * kw_per_cfm * hours

**Format:** integer

#### Annual cost of leaks

**Key:** cost

**Expr:** kwh * tariff

**Format:** currency

**Primary:** true

#### Annual CO2e from leaks

**Key:** co2

**Expr:** kwh * grid / 1000

**Format:** decimal

**Description:** Tonnes of CO2e.

**Primary:** true

#### Savings if repaired

**Key:** saving

**Expr:** cost * fix_pct / 100

**Format:** currency

#### CO2e avoided if repaired

**Key:** co2_saved

**Expr:** co2 * fix_pct / 100

**Format:** decimal

**Chart:**

#### Annual cost of leaks vs number of leaks

**Type:** line

**X:** leaks

**From:** 0

**To:** 100

**Steps:** 20

**Series:**

- cost

**Disclaimer:** Estimates only. Real flow depends on pressure, leak geometry and compressor control. Use an ultrasonic leak survey and a flow meter for audit-grade figures.

## Content

**Intro:** Leaks commonly waste a large share of a plant's compressed air output, and every cubic foot costs electricity. This calculator turns a leak survey count into energy, money and CO2e so the case for repair is clear.

**Sections:**

#### How to use the calculator

**Body:** Walk the plant with an ultrasonic leak detector and tag each leak. Group them by approximate size and run the calculator once per group, or use an average. Enter your operating hours, your compressor's specific power and your electricity price. The result shows total lost flow, the electricity it consumes, the annual cost and the carbon emissions. Then set the share you expect to repair to see the savings.

**Bullets:**

- Use hours the compressors actually run loaded
- Check specific power on the compressor data sheet or from a power log
- Use a market or location based emission factor consistently

#### The formula

**Body:** Lost flow in cfm is the leak flow times the number of leaks. Electricity is lost flow times specific power in kW per cfm times operating hours. Cost is kWh times tariff, and CO2e in tonnes is kWh times the grid factor divided by 1,000. Orifice flow rises roughly with the square of the diameter, so one large leak can outweigh many small ones.

#### Reading the result

**Body:** If your total lost flow is a large fraction of compressor capacity, you may be running an extra compressor just to feed leaks. After repairs, check whether a compressor can be switched off or the pressure setpoint lowered, which saves further energy. Repeat the survey every six to twelve months, since leaks return.

#### Common mistakes

**Body:** Estimating leak size by eye, mixing metric and imperial units, and counting savings without turning a compressor off. Savings only appear on the bill when the supply side changes.

**Cta:** If you want leak survey results, energy meter data and work orders tied together in your ERP, we can help set that up.

**Faq:**

#### What is a typical share of air lost to leaks?

**Answer:** Guides from energy agencies commonly cite 20 to 30 percent of compressor output in poorly maintained systems, and much less in well managed plants. Your own survey and flow measurement will give the real figure for your site.

#### How do I find the specific power of my compressor?

**Answer:** Look at the data sheet for kW per 100 cfm at your operating pressure, or divide measured power by measured flow. Part load operation raises the figure, so use a measured value when you can.

#### Does lowering pressure reduce leak flow?

**Answer:** Yes. Leak flow falls with pressure, and compressor power falls too, roughly one percent per 2 psi for many machines. Do not drop pressure below what the tools need, and repair leaks first.

#### Can I use this for scope 2 reporting?

**Answer:** It gives an estimate of the electricity wasted, which is already part of your scope 2 total. Use it to show the saving from a project, not as an extra line in the inventory.

## Search terms

compressed air leak cost calculator, air leak cost per year, compressed air leak CFM calculator, compressed air energy savings, compressed air leak CO2 emissions, cost of compressed air leaks, air leak audit calculator

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