Maintenance · Free Template
Compressed Air Leak Survey Record Template
Record a compressed or instrument air leak survey: each leak with its location and estimated flow, the annual energy and cost it wastes, and the repair status, with totals of losses and savings.
Excel (.xlsx)Printable PDFFilled exampleFree, no sign up
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- How to Use sheet with steps
- Template sheet, blank and ready
- Example sheet, filled in
- 168 built in formulas
- A4 landscape print setup
- Works in Excel, Google Sheets and LibreOffice
Preview of the Filled Example
This is the Example sheet from the download, so you can see exactly how the completed compressed air leak survey record looks.
Area surveyedBoiler house and utilities
Specific power (kW per Nm³/min)6.5
Operating hours per year8000
Electricity cost (per kWh)8
Leaks found
| No | Tag | Location / component | Size | Est. leak (Nm³/min) | Energy (kWh/yr) | Cost per year | Action | Status | Repaired on | By | Remarks |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | FV 3101 | Positioner tubing fitting | Small | 0.020 | 1,040 | 8,320 | Retighten fitting | Repaired | 23 Oct 2026 | Tech A | |
| 2 | IA header | Drain valve at header end | Large | 0.250 | 13,000 | 104,000 | Replace drain valve | Open | |||
| 3 | XV 1101 | Actuator diaphragm | Medium | 0.080 | 4,160 | 33,280 | Replace diaphragm at next shutdown | Open |
Leaks found:3 · Total leakage (Nm³/min):0.350 · Total cost per year:145,600 · Cost still open per year:137,280
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About the Compressed Air Leak Survey Record
Air leaks are invisible but expensive: plants commonly lose 10 to 30 % of their compressed air to leaks. A tagged survey with an estimated cost per leak makes it easy to justify repairs and to track the savings achieved.
How to fill in this template
- Set the compressor specific power, operating hours and electricity cost.
- Walk the system with an ultrasonic leak detector and tag each leak.
- Estimate each leak flow and enter it; energy and cost are calculated.
- Repair leaks and update the status; the remaining open cost shows the savings still available.
What the formulas do
- Energy (kWh/yr) = leak (Nm³/min) × specific power (kW per Nm³/min) × hours.
- Cost = energy × electricity price.
- Open cost = sum of cost for leaks still open.
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Frequently Asked Questions
How much does an air leak cost?
Each Nm³/min of leakage at about 6.5 kW per Nm³/min and 8000 hours uses about 52,000 kWh per year.
How are leaks found?
By sound and soapy water for large leaks, and with an ultrasonic leak detector for small ones, ideally when production is quiet.
Do instrument air leaks matter?
Yes: besides energy, leaks reduce header pressure margin and can starve positioners and actuators.
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