Formula & worked example
For choked flow: m=Cd·A·P0·sqrt(γ/(RT))·(2/(γ+1))^((γ+1)/(2(γ−1))).
A small leak at plant pressure can waste thousands of cubic metres of free air each year, so diameter and pressure both matter.
Plant engineering calculator · Updated Sep 17, 2026
Compressed Air Leak Calculator — Orifice Flow, Annual Air Loss & Energy Cost
Estimate sonic-orifice compressed-air leakage, annual free-air loss and electricity cost from hole diameter, upstream pressure, temperature, compressor specific power and operating hours.
Inputs
Live engineering result
Leak mass flow 0.0086174453 kg/s
Approx. free-air leak 0.4294408 m³/min
Annual free-air loss 154,598.69 m³/year
Annual electricity 18,036.513 kWh
Annual energy cost 2,164.3816
Assumptions & limits
- Uses ideal-gas choked-flow screening when downstream/upstream pressure ratio is below critical.
- Leak geometry and discharge coefficient affect actual flow; ultrasonic surveys remain the field verification method.
Frequently asked questions
What does this Compressed Air Leak Calculator calculate?
Estimate sonic-orifice compressed-air leakage, annual free-air loss and electricity cost from hole diameter, upstream pressure, temperature, compressor specific power and operating hours.
Can I use the result for equipment selection?
Use the result as an engineering screening and cross-check. Confirm final selections against manufacturer performance data, design conditions, applicable standards and local code.
Why does MAXScanner show assumptions?
Plant calculations can move materially with pressure, temperature, fluid properties, diversity and operating conditions. Visible assumptions make the result auditable.