Compressed air leak load test poster

The simplest way to measure compressed air leakage is the load test from the US Department of Energy's compressed air sourcebook: with no production using air, time how long the compressor runs on load and off load over a few cycles. Leakage as a share of output is on-load time × 100 ÷ (on-load + off-load time). This poster sets out the test and works one example: three minutes on load and seven off is 30% leakage, where the DOE says a well-maintained system should lose under 5 to 10%.

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Compressed air leak load test poster — 24 x 36 in18 x 24 inA2A3LetterA4PNG 300 dpi

The words on the poster

How much air leaks?

The load test: run it with no production, before and after a leak walk.

The test

Stop every air user Nothing should need air. Keep the system pressurised.
Time the compressor Minutes on load and off load, over several cycles. Average them.
Work it out Leakage % = on-load time × 100 ÷ (on-load + off-load time).

Worked example

3 min on load
7 min off load
3 × 100 ÷ 10 = 30%

Well-maintained systems leak under 5 to 10% of output (US DOE). Find the leaks, fix them, test again.

Method and target after the US DOE compressed air sourcebook. Example figures; for load and unload compressors.

On the floor

How to use it

Putting the Compressed air leak load test poster to work

1
Run the test on a weekend or a planned stop, before and after a leak walk.
2
Post the result next to the poster, and re-test each quarter.
3
If the compressor modulates instead of loading and unloading, ask maintenance for the pressure-decay test instead.
4
Pair it with the air and water leaks poster and the free compressed air leak survey log.

Where the poster goes and how to teach with it, in the order to try them.

Which size to print

24 x 36 in or A2: a main wall or team board, read from a few metres away.
18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
Letter or A4: a clipboard, binder or handout, on any office printer.

Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.

Sources and notes

The worked figures are an example. The load test fits compressors with load and unload control; for other controls the sourcebook describes a pressure-decay method. Under 5 to 10% is the DOE's level for a well-maintained system; poorly maintained systems can lose 20 to 30%.