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Compressed air leak survey log
A compressed air leak survey is a walk through the plant, usually with an ultrasonic detector, to find leaks, tag them, size them and fix them. Compressed air is expensive to make, and a leak costs money in every hour the compressor runs, including nights and weekends. This template covers the whole job: a walk sheet to log each leak, tags to print and attach, cost inputs and a size table that turn a leak into a flow and an annual cost, and a tracker with a fix-by date, a fixed date and a verified check. The Excel version works out the cost of each leak from your hours, your compressor's specific power and your electricity price, and summarises cost found and cost saved by area and size. The PDF has the walk sheet, the tags, the inputs and a worked example.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for survey date, walked by, area, detector and plant running above a table with columns for tag number, area, location, type, size, measured flow, fix by, fixed on, fixed by and verified.Survey walk sheetPrintable leak tags with stubSize class to flow tableAnnual cost per leakFix-by, fixed and verifiedCost found and saved
When to use it
When to use a leak survey log
- For a leak walk on a weekend or a quiet shift, so that every leak found is recorded, tagged and given an owner.
- To show what leaks cost with a figure for each one, so that maintenance can fix the costly ones first.
- To track the fixes, the dates and the cost saved, and to repeat the walk and compare.
- As part of an energy programme or a compressed air review, to feed an energy loss list.
- Not for measuring compressor efficiency or sizing a compressor. This logs and costs leaks only.
How to fill it in
- 1
Set the cost inputs
Enter the hours the compressor runs in a year, its specific power in kW per cfm and your electricity price. Check the flow given for each size class against your own measurement or your supplier's orifice table.
- 2
Walk when it is quiet
Go at a break or on a weekend with the compressor running and the machines idle. Use an ultrasonic detector, or soapy water on joints. Never put a hand on a high pressure leak.
- 3
Tag every leak where you find it
Print the tags, cut them out and attach one to each leak, with the number, the area, the place on the equipment and the size. Write the same number on the walk sheet.
- 4
Log and size
One row per leak: area, location, type (fitting, hose, coupling, drain, seal, regulator, valve), size class and a fix-by date. The sheet works out the flow and the annual cost.
- 5
Fix the biggest first
Rank by cost, not by how easy the leak is to reach. When one is fixed, enter the date and who fixed it. Another person checks with the detector and marks it verified.
- 6
Repeat the walk
Leaks come back. Walk again on a schedule, compare the cost found, and find out why a leak started: a worn hose, a missing clamp or an open drain.
A filled-in example
Illustrative, not a benchmarkAn invented plant walks its five areas on a Saturday and finds 35 leaks: 3 large, 12 medium and 20 small.
- At 6,000 operating hours a year, 0.185 kW per cfm and $0.12 per kWh, one cfm of leakage costs about $133 a year.
- The 35 leaks add up to 140 cfm and $18,648 a year, which the walk reports as about $18,600.
- Ten days later, 21 of the 35 leaks (60%) are fixed. The large leaks and ten of the medium ones were done first.
- Those 21 fixes already save $15,718 a year, 84% of the cost found. The 14 open leaks are small or medium.
Fixing the leaks in order of cost, not in the order they were found, is why 60% of the leaks account for most of the money. The tracker shows the other 14 and their fix-by dates.
Common mistakes
Walking a noisy plant
Leaks are hard to hear over running machines. Walk when the plant is quiet, with the compressor loaded, or use an ultrasonic detector that filters the noise.
Tagging but not logging
A tag with no entry in the log means nobody sees the total or the age of the leak. Every tag has a row.
Fixing the easy ones first
A hissing quick-connect at head height gets fixed in a minute, but the large leak behind a guard saves more. Work down by cost.
No verification
A leak marked fixed by the person who fixed it is not checked. A second look with the detector catches the leak that was only moved.
Assuming leaks stay fixed
Hoses wear, couplings loosen and drains get left open. A one-off walk saves money for a few months; a repeated walk keeps it.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite a professional maintenance tag becomes a work order with photos, location and equipment ID attached, rules route it to the right technician and set its due date by priority, and the technician records the fix and the parts used when closing it.
See it in a 45-minute demoFAQ
Compressed air leak survey log: common questions
A compressed air leak survey is a walk through a plant to find, tag, size and cost compressed air leaks, then fix them. It is usually done with an ultrasonic detector on a quiet shift, with the compressor running and the machines idle.
Multiply the leak's flow in cfm by the compressor's specific power in kW per cfm, by the hours a year it runs, by your price per kWh. The result is the yearly electricity cost of the leak. The flow is the uncertain part, so measure it when the decision matters.
Rate it small, medium or large by what you see and hear, and give each class a flow from your own measurement or your compressor supplier's orifice table. The starting flows in this template are rough assumptions to replace.
There is no fixed rule. Many plants repeat it every few months to once a year, and after major work on the air system. If the cost found keeps falling, you can lengthen the gap; if it keeps rising, find the cause.
An ultrasonic leak detector is the usual tool because it picks up the high-frequency sound of a leak over background noise. Soapy water on joints also works. Walk when the plant is quiet and check couplings, hoses, drains, regulators and cylinder fittings.
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- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Hazard prediction worksheetA pre-task worksheet: score what could go wrong at each step of a job, add a countermeasure and score again.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.