Utility Air Leakage

Don't bother. Just fix your leaks.

Do the worst ones first.

I am not aware of any single formula for calculating leaks because it depends on so many variables (age of pipes and connections, corrosion, joint sealing methods, earth movement, etc, etc), there are rough guidelines and estimates however but they are very subjective and application specific.

The best method is to go around and check for obvious leakages and fix them, alternatively you could try an internet search of "compressed air leakage" or "compressed air leakage calculator" for more information on the subject (if you need to quantify potential savings for your management for example).

The easiest way to get an overall view of your estimated system losses is to calculate or estimate your air usage on site and compare it to your air generated. To simplify large site estimations check air usage VS generation for sections of the plant (back to each individual air compressor ideally). There are formulas and air compressor manufacturer literature to convert air generated into energy used (and hence potential money savings for justifying site maintenance).

The more accurate you can be the better, but again it is only a rough guide to your losses. Ideally concentrate on parts of the plant you know (or can show) have the greatest losses (and hence greatest benefit for maintenance) and work from there.

Less time calculating losses and more time fixing will always result in better efficiency.

Fix it first them worry about what you have lost and how you are going to explain it. If you calculate and then fix it there is always more explaining to do.

BAB.

What pressure/ volume rate is your requirement? What uses? How many uses/ branch offs? Do you know how much percent of air is leaked? Do you have driers too?

what formula or guidelines any one can give you for calculating the extra working hours or extra power consumption? simply it is directly proportional to the quantum of leakages.