You do not always need a service call to know that something may be wrong with your compressed air system.
These free tools from Pye-Barker Engineered Solutions can help you put a number on compressed air waste, identify dryer and filtration risks, and start a more productive conversation with your maintenance team, management, or equipment supplier.
Use the calculators to get a fast, directional assessment based on your actual operating conditions. No sales presentation. No guessing. Just practical information you can use to decide what deserves a closer look.
A compressed air leak may not look serious, but it runs every hour your system is operating. One leak becomes several, compressors work harder to maintain pressure, and the wasted electricity quietly shows up on your utility bill.
The Air Loss & Leak Cost Calculator helps you turn that invisible waste into an estimated dollar amount.
Use the calculator to:
The result can help you decide whether fixing a few leaks, lowering system pressure, or scheduling a complete leak-detection survey deserves priority.
Stop treating leaks like background noise. See what they may be costing your plant.
Wet compressed air can contribute to rusty piping, damaged pneumatic equipment, clogged or deteriorating filters, valve problems, and product-quality issues.
Dryer nameplate capacity alone does not tell the whole story. Peak air demand, inlet temperature, humidity, filtration condition, pressure drop, drain performance, and maintenance history can all affect how well a dryer performs in actual plant conditions—especially during hot, humid Southeastern weather.
The Dryer & Filtration Risk Checker reviews:
After answering a few questions, you will receive a directional moisture-risk score that can help you determine whether the problem may involve dryer capacity, filtration, drainage, maintenance, or changing operating conditions.
Do not wait for water in the lines to prove there is a problem. Check your dryer risk now.
These tools are designed to help you recognize opportunities and warning signs. They do not replace onsite testing, correction-factor calculations, air-quality requirements, or a complete compressed air system review.
When the results indicate a concern, Pye-Barker Engineered Solutions can help investigate the system, verify actual operating conditions, and recommend the next practical step.
Learn how to use our compressed air leak-cost and dryer-risk tools,
understand the results, and decide when your system needs a closer review.
Yes. Both tools are free and are designed to help plant managers,
engineers, maintenance teams, and equipment buyers perform a quick
first assessment of their compressed air systems.
No. The calculators use practical operating information such as
system pressure, leak size, dryer capacity, airflow, temperature,
humidity, and equipment condition. Enter the best information you
have, and the tool will provide a directional result.
The results are estimates based on the information entered. They
are useful for identifying possible waste, comparing operating
conditions, and deciding whether a system deserves further
investigation.
Actual performance can be affected by equipment condition,
operating schedules, piping layout, pressure variations, ambient
conditions, and measurement accuracy.
No. These calculators are intended to be a starting point. An
onsite assessment can verify actual airflow, pressure, temperature,
dew point, leakage, pressure drop, dryer performance, and system
demand under real operating conditions.
For the Air Loss & Leak Cost Calculator, gather your system
pressure, approximate leak size or pressure-decay results,
compressor operating hours, electricity cost, and number of known
leaks.
For the Dryer & Filtration Risk Checker, gather peak compressed
air demand, dryer type and rated capacity, inlet temperature,
ambient humidity, filter pressure drop, drain condition, and any
downstream moisture symptoms.
Compressed air leaks consume energy without contributing to
production. They can also cause compressors to run longer, make it
harder to maintain system pressure, and reduce available air at the
point of use.
The calculator converts estimated air loss into an operating cost,
making it easier to prioritize repairs and support a
leak-detection program.
Yes. A small leak may waste air during every hour the system is
operating. Most plants also have multiple leaks spread across
piping, hoses, fittings, valves, filters, regulators, and production
equipment.
The total leakage load is usually more important than any single
leak viewed by itself.
The result estimates the volume of compressed air being lost and
the possible cost of generating that air.
You can use the estimate to prioritize repairs, compare repair
costs with potential savings, support an energy-saving project,
establish a baseline before a leak survey, or explain the
opportunity to plant management.
A dryer should be evaluated using actual operating conditions, not
only its nameplate capacity.
Airflow, inlet temperature, system pressure, ambient humidity,
filtration, drain performance, pressure drop, and required pressure
dew point can all affect dryer performance.
Common warning signs include:
These symptoms do not always mean the dryer is too small. The cause
may also involve filters, drains, maintenance, piping, inlet
temperature, or changing air demand.
A compressed air system draws moisture from the surrounding air.
Higher humidity increases the amount of moisture entering the
system, while higher inlet temperatures increase the amount of
water vapor the air can carry.
This is especially important in Georgia and Florida, where hot and
humid conditions can place additional demand on compressed air
treatment equipment.
An undersized dryer may struggle to maintain the required pressure
dew point during periods of high demand or difficult ambient
conditions.
Moisture may then reach downstream piping and equipment,
contributing to corrosion, lubricant washout, valve problems,
increased maintenance, and possible product-quality issues.
The tool can identify possible capacity and moisture-management
risks, but final dryer selection requires additional information.
A proper recommendation should consider required air quality,
pressure dew point, airflow variation, inlet conditions, system
pressure, filtration, pressure drop, drainage, redundancy, and the
needs of the production process.
First, confirm that the information entered reflects your plant's
actual operating conditions. Then use the results to guide a
maintenance inspection, leak survey, dryer evaluation, energy
assessment, or broader compressed air system review.
Pye-Barker Engineered Solutions can help verify the findings and
recommend a practical next step. Visit
pyebarker.com for compressed
air equipment, engineering, service, and system support in Georgia
and Florida.
