ES Leak Surveys: Low Commitment, High Savings
June 17, 2026
Compressed air systems are often one of the most expensive utilities in a facility, and leaks can account for a significant amount of wasted energy. A compressed air leak survey helps identify and quantify those losses so businesses can address them quickly. By finding and repairing leaks, businesses can reduce energy costs, improve system reliability, and extend the life of their compressors and equipment. Many businesses are surprised to see how much energy and money can be saved simply by fixing leaks that often go unnoticed during daily operations. They have also noted that the survey helped them to better understand and reduce both their compressed air usage and electricity consumption, which supports their internal energy efficiency goals.
When a compressed air leak survey is done efficiently, with clear next steps, financial support, and a knowledgeable expert by their side, industrial businesses are able to use the information to make their system more efficient and inform annual planning.
Simple Process with Limited Interruptions
During the survey our team will walk through a facility, on their own or with a guide from the facility and will tag leaks as they are identified. We use a specialized tool, an ultrasonic leak detector, to detect leaks that might otherwise go unnoticed, helping the facility’s teams better understand the condition of their compressed air system and identify opportunities for improvement. Our team conducts the survey while the system is operating, so it does not cause delays in production or interruptions to employees’ work.
Upon completion of the survey a detailed report is shared reporting leaks found, along with estimated savings. It is very important to us that businesses can find the leaks after we have left their facility. A combination of location information, photos of the leaks, and tags, along with a brief leak description attached near the leaking components are provided so that leaks can be found after the survey. Our team manages the data collection, analysis, and calculations, so the facility’s team does not need to spend additional time on training or take on extra workload. This helps make the process smoother and allows the facility’s team to stay focused on their daily operations.
Our approach to compressed air leak surveys is very collaborative, ensuring the facility’s team is as involved in the process as they would like to be by providing all the necessary information for their team to make the repairs and future planning decisions. We like to think of ourselves as an extension of the facility’s maintenance program: keeping an eye out for other opportunities and providing the information in a clear and easy to understand way.
Even Small Leaks Add Up
Compressed air leak surveys frequently identify leaks that the facility’s team were not aware of. Even small leaks can add up to significant energy waste when they occur across an entire system. Across the board, there are a few types of leaks that we see commonly and many of them are very straight-forward fixes. When our team reviewed the data, we saw that connection threads and hose fittings were the two biggest categories of leaks that were tagged. Both threads and fittings are pretty easy to repair if they can be isolated with shutoff valves. However, the third biggest category of leaks, seals, can be little more complex to repair depending on the facilities situation. Leaking seals generally require a replacement part to repair the component or can require a full replacement. If the maintenance staff has access to replacement parts these types of leaks are easy to repair, but if they need to order parts or the component is out of production it can take longer.
Our team is often asked how quickly the facility will see savings. Since compressed air systems typically run continuously, the energy savings from repairing leaks can start almost immediately. In our experience, some facilities have even been able to turn off an additional compressor after fixing the leaks, because that compressor had primarily been compensating for lost air from leaks in the system.
Making Surveys More Affordable
For qualified participants, the survey may be utility-sponsored, meaning the survey itself can be completed at little to no cost, and they may also be able to receive utility rebates for implementing the recommended leak repairs and efficiency improvements.
To qualify for the rebate, businesses are typically required to repair at least 50% of the identified leak volume within 60 days of receiving the repair report. Because most of the leaks are easy to repair, the facility’s teams are usually able to address many of them quickly. The more leaks repaired, the greater the potential rebate they may receive. Some businesses are initially concerned about whether they can meet that requirement. However, we focus on identifying leaks that can typically be repaired with little to no cost, such as leaks at fittings, connections, hoses, or valves. Most repairs are simple and can be completed by the facility’s maintenance team during scheduled maintenance periods without requiring capital investments. In fact, last year businesses we worked with achieved an average repair rate of about 97%.
Our team supports businesses throughout the entire process. After the business’s facility team completes the repairs, we help document the fixes, complete the utility rebate application, and submit it to the utility on their behalf. Once the application is reviewed and approved, the business receives their rebate check. This process helps businesses improve their system efficiency while maximizing available utility rebates.
Annual Leak Surveys Make a Difference
We have surveyed all types and ages of facilities. The demands placed on a system often have a direct correlation with the number of leaks we find. Longer run times and systems that run at or close to maximum capacity place greater stress on components and usually result in more frequent leaks. Generally, we do tend to see more leaks in older systems than newer systems, but that doesn’t really tell the whole story. Maintenance practices play a much bigger role in how many leaks we find over the age of a system. If a maintenance staff is working understaffed, as many are, it’s harder for them to get ahead of their repairs.
Regular surveys allow facilities to maintain system efficiency, reduce energy waste, and continue taking advantage of available utility rebates for leak repairs and improvements. Businesses can typically receive a compressed air leak survey once per year to remain eligible for utility rebate opportunities. Conducting the survey annually helps facilities identify new leaks that may develop over time as equipment ages or system changes occur. For many businesses, we schedule their next compressed air leak survey a year ahead so they can include it in their maintenance and financial planning for the following year.
Your Ally in Energy Saving
Compressed air leaks are easy to overlook because they are not always visible or audible in a busy facility. Even in facilities where maintenance teams do a great job maintaining their systems, as equipment ages or connections loosen leaks can still develop over time. Our streamlined process for compressed air leak surveys and rebate application support provides valuable insight into business’s systems and removes financial barriers. Reach out today to start or continue your energy saving journey with our team here to support you every step of the way.
Co-Written by Alexis Southerland, Andrew Guthrie, and Ezgi McCarthy
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