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Run: Compressed Air Leak Survey

Use this compressed air leak survey template to find, tag, and prioritize air leaks, then document repairs and estimated energy savings in one walk-through.

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Survey Details

Survey area and system identified critical (required)

Specify the building, line, compressor room, or production area included in the survey.

Survey date and time recorded

Document when the survey was performed.

System operating pressure recorded critical (required)

Record the observed system pressure during the survey.

Operating conditions documented

Note whether production was running, equipment was isolated, or any conditions affecting leak detection.

Survey scope and exclusions documented

List any areas, machines, or lines excluded from the survey.

Ultrasonic Detection Equipment

Ultrasonic detector functional and calibrated critical (required)

Confirm the detector powers on, responds properly, and is within calibration interval if applicable.

Yes No N/A

Headphones or listening device available and functional critical (required)

Verify the inspector can clearly hear ultrasonic signals through the listening device.

Yes No N/A

Sensitivity setting documented

Record the detector sensitivity or gain setting used during the survey.

Background noise conditions assessed

Rate whether ambient noise or process noise affected leak detection.

Reference document or SOP available

Identify the procedure, checklist, or work instruction used for the survey.

Leak Identification and Tagging

Leak location identified critical (required)

Describe the exact location of the leak, including equipment, fitting, valve, hose, or connection.

Leak tag number assigned critical (required)

Record the unique tag or asset identifier applied to the leak.

Leak severity estimated critical (required)

Classify the leak size or priority based on audible intensity, estimated flow, or repair urgency.

Leak photo captured

Take a photo of the leak location and tag for traceability.

Leak source type identified

Select the component type associated with the leak.

Repair Planning

Repair action defined critical (required)

Describe the corrective action required to eliminate the leak.

Repair owner assigned

Identify the person, team, or contractor responsible for the repair.

Target repair date set

Record the planned completion date and time for the repair.

Repair priority assigned

Set the repair priority based on leak severity and operational impact.

Lockout-tagout required for repair critical (required)

Indicate whether OSHA 1910.147 lockout-tagout is required before repair work begins.

Yes No N/A

Energy Savings and Verification

Estimated leak flow rate recorded

Record the estimated leak flow rate for the identified leak.

Estimated annual energy savings recorded

Estimate the annual energy savings associated with repairing the leak.

Repair verification completed critical (required)

Confirm the leak was retested and no longer detectable after repair.

Yes No N/A

Closeout notes documented

Record any remaining issues, follow-up actions, or verification details.

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