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Compressor calculators: FAD, tank, hose, leaks

Compressor calculators: sizing, pressure drops, leaks, costs

Choose a compressor based on data, not guesswork. You’ll calculate the required FAD flow, the minimum receiver tank size for peaks, the risk of restriction (throttling) in the hose, and the cost of compressed-air leaks. You get a result and a short sizing recommendation.

Flow sizing (FAD) Demand from tools + duty cycle + simultaneity + safety margin.
Tank sizing Minimum buffer volume for peaks and allowable pressure drop.
Hose & restriction Assess pressure-drop risk based on length and internal diameter (ID).
Leaks & cost Estimate leak flow and annual energy cost.
Important assumption

A receiver tank helps during peaks. It won’t replace capacity for continuous operation. If a tool runs for long periods without breaks, compressor flow (FAD) is the key.


Choose a calculator

Start with flow. Then verify the buffer (tank) and the installation (hose). Finally, check leaks — that’s the fastest win on operating costs.

1) Compressor (compressor unit) flow demand

Add your tools. Set duty cycle. Set simultaneity. Add a safety margin. You get the required FAD flow. You get a compressor type recommendation.

The preset sets simultaneity and margin. You enter tools yourself.
This affects the comment. It does not change the flow calculation.
How many tools run in parallel. Typically 40–85%.
Margin for pressure drops, data errors, and expansion. Typically 20–35%.
Tool Flow Unit Work pattern Duty [%] Qty Remove
Tip: if you have “average” and “under load” figures, set duty to reflect real operation.

FAQ

What compressor for a garage does this calculator size?

You calculate required flow from tools, then add simultaneity and a safety margin. You get FAD to compare against a compressor.

What compressor for painting will the calculation suggest?

If semi-continuous work dominates, the calculator will show higher Q and suggest stable operation. The result uses the spray gun spec sheet (DTR) flow.

Does the result include hose pressure drops?

No. Here you calculate flow demand. Check pressure drop in the hose calculator.

What does FAD mean?

It’s the real amount of air delivered to the system. It’s the most important parameter when sizing a compressor.


2) Receiver tank sizing for compressor peaks

A tank buffers peaks. It does not replace capacity for continuous operation. Here you calculate the minimum tank volume for a given time and allowable pressure drop.

Enter demand as free air. If you have CFM, select the unit next to it.
How many seconds you want to keep running without a big pressure drop.
If you know it, enter it. Otherwise leave blank.
P2 must be lower than P1.

FAQ

What receiver tank for an impact wrench?

Here you calculate minimum volume for a chosen time and pressure drop. This is a buffer. It is not “compressor capacity.”

Does a bigger tank always fix the issue?

No. A tank helps in peaks. For continuous work, you need higher FAD.

What if P2 equals P1?

There is no pressure reserve. Then the tank does not “give” any air. The result does not make sense.

Does compressor make-up during peak matter?

Yes. If the compressor refills during the event, the required tank volume is smaller.


3) Does your compressor hose choke the tool?

Enter flow, hose length, and internal diameter. You get a status: OK, risk, choking. You also get a recommended diameter.

This is a decision threshold. Status uses thresholds, not CFD.
Affects the comment. Thresholds are conservative for workshop use.

FAQ

What hose for an impact wrench?

If flow is high, increase hose ID. Shorter hose helps. Quick couplers also matter.

Does hose length really matter?

Yes. A longer hose increases resistance. Pressure drop rises.

Does the result include quick couplers?

No. This calculator covers the hose. Fittings can worsen the result. Treat a “risk” status seriously.

What does “choking” mean?

The tool gets less air than it needs. Torque drops. Speed drops. Cycle time increases.


4) Compressed-air leaks: flow and cost

Choose a method. Calculate leaks from a pressure-decay test or from an “orifice”. You get annual cost and a repair priority.

Receivers + approximate piping volume.
P2 must be lower than P1.

Industry: often 4160 h/year. Workshop: often 2000 h/year.
If you leave it blank, I’ll use a preset.
The preset gives a fast cost estimate.

FAQ

How to calculate the cost of compressed-air leaks?

First calculate leak flow. Then compute power loss using specific power. Then compute cost from kWh and operating hours.

Is the pressure decay method reliable?

It’s good for audits. It works if you isolate consumers and measure decay over a controlled time.

Is the orifice method accurate?

It’s a quick estimate. Good for priorities. It does not replace a flowmeter measurement.

What is specific power?

How many kW you use per 1 m³/h of compressed air. It simplifies cost calculation for losses.


Want to size equipment for your installation?

Provide a tool list. Provide simultaneity (% overlap). Provide hose lengths. - You’ll calculate better. You’ll choose faster.