Hydraulic, Pneumatic & Fluid Power Systems worked example

Leak Cost at 58% continuous-leak duty factor: a worked example

Suppose continuous-leak duty factor falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Calculate leak cost for hydraulic, pneumatic & fluid power systems planning, quoting, troubleshooting, capacity review, or process improvement.

The inputs for this scenario

  • Leaked air or fluid volume: 100 units (held at the documented default)
  • Cost per unit of leaked media: 45 $ / unit (held at the documented default)
  • Continuous-leak duty factor: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed repair and labor cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Leak Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where continuous-leak duty factor sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • It computes the total cost of a leak — leaked volume times unit cost times duty factor plus fixed repair cost — and the per-unit cost of that leaked media. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Leak Cost calculator, set continuous-leak duty factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.