About
Amentum is a global leader in engineering, project management and solutions integration, trusted to modernize critical missions anywhere in the world today and in the future. They are uniquely positioned to deliver solutions faster and solve what’s coming next. They have earned their customers’ confidence by successfully managing and executing highly complex programs of scale, providing solutions for an unpredictable world.
The Problem
In this case study, Amentum was assigned to restructure the reliability program for Caterpillar Inc. Corinth, MS remanufacturing facility. Their purpose was to increase the facility’s pressure efficiency on their compressed air systems and improve quality assurance. Upon investigation, it was immediately clear that many compressed air leaks were present in their equipment. They have vertical mills, grinders, flash cleaner machines, dunk tanks, valves, arm drills, and many more types of equipment. Despite the use of air tools throughout the facility, the absence of a quantifiable ultrasonic program to precisely measure and assess the impact of air leaks on equipment was proving to be a huge challenge.
Amentum brought forth their reliability program to Caterpillar and implemented it successfully. This program provided ways to accurately locate, quantify, and repair compressed air leaks while simultaneously improving machinery efficiency.
The Solution
After thorough research on the most cost-effective and technically sufficient device, Amentum determined the Ultraprobe 3000 by UE Systems was the best solution. The Ultraprobe 3000 is an advanced digital ultrasonic leak detector that specializes in compressed air and gas leak detection, steam traps, and valves. This instrument is versatile and offers additional reporting capabilities such as on-board data logging. Combined with UE System’s DMS software, this instrument allows users to download leak data, add comments and pictures, and quantify leak costs, and create reports.
The Ultraprobe 3000 was the perfect addition to their arsenal because it is easy to use and fits all their needs – an affordable tool that allows them to quickly locate, quantify, and repair compressed air leaks. To ensure proper utilization throughout the facility, Amentum provided their technicians with introductory courses on how to use the instrument in their work areas.
In addition to acquiring two Ultraprobe 3000s to support their large team, Amentum strategically divided their extensive facility into 11 manageable zones. This segmentation allows each section to receive dedicated time and attention for leak detection routes. A maintenance technician was then assigned to inspect each zone according to a pre-planned schedule.
Results
Amentum recognized the benefits immediately, observing a substantial reduction in air leaks within each designated zone. This led to significant cost savings, customer satisfaction, several quality-of-life improvements, increased equipment longevity, and a much quieter working environment. Understanding the science of ultrasound, learning how to calculate for different types of compressed air, and properly training their technicians proved to be an instant success. Over the next 5 years, Amentum calculated over $828,000 in savings from air leaks alone.
Moving forward, Amentum plans to continue utilizing the power of ultrasound in all their customer’s facilities. While they continue to use the Ultraprobe 3000, they are actively looking to upgrade and grow their reliability program with an ultrasonic instrument that can provide more than just ultrasonic leak detection, such as the Ultraprobe 10,000 or UltraView Camera (Si124). These two instruments have allowed them to excel in condition-based lubrication, bearing condition monitoring, steam trap & valve inspection, and partial discharge detection, making them more valuable to their clients.
“The small leaks add up over time. One small leak isn’t necessarily a detriment to the facility, but when you look further and see that there are multiple leaks, it adds up quickly.” – Austin Lemons, Predictive Maintenance Program Manager at Amentum
Summary
