This Utility and Telecom Company Located and Quantified Over $100,000 in Gas Leaks Alone After Purchasing Two Ultraprobe 15,000 Hand-Held Instruments from UE Systems

About
This company operates as a comprehensive supplier of highly engineered structures and components, catering to the utility and telecom sectors with a special focus on efficiency, evolving technology, and sustainability.

Through their manufacturing process at their state-of-the-art facilities, they can execute world-class solutions for their customers through efficient measures with recyclable American-made products. As a result, they gained an impeccable reputation from their customers, teammates, and communities served.

This case study pertains to two different facilities within the company.

The Problem

This company faced a challenge centered around achieving energy efficiency in their compressed gas systems. Although they lacked a comprehensive air/gas leak program, they monitored their gas consumption by comparing anticipated usage with the remaining gas in their bulk tanks. However, the tanks were depleting faster than expected, indicating an unidentified gas loss. Without a proper leak program in place, the ability to pinpoint the precise source of the loss was impossible.

The Solution

This company recognized it was time to implement an ultrasonic leak detection program in their facility to be able to pinpoint the exact gas leak locations, putting an end to costly leak loss and improving their equipment’s efficiency. To accomplish this, they purchased two Ultraprobe 15,000s from UE Systems and utilized its built-in integration with their Leak Survey SideKick App.

The Ultraprobe 15,000 is a versatile, handheld monitoring system allowing users to analyze everything from bearings and electrical systems to steam traps and air/gas leaks. Featuring an intuitive touch screen interface, this all-in-one instrument can easily test and report on every aspect of a plant’s equipment, all in the palm of your hand. The simplicity of the Ultraprobe 15,000 revolutionizes the way that facilities detect and prevent equipment failure, resulting in optimal efficiency.

Together, the Ultraprobe 15,000 and accompanying Leak Survey SideKick app allowed this company to accurately pinpoint the exact location of their gas leaks and quantify how much these leaks were costing them. With this newfound information, the objective going forward was not only to be able to locate these leaks but to also prevent their occurrence in the future. If leaks did occur again, they would be able to identify and locate them immediately, saving them both time and money.

Results

This company immediately noticed the benefits of using the Ultraprobe 15,000 and Leak Survey SideKick app. During the initial test with their brand new Ultraprobe 15,000, they promptly found a leak and were able to run the calculations in the app. Encouraged by this first test, they conducted a comprehensive leak survey over the next 2-3 weeks, uncovering leaks in various areas in their facility such as metal presses, welding stations, automated fabricators (CNC torches), the main airlines, and welding gas lines. Altogether, they located over $100,000 in gas leaks alone.

The significance of their gas leak findings became even more evident when they calculated the impact of these leaks on their oxygen consumption. Prior to the Ultraprobe 15,000, they were using oxygen at an alarmingly high rate of 5.2 inches per day, which was at least double the expected amount. However, following the identification and repair of the leaks with the Ultraprobe 15,000, their oxygen usage reduced significantly to just 2.8 inches of oxygen per day – a remarkable 46% decrease in oxygen consumption, allowing their equipment to run more efficiently.

All employees made note of how easy the Ultraprobe 15,000 was to use, and they couldn’t believe how much gas leaks were costing them. Moving forward, this company will continue utilizing the power of ultrasound with the Ultraprobe 15,000 and Leak Survey SideKick app while intending to explore using ultrasound for other applications in their facility.

“With the help and guidance of UE Systems through their technology and training, they are going to provide this company the opportunity to identify leaks and energy savings now and moving forward.” – Anonymous Employee

Summary

• New Focus on Energy Savings: This company was experiencing significant gas leaks within their facility causing their machinery to run less efficiently. While they were aware this was occurring, they didn’t have the tools or plans in place to be able to locate, identify, and quantify leak loss.
• The Ultraprobe 15,000 and Leak Survey App: This company did their homework and purchased two Ultraprobe 15,000 instruments from UE Systems. These all-in-one monitoring, handheld instruments combined with the Leak Survey SideKick app allowed them to pinpoint exact leak locations and quantify the amount of wasted gas, confirming what they suspected – their machinery wasn’t working in optimal conditions and valuable dollars were being tossed aside.
• This Company Located and Quantified Over $100,000 in Gas Leaks: This company noticed the benefits of using the Ultraprobe 15,000 and the Leak Survey SideKick app right away. After doing a full leak survey over their facility, they found over $100,000 in gas leaks that would have otherwise continued to go undetected. Additionally, they went from using 5.2 inches per day of oxygen to just 2.8 inches per day – a 46% decrease in oxygen consumption!
• The Ultraprobe 15,000 Makes Leak Detection Simple and Effective While Providing a Long-Term Solution: This company’s employees made note of how easy the Ultraprobe 15,000 was easy to use and noticed an immediate impact in cost savings and efficiency. Moving forward, they will continue to utilize these tools and they intend to explore the power of ultrasound for other applications in their other facilities soon.