How did this outdoor tank yard in Osan solve its recurring film-type sensor failures? This case study shows how the site secured long-term durability and significantly reduced maintenance costs by replacing damaged film sensors with Yoohantech electronic leak detectors (point sensors) designed for rain, wind, and organic solvents.
Hello, this is Assistant Yoo from Yoohantech, committed to safer industrial workplaces.
Today, we would like to introduce a hazardous chemical leak detector replacement project carried out at the outdoor tank storage area of “0000 Co., Ltd.”, a leading Korean manufacturer of synthetic leather and wallpaper located in Osan, Gyeonggi-do.
This was not just a simple sensor replacement. It was a case of finding the most suitable technical solution for the site’s environmental conditions (Outdoor) and the chemicals handled (Organic Solvents).
1. A Pioneer in Polymer Technology, “0000 Co., Ltd.”
Founded in 1974, “0000 Co., Ltd.” has played a major role in the history of Korea’s synthetic leather and wallcovering industry.
Beyond manufacturing, the company possesses strong expertise in polymer chemistry, with outstanding capabilities in precisely controlling and processing material properties.
[Why is a hazardous chemical leak detection system necessary?] To manufacture high-quality synthetic leather, organic solvents such as DMF (Dimethylformamide), MEK (Methyl Ethyl Ketone), and Toluene are essential.
- Dissolution: To dissolve solid polyurethane (PU) resin into a liquid form suitable for coating
- Viscosity control: To achieve precise viscosity control for uniform coating thickness
- Porous structure formation: To create the cell structure that gives synthetic leather its soft texture and breathability
Although these materials are essential to the process, they are also classified as hazardous chemicals, which requires strict safety management and the installation of a leak detection system in accordance with applicable chemical safety regulations.
2. The Site Problem: “Film-Type Leak Sensors Failed Within Just 3 Months”
The site had been operating with existing film-type leak detectors installed in the outdoor tank storage area where hazardous chemicals were stored. However, a serious issue arose.
- Durability issue: Because the sensors were fully exposed to rain, wind, and temperature changes typical of outdoor installations, the sensor film was severely damaged in less than three months after installation.
- Difficult maintenance: Frequent damage led to repeated replacement costs, while false alarms and failures significantly increased the burden on site personnel.
As a result, the site manager strongly requested “a product that can withstand outdoor environments and offers reliable maintenance,” and decided to replace the old system with Yoohantech’s electronic leak detector, Point Sensor YHSP-SA.
Now, let’s take a look at the leak detector replacement work on site.
The photos above show the Yoohantech field engineering team carrying out the leak detector replacement work on site.
Please take a close look at the floor in these photos.
You can see the previously installed film-type leak sensors, and the sensors mounted on the outdoor floor were so severely damaged that they were barely recognizable.
According to the site manager, there was a frustrating story behind this. These film-type sensors had failed only three months after installation.
“When we requested a repair quotation, we were told the entire film had to be replaced, and the cost was not small. Since it was likely to fail again within another three months anyway, we simply turned off the receiver power.”
It was an unfortunate situation where equipment installed at significant cost to protect safety and the environment had become virtually useless due to frequent failures and difficult maintenance.
To break this cycle, the site decided to fully replace the fragile film-type system with Yoohantech’s electronic leak detection point sensor (YHSP-SA).
[Installation Completed] No More Worries About Rain or Sunlight! Outdoor Tank Leak Detection Upgrade Completed
Done at last. The replacement work has been completed.
The worn-out film-type leak detector is gone, and in its place the electronic leak point sensor (YHSP-SA) is now securely installed.
Looking around the outdoor tank area, the neatly installed sensors give a strong sense of reliability.
The true strength of this product is its resistance to harsh outdoor environments. Whether under intense summer sunlight or heavy seasonal rain, the system remains dependable.
Because it is not affected by weather conditions, it performs its core task as a leak detector with stable, reliable operation. Installation is also simple and efficient, which improves work productivity on site.
Most importantly, what site managers appreciate the most is its outstanding ease of maintenance.
Let’s assume that a hazardous chemical leaks from the piping and comes into contact with the sensor.
- Conventional film-type system: The entire contaminated film section must be removed and reinstalled. (Higher cost, more work)
- Yoohantech leak detector YHSP-SA: No problem. Only the floor sensor (YHS-FS) tip that contacts the floor needs to be detached and replaced.
The main body stays in place, and only the contaminated tip needs replacement. This makes maintenance simple for anyone while providing clear cost savings.
Lower cost, higher safety. That is the smart chemical safety solution offered by Yoohantech.
Built for Harsh Weather: SUS Enclosure and 24/7 Leak Monitoring System
The biggest challenge at this site was the outdoor environment. Since the equipment is exposed year-round to rain, wind, and direct sunlight, durability was absolutely critical.
To overcome these harsh conditions, Yoohantech applied the following customized leak detection solution.
1. SUS enclosure with strong alarm system for corrosion resistance and rapid warning
- SUS enclosure applied for improved corrosion resistance: Standard steel enclosures corrode quickly outdoors. We specially fabricated a dedicated enclosure using stainless steel (SUS) to protect the receiver against moisture and contamination.
- Improved visibility for fast response: In leak incidents, detection speed matters. The receiver panel was installed close to the tank and in a highly visible location so operators can quickly recognize an alarm while moving through the site.
- 105 dB high-output warning beacon: In noisy industrial environments, sound alone may not be enough. For this reason, we added a high-output beacon that combines a powerful 105 dB siren with a flashing strobe light, allowing both audible and visual alerts to work together.
2. The technical core: precision specifications inside the receiver
It is not only the exterior that is robust. The real strength lies in the internal control system of the receiver (YH-100L).
- Precision analysis module (YHSM-04S-A / YHSM-01S-A): The receiver is equipped with core modules that improve signal reliability. These modules filter out noise from minute sensor signals and precisely determine whether an actual leak event has occurred, helping to reduce false alarms.
- Backup battery for continuous monitoring: Safety equipment must not stop during a power failure. To ensure uninterrupted monitoring even during emergency power loss, a high-performance backup battery is built in. Even when external power is lost, Yoohantech’s leak monitoring system continues protecting the site 24/7.
An investment in safety begins with choosing the right leak detector.
We hope you found these real field photos from the replacement project helpful.
Many site managers worry, “What if it fails again?” or “The replacement cost is too high...” As a result, failed leak detectors are often left unrepaired and simply powered off.
But it is time to stop losing money and time because of the wrong product choice.
- Leaving it inactive means accepting risk: The purpose of installing a leak detector is not just to satisfy regulatory requirements. If the detector does not operate during an actual incident, the resulting loss and responsibility will remain entirely with the company. Do not let your final safety barrier become useless.
- Proven products save cost: Choose a verified leak detector that can withstand harsh outdoor conditions, not one that fails within three months. Yoohantech’s electronic leak point sensor (YHSP-SA) offers reliable durability, reduced maintenance burden, and long-term cost savings.
"A leak detector is no longer optional. It is essential."
Do not handle complex chemical safety challenges alone. Yoohantech provides the most practical and reliable safety solution for your site.
Your dependable safety partner, always ready to help.
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