Gas leak at meter regulator, now in dryer

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mark2741

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Joined
Dec 28, 2024
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Location
King of Prussia, PA
Sorry in advance for long post. I'm at my wit's end with this and hoping for some guidance.

So about 6 or 7 weeks ago the local gas/electric utility came through and replaced the main gas pipeline that feeds the houses on my street. The original pipe ran underneath everyone's lawn. They rerouted it to the street. During that process they mistakenly ruptured my sewer line, causing a backup and, well, that's fixed now (they admitted fault and paid to repair it).

As part of the process they also replaced the meter that is positioned right in front of the house. After they replaced the meter I walked up my driveway and smelled gas. An hour later I smelled it again when I went out there. I called over one of the crew, who were working a few houses up by then as they proceeded replacing the line up the street. They checked it and eventually said something like, "At first we couldn't detect the leak but right before giving up we smelled it and tested again and it turns out it is a bad regulator. It is releasing gas intermittently. We need to call it in to get a replacement. It'll be replaced this afternoon. I said "great - thank you!" and went about my business. I continue to smell the gas intermittently over the next couple of weeks. The crew that was working on the street had long finished the pipe replacement and were gone.

Realizing this isn't going away on its own, I call the utility company's "gas leak emergency" line. They send out a guy within the hour. I explain the situation and mentioned the regulator that was replaced (or at least supposed to be). He dabs soap solution all over the meter and insists no leak. He then goes inside my basement and, with a leak detector, gets a hit on the pipe section that is connected directly the meter on the outside and runs in through my siding. He calls in someone else from his crew and they replace the pipe. They then tested the old section in their truck via pressure test and say it turned out it was fine. So the guy goes through my entire basement with the leak detector, testing every connection. He eventually gets a hit at my hot water heater. Tightens everything and insists all is good now, and that the only reason he fixed it and not insist I call a plumber and pay for it myself is because it probably happened as a result of the utility company changing the meter and rattling the pipes during the process. He leaves. I continue to smell gas outside near the meter....

A week later, we have a cold spell and my furnace isn't keeping up. Never had an issue with the furnace before. I call my HVAC guy. He comes and says everything seems fine and is perplexed. He then, since I told him how the util company changed the gas main and the meter recently, and also mentioned the regulator leak thing, he tests the gas pressure coming into the furnace. He does this from within the furnace itself, not at the meter or the gas pipe going into the furnace. He says the gas pressure coming into the furnace is way too high - well above the max rating for any furnace or appliance. He said he set the furnace to work with it but that I'll need to call the utilities company to fix the pressure, and then he would need to reset at the furnace to regulate based on the adjusted input pressure. Sounds reasonable. This was the day before Christmas Eve. Even though the smell of natural gas outside of my house has me stressed out, I figure I would have blown up by now if it was dangerous as it's been weeks. And I was busy with the holiday. I decide to not do anyting until after Christmas.

Yesterday morning, I go to HD and buy a cheap ($31) natural gas leak detector. I walk out to the meter and smell a little gas. I put it near the gas meter, specifially under the regulator, and it lights up as a small to medium sized leak. I go inside and call the utility company's emergency leak line. While waiting for the guy I go back outside about 10 minutes later and test again. I smell no gas, and sure enough - it doesn't detect any leak. Guy shows up 20 minutes later and no leak. Insists there is no leak. I tell him the story of what has happened up until this point. He of course looks at me like I'm crazy, puts his leak detector inside the furnace's PVC exhaust, which is located only a few feet from the meter. His detector lights up. He says the problem is my furnace and I need a new/better HVAC tech and they need to do an "efficiency test." He then insists that he's a professional, is using a detector that costs many thousands of dollars vs my $31 detector, and that I have no leak at the meter. He then uses another tool to poke some holes in my lawn to verify it isn't an underground leak. He begins to pack everything up and again tells me I need to find another HVAC guy. Just as he starts walking away I catch a whiff of natural gas. I beg him to come test the meter with his detector one last time. He obliges and sure enough - he looks up at me and says, "We have a gas leak." He then cuts the gas to the house and disassembles the meter and replaces the regulator. He said it must have never been replaced. He leaves after it's replaced, after using his detector one last time. He insists the gas pressure is the appropriate 6.5". I said "Awesome! Thank you!" thinking all was well.

I still smell a little gas out there but figure it is coming from the furnace exhaust being inappropriately set for the super high pressure from before. I put a call in to my HVAC guy, thinking he needs to come out and readjust. Told him to wait until after the holidays as no big rush. Furnace, BTW, has been running fine since the HVAC guy came out and adjusted. Probably very inefficiently, but fine.

While about to do some laundry, this morning, I open up my dryer and smell inside and notice natural gas smell inside. I start up the leak detector and put it inside the dryer (after calibrating the detector) and it detects a small/medium leak. Ugh!! I cut the gas to the dryer and turn it on air dry for 10 minutes. Then turn it on heat to hopefully expel any leftover gas. I then turn the gas back on and run it for 10 minutes. Still the smell of gas inside the dryer. Any advice before I give up and just live with this?

Could the bad regulator have caused a spike in pressure inside the house and caused the dryer internals to begin leaking gas?
 
If all these things are happening since your streets has main has been re routed it's the work in the street that causing this since you you say all was normal before
 
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First off check the gas flex connections from wall, valve, flex etc. that is where 99.9% of the time we find leaks. Extrodinarily rare for even high pressure to cause leak in the hard piping within a dryer.
On most appliances you can pull off the access covers and check with your sniffer inside.
 
First off check the gas flex connections from wall, valve, flex etc. that is where 99.9% of the time we find leaks. Extrodinarily rare for even high pressure to cause leak in the hard piping within a dryer.
On most appliances you can pull off the access covers and check with your sniffer inside.
Thanks - yes I replaced the gas flex connection to the dryer yesterday. Unfortunately I think I've definitely isolated the leak to be coming from outside. After pulling the dryer away from the basement wall, I pulled the dryer exhaust duct and there was a gas smell within the duct. I'm positive it is coming from outside, as the gas meter is right next to the dryer exhaust vent. I removed the entire dryer exhaust duct and wrapped the last portion that was open to the outside off with plastic to create a seal between the basement and the exterior. After waiting a while for the residual gas to dissipate, no gas smell or detection inside the house. This morning, I went out to the meter again and did the soap solution test on all of the connections. No leaks. But I could smell gas. I then used the detector on all of the connections - no leaks detected. I then placed the detector down at the pipe that comes out of the ground and the meter connects to. Detector went off. It's likely a leak in the pipe underground. I tested again about 30 minutes later and it was still there. I'm going to test it a few more times today.

I have the contact info for the utility company project manager who was in charge of the project to replace the gas main. Since calling the emergency line and each time getting two miserable fellows who don't seem to want to fix it, I am going to wait until first thing tomorrow AM and call that project manager. If no response then I'll call the utility company main line and explain what is going on. They'll probably push me to the emergency line, which is fine, as I've don their job for them and isolated it.
 
Thanks - yes I replaced the gas flex connection to the dryer yesterday. Unfortunately I think I've definitely isolated the leak to be coming from outside. After pulling the dryer away from the basement wall, I pulled the dryer exhaust duct and there was a gas smell within the duct. I'm positive it is coming from outside, as the gas meter is right next to the dryer exhaust vent. I removed the entire dryer exhaust duct and wrapped the last portion that was open to the outside off with plastic to create a seal between the basement and the exterior. After waiting a while for the residual gas to dissipate, no gas smell or detection inside the house. This morning, I went out to the meter again and did the soap solution test on all of the connections. No leaks. But I could smell gas. I then used the detector on all of the connections - no leaks detected. I then placed the detector down at the pipe that comes out of the ground and the meter connects to. Detector went off. It's likely a leak in the pipe underground. I tested again about 30 minutes later and it was still there. I'm going to test it a few more times today.

I have the contact info for the utility company project manager who was in charge of the project to replace the gas main. Since calling the emergency line and each time getting two miserable fellows who don't seem to want to fix it, I am going to wait until first thing tomorrow AM and call that project manager. If no response then I'll call the utility company main line and explain what is going on. They'll probably push me to the emergency line, which is fine, as I've don their job for them and isolated it.
If I smell gas, never would I turn on or run anything connected to electricity in that area.
Heck, I wouldn't even use a cell phone near gas.
 
Right. You'd call the utility company's emergency line and expect them to troubleshoot and repair it. I tried that twice. They failed both times. Hoping the third time's a charm. This has been going on for weeks. If I was going to blow up it would have happened by now.
 
Right. You'd call the utility company's emergency line and expect them to troubleshoot and repair it. I tried that twice. They failed both times. Hoping the third time's a charm. This has been going on for weeks. If I was going to blow up it would have happened by now.
Fateful last words, perhaps.
 
Intermittent problems are a pain to fix, and even more so when a utility has to do it.

Try keeping a spray bottle of soapy water handy, and the next time you smell gas go over the meter and junctions near it thoroughly. If you see bubbles somewhere document it with your phone. Then you can wave it in front of the gas service person, even if it isn't leaking when they get there.

That is the best case scenario.

It is quite possible that the leak is underground somewhere "near" your meter, and if that is the case, you won't get any bubbles. My impression is that underground leaks are often smelled only intermittently, as if they slowly build up gas in some pocket and it only "burps" through to the surface once and a while. I have seen the gas company looking for these things around my neighborhood, and sometimes they find the problem, and sometimes they don't, and then I see them again one or even several more times when the homeowner calls them back. Because unlike a little drip at the water meter, a gas leak is actually dangerous. In one instance they finally started boring holes through a driveway every couple of feet, and that's where the problem was, even though the homeowner later told me that isn't where he had smelled the gas.
 
Intermittent problems are a pain to fix, and even more so when a utility has to do it.

Try keeping a spray bottle of soapy water handy, and the next time you smell gas go over the meter and junctions near it thoroughly. If you see bubbles somewhere document it with your phone. Then you can wave it in front of the gas service person, even if it isn't leaking when they get there.

That is the best case scenario.

It is quite possible that the leak is underground somewhere "near" your meter, and if that is the case, you won't get any bubbles. My impression is that underground leaks are often smelled only intermittently, as if they slowly build up gas in some pocket and it only "burps" through to the surface once and a while. I have seen the gas company looking for these things around my neighborhood, and sometimes they find the problem, and sometimes they don't, and then I see them again one or even several more times when the homeowner calls them back. Because unlike a little drip at the water meter, a gas leak is actually dangerous. In one instance they finally started boring holes through a driveway every couple of feet, and that's where the problem was, even though the homeowner later told me that isn't where he had smelled the gas.
Thanks. I do think it's underground now, in the section of pipe between the old gas connection and the meter. I called the crew leader that was in charge when they put in the new gas main on the street this morning and left a voicemail. No call back but suspect it is because of the holiday. I would call the emergency line yet again, but it's a very windy day today and no smell anywhere. This morning when I first went out there I smelled it by the meter. The detector went off when I pointed it at the ground adjacent to the pipe coming out of the ground and that the meter connects to.

Unfortunately, my dryer exhaust is right next to the meter. So I was getting gas fumes coming down through that and into my dryer. I confirmed it is coming from outside, and not inside, by:

a. Replaced the flexible cable to the dryer. Old one wasn't leaking (confirmed by both soap and detector tests) but it there was a kink in it so I changed it anyway with a new one. Soaped and tested new one. No leaks.
b. I removed the dryer exhaust duct completely and blocked off the last foot that goes outside with some plastic to seal it off. This was done yesterday morning. Today - absolutely no gas smell/detection in basement.

I'm pretty much stuck, due to this being intermittent, until the wind calms down. This has ruined my Christmas vacation : (
 
Problem finally solved. It turned out to be exactly what I thought it was....the meter was leaking. Badly. Full story below.

Yesterday morning I called the utility company emergency gas leak line again (3rd time). Guy comes out 20 minutes later (they guarantee response within 60 for leaks). He is pissed at me, basically tells me I'm nuts and obsessed with a leak that isn't there and he spoke to the other two guys that responded already and that the problem isn't the meter or a leak it is that my furnace is burning too rich and I need to get my hvac guy out to readjust the furnace to run efficiently, and the gas from the furnace exhaust is the cause.

The day prior it was an unseasonably warm 60 degrees here. I replied, "My furnace didn't run yesterday at all due to it being so warm, and yet the gas smell was prevalent. How do you explain that?" With that, he gumbled something along the lines of, "I'll do a check." He inspects the meter with his leak detector. Like the first and second guys, he checks all of the connections/joints on the meter with his detector. He says to me, basically like the other two guys, "You're not nuts. I do smell it." But he can't find it. The detector leads him to the nipple pipe connected to the meter that runs into my house. Just like the first guy...

He asks to go into the basement. I bring him down. He detects lots of gas in the one joist bay where that pipe leads out. He concludes it must be a pinhole in the pipe where it exits the house's siding. I explain that's what the first guy determined, and he called another guy in and they actually replaced the pipe. This guy said he shouldn't have done that, that that is my property. I told him I never had any gas issues until the utility company (PECO) replaced the meter along with the main pipe in the street. So the first tech correctly assumed that the utility company caused it when they replaced the meter. This 3rd tech just said, "Look. You need to call a plumber and have them replace that nipple section. It's an easy job, but with it being New Year's Eve it might be tough together someone out here. I will shut off the gas but not tag it. If you can't get someone out here before the holiday then you can turn it back on if you need to. It's a small leak." Before leaving, he also did a ground penetration test right near the meter where the gas line would be leading to it. No gas in the ground. BTW, just like the last emergency guy, who wound up wasting everyone's time just by replacing the regulator, this guy showed up angry/disgruntled and then by the time he left he agreed it was a leak and was pretty friendly. I just wish they were competent at their jobs....

With that, he leaves, I jump on the phone and call a plumber. Plumbers (2 guys) get here in about 40 minutes and I explain everything. They offer to test to see if it is the meter or not but I just tell them this ordeal has been ongoing, and while I am certain it is the meter, all of the gas piping in the basement is old anyway (house built in 1950's) and so I wanted an estimate to replace the nipple as well as the piping near the joist bays on that side of the basement. After calling around to confirm parts were available, they quoted me $1239 and a two hour job that could be done that afternoon. They proceeded to replace all the piping.

After replacing, which took about 2 hours, they pressure tested. A couple of minor leaks in a couple of joints, both in sections they didn't replace. They tightened, re-tested for 15 minutes, and all good. Then they hook it up to the meter and.....gas smell. Even worse than before because there was no breeze yesterday. They were perplexed but immediately went to soap testing every nook and cranny of the meter. No leaks. The lead plumber looked at me and said, "You definitley have a leak and it's definitely outside here, and I think it's the meter itself but I can't find a leak with the soap anywhere." I ask him if he'll stay for another hour while I get the utility company out here. He said absolutely, that's what we was going to recommend. He said with the plumbers there to explain they'll have no choice but to find the cause.

I call the utility company emergency line for a 4th time over the past 9 days. Guy shows up in 20 minutes. Different guy unfortunately or fortunately...He quietly walks up and I explain that he's the fourth guy, and the third guy this morning insisted I needed to replace the nipple. From there, my plumber jumped in and said they replaced all of the piping that leads from the meter in the basement and pressure tested successfully, and they are sure it is the meter itself leaking. The utility tech pulls out his detector and sniffs every nook and cranny of the meter. His detector is going off at what looked like the bottom corner edge of where that back plate is screwed into the meter. No other tech had tested the back plate. It occurs to me immediately that that spot, if it is source of the leak, would shoot gas directly at the nipple pipe as it enters into the house, concentrating at the siding. Eventually, he starts feeling the back plate of the meter. It's supposed to be a smooth metal plate cover.

He gets up and quietly says, "I think it's the meter. I will go grab a new one from my truck and replace it." He comes back and pulls the old meter out and flips it over.....there is what appears to be an small crater, like someone had dropped the back of the meter onto something pointy. A small hole in the center with thin cracks leading out from it. My plumber and I immediately knew that was the cause the whole time.

The utility guy replaces the meter. No gas smell ever since. I have my life back. And it turns out I'm not crazy or obsessed (in a bad way) after all : ) I asked the utility guy to PLEASE show that bad meter to the other three guys who were here.
 
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