Inspectahire Newsroom

The Challenge

A UK food manufacturer operating a 2,800m³ on-site anaerobic digestion (AD) plant detected a small leak in the roof of their Anaerobic Bioreactor during a routine inspection.
The leak posed two immediate risks:

• Environmental impact – Methane emissions needed to be controlled to meet regulatory and sustainability commitments.
• Operational safety – Maintaining safe pressure and operating conditions was critical for ongoing plant performance.

Time was of the essence. The client contacted Alpheus for urgent support, who in turn engaged Inspectahire to deliver a specialist survey capable of pinpointing the leak with precision and speed.

Inspectahire’s Involvement

1. Rapid Deployment of OGI Survey Specialists
   Inspectahire mobilised a field team with deep expertise in Optical Gas Imaging (OGI) technology and ATEX-compliant survey work. Within hours, the team was on site, ready to conduct a targeted methane leak assessment without the need for shutdown.
2. Advanced Leak Detection Techniques
   The survey combined:

• Optical Gas Imaging Cameras – Highly sensitive thermal-imaging devices capable of visualising methane plumes in real-time, even from small pinhole leaks.
• Gas Analyser “Sniffer Test” – Calibrated instruments to verify gas type, concentration, and emission rate for quantification and regulatory reporting.

This dual-approach allowed Inspectahire to:

• Identify the exact location of each leak.
• Measure the scale and emission rate of methane escape.
• Provide immediate, actionable data to Alpheus for repair planning.

3. Survey Findings
   The OGI survey identified four pinhole leaks across the bioreactor roof. Although production levels were temporarily reduced, meaning immediate risk was lower, Inspectahire advised that prompt repair was still critical to prevent escalation and to remain compliant with safety and environmental standards.

Facilitating Safe and Effective Repairs

Based on Inspectahire’s survey data, Alpheus implemented a temporary repair solution using Belzona — a high-performance industrial sealant — allowing operations to continue safely until the planned full tank emptying and permanent repair.

The leak locations and severity grading provided by Inspectahire meant:

• Repairs could be targeted exactly where needed, saving time and cost.
• Work could be completed in a single day, minimising operational disruption.
• Safety controls could be tailored for each repair site based on risk profile.

The Outcome

• Zero unplanned downtime – Operations continued without interruption.
• Environmental compliance maintained – Methane emissions minimised and documented for regulatory reporting.
• Data-driven repair plan – Detailed OGI survey results to inform both temporary and permanent repair strategies.

Inspectahire’s rapid response and specialist gas imaging capabilities provided the critical intelligence that enabled safe, efficient, and compliant repair work in a high-risk ATEX environment.

Why Inspectahire?

• UK leaders in Optical Gas Imaging for methane detection.
• Extensive experience in ATEX-rated environments and AD plant infrastructure.
• Proven track record in rapid mobilisation for emergency response.