Manufacturers in Ireland are making significant cost and carbon savings with the use of the latest ultrasonic imaging solutions. Ultrasonic imaging has become a key technology in condition monitoring activities, which are vital for maintenance in manufacturing environments. Identifying air or gas leaks, if left unresolved, is essential to prevent production downtime, reduce energy consumption, and cut carbon emissions. It can also mitigate health and safety risks for employees.
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The Role of Leak Detection in Condition Monitoring
Leak detection devices have long been a key tool for maintenance teams, helping to locate leaks in pressurized systems. However, the latest advances in ultrasonic imaging technology enable manufacturers to detect leaks more quickly, reducing reliance on human judgment and mitigating the risks of error.
Kieran Murphy, technical sales and innovation support for RS Ireland, explained: “The last five years have seen huge advances in ultrasonic acoustic imaging technology, which uses sound waves to pinpoint the source of leaks in systems like pipelines, tanks, and industrial equipment. In industries such as F&B, medical devices, and pharmaceuticals—where nitrogen use is prevalent—detecting leaks becomes even more critical for safety.”
These advancements enable maintenance teams to execute identification in-house, thanks to the accessibility of newer, more affordable technology. Modern cameras no longer rely on hearing ability, eliminating the risk of human error. Additionally, they speed up the process and enable non-invasive inspections from greater distances, even while equipment is in operation.
Challenges of Implementing Ultrasonic Imaging Technology
Despite its benefits, the adoption of ultrasonic imaging still faces barriers, particularly the high upfront costs, ranging from €20,000 to €30,000. These costs make the purchase of advanced systems unviable for some operators, who may continue relying on slower, outdated methods.
To overcome this, RS Ireland provides outsourced services, allowing manufacturers to access cutting-edge ultrasonic imaging technology without a large initial investment.
Cost and Carbon Savings Through Leak Detection
By using outsourced services, manufacturers can realize significant benefits, including cost and energy savings:
- Cost-effective repairs: Once leaks are identified, targeted fixes—such as replacing pipe clips—can reduce expenses. Savings can range from €20,000 to €120,000, depending on the scale of repairs.
- Carbon reduction: Air leaks can contribute to emissions of 5-40 tonnes annually. Repairs directly address this issue, providing measurable environmental benefits.
Kieran Murphy stated, “Recent increases in energy costs, combined with a focus on ESG targets and the need to ensure safety and efficiency, make leak detection essential. Outsourcing this activity enables businesses to deploy their resources more effectively elsewhere.”
A Holistic Approach to Leak Detection
Effective ultrasonic imaging surveys often yield immediate results, providing substantial cost and carbon savings. The ROI of annual air leak surveys is incredibly high, as savings from energy reductions far outweigh the cost of the surveys.
RS Ireland also takes sustainability further by partnering with Reforest Nation. For every tonne of carbon produced by compressed air leaks, RS plants one tree on behalf of its customers. RS Group has earned a Platinum EcoVadis rating, placing it in the top one percent of B2B companies globally for ESG performance.
By integrating ultrasonic imaging into their operations, manufacturers in Ireland are not only improving maintenance efficiency but also addressing pressing environmental concerns, reducing costs, and enhancing safety.
