We’re proud to announce that Shawcity has been awarded the Ion Science Application Award for our successful fixed VOC detection project at a leading fuel blending facility in Essex.
This award celebrates our work in overcoming the significant challenge of reliable gas detection in high-moisture environments. Working in close partnership with the site’s safety and maintenance teams, we implemented ION Science’s FALCO detectors to deliver a robust, accurate, and low-maintenance monitoring solution. The project not only enhanced operational safety and reliability but also resulted in the UK’s largest single-site deployment of FALCO units, setting a new benchmark in gas detection excellence.
Read more about this project below:
Overview
A leading company in bespoke fuel blending and sustainable fuel innovation operates a state-of-the-art facility in Essex. The site includes advanced laboratories, extensive storage infrastructure, and blending capabilities, producing over 4,000 unique fuel blends annually, more than 14 million litres of bespoke fuels in total for use across the globe. As part of its ongoing commitment to safety and operational excellence, the company partnered with Shawcity to implement advanced VOC detection systems across its operational sites.
One of the key challenges the company faced was reliable VOC monitoring in areas exposed to high moisture levels, due to its location next to the River Thames. The previous infrared (IR) detection technology proved inadequate in these challenging conditions, resulting in frequent false alarms and unplanned staff callouts, particularly in the fuel storage bunds, where precise and dependable VOC detection is essential for ensuring safety and compliance.
Solution Implementation
In Autumn 2022, the fuel blend company contacted Shawcity’s Fixed Gas detection team for assistance. Following a comprehensive site survey, Shawcity identified ION Science’s FALCO VOC monitors as the optimal solution for the facility’s unique challenges.
The FALCO fixed VOC detector is renowned for its high sensitivity and reliable performance in demanding environments. Equipped with ION Science’s innovative Typhoon Technology, the FALCO is uniquely engineered to protect the PID sensor from condensing moisture, ensuring reliable operation in harsh outdoor environments without the need for additional weatherproof enclosures.
The FALCO’s PID sensor features patented Fence Electrode Technology, which also neutralises the effects of airborne humidity and prevents sensor contamination. This innovation not only maximises safety but also eliminates the false readings commonly associated with competing PID systems, making the FALCO a standout solution for high-precision VOC monitoring in this type of environment.
- Laboratory Integration: Four x FALCO 1 units were deployed across laboratory areas - two installed internally and two externally - to monitor zones where fuel blends are mixed and ignited for burn rate testing. Previously unprotected, these critical areas were at risk from undetected spills, making the implementation a key step forward in safety assurance.
- Bund Monitoring: In response to persistent false alarms caused by moisture and hazardous conditions impacting older IR-based systems, the company then replaced the existing detectors in fuel bunds with 16 x FALCO 2.2 units. The upgrade significantly reduced false alarms, improved response accuracy, and enhanced site safety. Given that each bund holds between 25,000 and 50,000 litres of fuel, reliable monitoring is essential for both operational efficiency and risk mitigation.
Results and Expansion
By December 2024, the facility had installed 20 FALCO detectors, with no recorded false alarm callouts, a marked improvement in operational reliability. Building on this success, plans are underway to extend the system further in summer 2025 with the installation of an additional eight units.
These will cover drum storage areas housing returned fuel from Formula 1 races, reflecting the company's central role in sustainable motorsport fuel development. In partnership with Petronas, it blends and repurposes these fuels using environmentally responsible methods, reinforcing its leadership in innovative, sustainable energy solutions.
This upcoming expansion will make this fuel blend company the largest single-site deployment of FALCO detectors in the UK.
Senior Maintenance Supervisor explains:
“Since the FALCOs were installed in December 2024, we’ve seen a dramatic improvement; our out-of-hours callouts for false gas detection alarms have dropped to zero. This is a significant improvement and step forward compared to the previous infrared system.”
“We’ve also observed much greater accuracy during inspections around the bunds. Sensor readings now show increased PPM levels when tanks are being emptied, providing clear evidence that the FALCOs are delivering the reliable performance we need. That’s why we’re planning to invest in additional units.”
In summary, the customer was struggling to achieve reliable VOC monitoring in a high-moisture location. The previous infrared system was unsuitable technology, resulting in frequent false alarms and unplanned staff callouts, as well as unreliable data for VOC levels.
With its Typhoon Technology, the ION Science FALCO could protect its PID sensor from condensing moisture, ensuring continuous, reliable operation. The Fence Electrode Technology also neutralised the effects of airborne humidity, preventing sensor contamination and eliminating false readings.
Fixed Gas Detection from Shawcity
The success of this project highlights Shawcity’s dedication to solving complex detection challenges with innovative, reliable solutions. By working closely with our customer and deploying ION Science’s advanced FALCO technology, we delivered measurable improvements in safety, accuracy, and operational efficiency.
Receiving the Ion Science Application Award is a proud achievement for our team and reinforces the importance of tailored gas detection strategies in demanding environments. We remain committed to helping organisations across all sectors achieve safer, more resilient operations through expert support and cutting-edge technology.
For more information on our fixed gas detection services, visit: https://www.shawcity.co.uk/fixed-gas
01367 899553
info@shawcity.co.uk
