Gas sensing
SPOT ROBOT DOG TO SNIFF OUT GAS HAZARDS WITH BLACKLINE DETECTOR
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to effective control of both coating processes and the RTO. “The analyser helps us optimise oxidiser performance, manage emissions from the coating lines, and control fuel input.” he says. “Any issue with the RTO could have serious consequences, so early detection is vital.” An integrated monitoring and alarm system provides management staff with real-time displays, historical data and automated alerts. The system also confirms correct operation and calibration of both the analyser and the heated sample line. Sean O’Brien, health, safety and environment manager at the site, adds: “Continuous VOC monitoring allows us to identify potential problems early and address them before they escalate. It gives us confidence that compliance monitoring will demonstrate performance that meets permit requirements, while providing additional reassurance to the regulator.”
PROVEN PERFORMANCE FROM SIGNAL GROUP Following more than 20 years of reliable service from its first Signal Group analyser, PAC selected Signal once again when upgrading its monitoring system for the new RTO. The original instrument has been replaced with an MCERTS-approved SOLAR CEMNEX continuous FID analyser, installed at the base of the RTO exhaust stack. Signal Group also supplied the heated sample line. As an MCERTS-certified system, the analyser’s data are accepted by regulators including local councils, Natural Resources Wales, SEPA and the Environment Agency.
The system is supported by daily automatic zero checks, periodic span checks using calibration gas, and comprehensive on-site servicing every six months under a long-term maintenance agreement with Signal Group.
SUMMARY
Regenerative thermal oxidisers are designed for continuous operation, and any interruption to their operation would also increase the cost of recreating sufficiently high temperatures within the RTO. Also, thermal cycling can cause mechanical stress, increase energy consumption and damage ceramic media affecting the performance of the RTO. At the Wrexham site, where production schedules vary daily, continuous monitoring is critical for providing assurance that the RTO is performing well and for ensuring operational efficiency, environmental protection and regulatory compliance.
Signal Group
www.signal-group.com Instrumentation Monthly June 2026
lackline Safety has announced its partnership with MFE Inspection Solutions to integrate Blackline’s cloud-connected portable
detector with Boston Dynamics’ Spot, the world’s leading mobile industrial robot. The solution extends connected gas detection into robotic workflows, instantly delivering gas readings, alerts and location data to remote monitoring teams, before sending personnel into potentially dangerous areas.
“Gas detection is critical for safety. And teams are no longer limited to collecting that data only when a person enters the area,” says Dylan Duke, CEO of MFE Inspection Solutions. “Robots like Spot are already being used to collect inspection data remotely in hazardous environments. This solution adds real-time gas detection to those workflows, giving operators insight into gas hazards before deciding how and when to send people in.” Industrial gas monitoring has traditionally relied on personal monitors worn by workers. Connected gas detection provides a new model, giving teams access to gas data from multiple sources—personal monitors, area monitors, and remote systems like robots or drones—with live, detailed views of atmospheric conditions that help organisations make faster decisions. The MFE Spot Connected Gas Detection Solution provides a crucial piece of the connected worker puzzle, allowing teams to monitor gas conditions remotely without endangering personnel. “This is about connecting technologies customers are already using and making them more useful together,” says Christine Gillies, chief product and marketing officer, Blackline Safety. “MFE has built the digital plumbing to connect Spot with Blackline’s connected gas detection platform, adding another layer to worker protection while giving organisations critical exposure data
as it happens, not after the fact like with traditional monitors, so they can make informed decisions in the moment.” The solution lets operators view gas readings and alerts in Blackline Safety’s Blackline Live software, directly on the Spot tablet during operation, providing real-time awareness in the field. It also triggers automated return-to-home actions when defined gas thresholds—such as rising LEL—are detected, helping teams move Spot out of hazardous conditions and protect site personnel. Teams can use a wide range of hot-swappable, configurable, cartridge-based sensors that can be tailored to different environments and applications: oil and gas operators can use it to monitor combustible gases like methane or LEL conditions; semiconductor facilities can use it to detect gases like ammonia; and, chemical processing plants can use it to monitor for toxic gases like hydrogen sulfide (H₂S), carbon monoxide (CO), or sulfur dioxide (SO₂) “Spot’s thermal, acoustic, and visual inspection abilities provide AI-powered predictive insights into facility health,” says Merry Frayne, senior director of Product at Boston Dynamics. “Integrating the Blackline Safety portable device gives process manufacturers an even more complete picture of their site while keeping people out of harm’s way.” MFE supports deployment of the MFE Spot Connected Gas Detection Solution with Blackline Safety. by helping customers determine where robotic gas detection fits within their existing safety and inspection workflows. The team works with operators to evaluate site needs, configure the right gas detection setup, train personnel, support implementation, and remain engaged after deployment so the system is used effectively in real field conditions.
Blackline Safety
blacklinesafety.com 39
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