The Challenge 

Not as straight-forward as the brief, this project was challenged by scale, limited supplier options, and the need for unique tooling for complex install applications. 

The primary challenges included managing the large-scale project with sourcing unique tooling compliant with Australian standards and collaborating effectively with third-party contractors. All of this being provided whilst maintaining a strong focus on safety compliance for all parties involved. 

The Objective  

This project was ATP Solutions’ first major engagement with the Nickel Refinery, following a successful, smaller design project, to provide a comprehensive fire detection system using the client-preferred Tyco MX equipment, known for its suitability in high-risk, high-voltage environments. 

The goal was to minimise downtime, adhere to the tight timeframe, and ensure flawless execution despite the logistical and technical challenges.  

The project’s ambitious scope and the refinery’s operational constraints demanded innovative solutions and rigorous project management to ensuring all requirements were fulfilled by external contractors. 

The ATP Solution 

ATP Solutions tackled challenges with robust financial management and hour-by-hour project management, alongside a unique, effective approach which grouped buildings on-site together, rather than the traditional one-by-one approach, for greater efficiencies and timeline. 

A key innovation to arise from the project was networking the fire detection system onto a live digital mapping system. 

This technology allowed for instant alarm notifications in the control room, enabling remote preventative maintenance and better preparing responders for onsite emergencies. This capability was new for the client and marked a significant advancement in their fire safety solutions.  

Getting it Right  

The project’s success hinged on disciplined project management and strategic, evolving adaptations. The implementation process involved meticulous supervision of the installation by a third-party ATP contractor, followed by thorough testing and sign-off by ATP.  

ATP and its subcontractor contributed innovative, out-of-the-box strategies to overcome complex challenges, leveraging detailed planning to pre-empt potential setbacks. 

A standout contribution was made by the ATP site supervisor, whose expertise was pivotal in managing the project’s complexities.  

Results & Impact  

The innovative strategy approach taken by ATP, working on similar stages across multiple locations, akin to a production line, enhanced efficiency and will be adopted company-wide to guide future project delivery.  

The client greatly appreciated the streamlined communication and project management provided by ATP, which eliminated the need to manage multiple contractors independently.  

The Outlook 

ATP Solutions transformed all these project challenges into a partnership of strength, thanks to stringent project management and innovative installation strategies, ultimately leading to improved operational efficiencies.  

This project has not only met but exceeded expectations, laying the foundation for an ongoing partnership with the client. It stands as a testament to ATP Solutions’ adaptability, technical prowess, and commitment to delivering high-quality fire safety solutions.  

The Challenge  

This project presented unique challenges, along with the scale of the ask, there was a need for custom-designed firefighting equipment as well as attentive management of the complexities of integrating this equipment into the existing infrastructure.  

The main hurdles presented in ensuring overall project management, maintaining stringent quality control over subcontractor work as well as ongoing reorientation and relationship building with coordinating multiple lead engineers due to high turnover at the client’s end.  

 The Objective  

ATP’s primary goal was to maintain the integrity of the client’s safety standards in design and supply of comprehensive wet firefighting systems, encompassing hydrants, pipe rises, and modifications to existing piping lines for this new site to become operational.  

The second part of this project included fabricating two skid packages from scratch, incorporating a foam system, and customising parts to fit specific requirements.  

The ATP Solution  

ATP collaborated closely with a foam skid manufacturer on the east coast, engaging in regular communication to uphold quality standards. This partnership included an on-site inspection at the manufacturing facility prior to sign-off, ensuring that all specifications were met. 

When unexpected challenges arose with the availability and capability of the initially selected steel fabricator and painting vendors, ATP’s engineering team swiftly identified and secured alternative suppliers. These alternatives not only met the client’s strict timeline but also maintained the high-quality standards required. 

This proactive and flexible approach highlights ATP’s commitment to thorough communication, rigorous quality control, and innovative problem-solving under demanding project conditions. 

Getting it Right  

The project’s success depended on ATP’s meticulous approach, from the initial design to the final implementation. Quality was paramount. This involved customising solutions, managing process challenges, and ensuring all modifications met the highest standards.  

Results & Impact  

The project culminated in the successful installation of a functioning fire protection system, vital for the new site’s operation. ATP’s expertise in project management and engineering support played a crucial role in overcoming hurdles and ensuring timely completion.  

The Outlook  

This project underscored ATP Solutions’ capacity to deliver complex, custom-designed firefighting systems, reinforcing their role as a leader in innovative safety solutions and a true partner to their client, going above and beyond to produce the best outcome. The successful completion of the project has laid a strong foundation for continued collaboration with the client.  

The Challenge

After the successful installation and results of a state-of-the-art ASD system at an existing site in 2017, it came time to upgrade a second site in this remote area.

Unlike the original location, the new site presented its own set of unique challenges, with a need for a advanced reporting and communication system a customised design was required to meet this unique application. Pushing the limits previously set in other projects.

ATP Solutions was tasked with overhauling the existing system and ensuring seamless integration with a live existing control monitoring system, despite the complexity of integration across four different systems. And introducing a whole new level of communication.

The Objective

The primary goal was to enhance fire safety and identification by redesigning the system to maximise coverage and reporting of events while utilising existing infrastructure as much as possible.

ATP Solutions set out to raise a new standard in fire detection technology, ensuring the safety of people, the facility and its operations and surrounding environment.

The ATP Solution

The first step in the project was to complete a full desktop review based on all available information provided from site, this step was ongoing as COVID-19 was in effect, following that a full site audit for the existing ASD system, which revealed a requirement to redesign, from scratch.

The new design included systematic piping rerouting and communication reporting to improve coverage, detection and identification; a solution that marked a significant innovation in fire safety, as the first to have such an extensive level of ASD coverage, including in-cabinet detection at an unprecedented scale.

The technology, combined with precision design, created an advanced pioneering project in fire safety.

Getting it Right

ATP Solutions capitalised on its strong working relationship with the client’s system owner. Taking responsibility and initiative, ATP’s expertise and guidance proved instrumental in resolving technical issues and ensuring a high-quality outcome.

The project execution involved careful planning, regular adaptations to initial plans, and a step-by-step implementation process.

Results & Impact

This system is a significant improvement on the outgoing, disjointed comparison, allowing for a level of response un-seen within the industry. The ability to not only very accurately locate and respond to a smoke event but to do so from the Perth control station on a site 1500km away.

This quick intervention, not possible with the old system, underscored the necessity and effectiveness of the new ASD system. And will be foundational to all future endeavours by this Gas Giant.

The Outlook

This project exemplifies ATP’s capability to deliver custom, innovative solutions in fire prevention and highlights the importance of understanding specific client needs and the impact of advanced fire safety systems in industrial settings.

Delivering Critical Fire and Gas Detection Systems

ATP Solutions Business Development Manager Jordan Robers said the contracts represented an opportunity to contribute to a major project in Australia’s energy sector development.

“The two packages ATP Solutions will deliver are designed to protect workers in the accommodation on-site as well as the FCS itself when unattended,” he said.

“ATP Solutions has been tasked with providing fire and gas detectors (ITB-02) and the addressable fire alarm system (ITB-18) for the normally unattended floating FCS.

“We are proud to contribute to the expansion of the Gorgon LNG project, leveraging our local expertise and decades of experience in the industry.”

Comprehensive Safety Solutions: ITB-02 and ITB-18 Packages

The first package (ITB-02) involves the provision of comprehensive fire and gas detection devices for accommodation and throughout the FCS. “ATP Solutions will be responsible for the design, engineering, assembly, supply, inspection, testing, commissioning, and transport of the system components for installation in the FCS as part of the Jansz-Io Compression Project,” Mr Roberts said.

The second package (ITB-18) will see ATP Solutions deliver the addressable fire alarm system including field devices, with the aim to detect fires promptly via multiple methods, then activate alarms and initiate signals to the master control panel for activation of platform alarms and fire protection systems ensuring compliance with Australian safety and regulatory standards utilising ATP Solutions unique local expertise.

35 Years of Expertise and Commitment to Australia’s LNG Sector

With over 35 years of experience in the local industry and a proven track record in LNG projects, ATP Solutions is well-positioned to deliver exceptional results. The Jansz-Io Compression Project, part of the Chevron-operated Gorgon Project, involves enhancing the recoverability of the Jansz-Io field to support maintaining long-term natural gas supply.

Chevron’s Continued Investment in Australian Industry

Hanwha Ocean Co., Ltd. is responsible for the engineering, procurement, construction, and transportation of the FCS for the Jansz-Io Compression Project.  ATP Solutions’ involvement in the Jansz-Io Compression Project provide local opportunities and further Chevron’s investment in Australian goods and services. With over $40 billion invested in Australian contracts and more than 700 contracts awarded to Australian companies, the Gorgon Project continues to drive economic growth and development in the region. As ATP Solutions continues its longstanding involvement in the Gorgon Project, they remain committed to delivering tailored safety solutions and supporting Australia’s energy sector for years to come.

The Gorgon gas project includes both the Greater Gorgon gas fields and a liquefied natural gas plant on Barrow Island. In 2009 a development consortium between three major oil and gas companies received approval from the WA Government to develop what was set to become Australia’s largest resource project there.

As it turned out, that meant accommodating nearly 8,000 people on Barrow Island. If the camp were a hotel, it would be the third largest hotel in the world – and it needed to be safe as houses. Our client essentially required three projects in one. They needed fire detection and suppression in the camp/kitchen, in the site offices, and in the operations buildings/control room.

As such, Advanced Technology Products (ATP) submitted a winning proposal to the Gorgon LNG project operator to implement fire detection and suppression in the camp.

The ATP solution

Stage 1 of our winning proposal detailed:

• Fire and gas detection and suppression systems for the complete camp
• Operations & TCF
• Ex Telephone Systems
• Junction Boxes
• Security System CCTV
• Access Control Interfaces including design, assembly, documentation, FAT, SIT and SAT.

This would be followed by Stage 2, which included the design and supply of fully networked fire alarm panels, the integration of twin graphics packages and over 7,000 field devices. We designed state-of-the-art fire detection technology in each of the 8,000 rooms and planned to install 160 fire panels in all temporary facilities, camp facilities, main operations building and control rooms.

Network monitoring was an important technical component of the ATP solution. This essentially involves a graphic display denoting the location of every smoke detector onsite in real-time. The system operates via mixed media (including fibre optic, microwave, ethernet) to facilitate instant risk awareness and maximum response time.

We also devised a water-mist sprinkler system for the control room. It was pertinent the control room be well-protected considering the room must be manned at all times – if a fire starts, the gas plant cannot be left running. The fire suppression system in the control room was designed to put the fire out while staff continued to operate the control room.

Implementation 

We were able to mitigate integration factors easily since we entered the project in the construction phase. We did, however, liaise with our downstream client in regards to different types of communication tech in use, including microwave, fibre optic and regular switch networks. For the hardware, we incorporated a modular design to accommodate for the sheer number of units. We made all the hardware as interchangeable as possible so that supply lines wouldn’t need to stock unique singular items. Of the 160 panels, we whittled the variety down to just 5 or 6 different types which made production easier and improved our build efficiency by reducing the number of spares per type.

One major integration factor we managed was Barrow Island’s classification as a Class-A nature reserve. Having a gas plant built on a nature reserve generates obvious concerns, so we went above and beyond in our mission to keep the plant safe and maintain the world-class environmental integrity of the location. The quarantine restrictions also meant we were unable to ship anything in cardboard, and that all hardware delivered had to be fumigated. That additional layer of quarantine and biosecurity measures posed a complex challenge – but challenge is what ATP does best. Working through an additional layer of restrictions simply meant we had to come up with better, more innovative ways to implement our design.

Outcome & future plans

At the project’s conclusion, all of the deliverables were on time and in their required places despite the extra layers of restriction. There were no project management targets missed, and no shortfalls to speak of. The improved worker safety conditions for those staying at Barrow Island are a significant benefit for our downstream client, not to mention the ability to manage control room fires at times when evacuation would mean catastrophe.

We have since engaged in an ongoing maintenance contract with our client that has spanned a decade. From the first fire panel supplied in 2009 to the monitoring system upgrade in 2019, ATP is proud to have designed and implemented a bid-winning solution for fire detection and suppression at one of Australia’s biggest resource exploration projects.

Quantum Minerals is a rapidly growing international mining company that, in 2013, assumed an 80% equity interest in the company that owns Cobre Panama – a large open-pit copper mine development spanning 13,600 hectares of dense rainforest in Central America.

With plans to ramp up production to unprecedented levels in 2018 in order to take advantage of the site’s rich copper deposits, FQML engaged an engineering firm to upgrade the existing fire system.

As the beginning of a new era for Cobre Panama, FQML was prompted to seek out a superior life and asset safety solution to match its lofty ambitions. Notifier, a leading manufacturer of engineered fire alarm systems who had worked with FQML on previous projects, referred the mining company to ATP, Notifier’s Western Australian based distributor.

On the surface, choosing ATP made sense. As the market leaders in the design, engineering, procurement, testing and commissioning of special hazard detection and protection systems, ATP has a reputation as fire industry specialists. However, the partnership would also mean establishing a supplier base some 17,000km away in Australia. This tyranny of distance would add extra demands, such as working around reduced lead times for coordinating and assembling product elements, adapting to American Standards and deploying supervision on site to work with US personnel and ensure installation is performed as per the NFPA code requirements.

After a lengthy due diligence process, FQML concluded that, despite the logistical challenges, ATP had the right capabilities to deliver the most reliable, high quality fire detection system engineering.

Leading the way

ATP’s expertise had immediate impact. What began as a simple VESDA Very Early Warning Smoke Detection solution grew into something far more comprehensive after ATP’s value-adding recommendations. ATP produced the solution’s design, drafting drawings, then supplied three packages across three core Cobre Panama sites utilising the Notifier system as the fire detection system’s main hardware.

The first network package was designed for the 26 substations being built, which included an Xtralis VESDA system and a normal fire detection system, designed in line with National Fire Protection Association 72 fire alarm system code standards. Field devices were connected to each fire panel, and each one was equipped with a single mode fibre to create a site wide fibre network. The panels were also equipped with notification outputs to alert personnel in the event of fire scenarios; there were two separate fire networks, located in the port and mine areas. The main fire panels (NCA-2) provided network control and status/history display of all of the fire alarm panels connected in the network.

The Paco power plant site was supplied with an explosion-proof detection, linear heat detection and protection package. The solution comprised detectors, manual call points and horn strobes. The fire alarm control panels were fully networked and connected to a central monitoring station, NCA-2, in the main turbine building. In some areas, such as the conveyors, in the event of fire detection, the water spray system will activate and suppress the fire, while FQML personnel are alerted of the fire location. If none of the workers in the vicinity are trained to take action, the control station is notified to deploy the response team.

Site three is the Jetty Conveyor, located in the port area. After being loaded from ships into the hopper, the conveyor will transport coal to a storage shed to run the plant, necessitating a Signaline linear heat detection system. ATP worked alongside other engineers and electrical contractors to provide a solution comprising design, support and interfacing. The package involves linear heat detection along the conveyor belt, with Honeywell flame and ember detection along the transfer station, MEDC manual call points for the pull station, dust suppression in the hopper and a water spray system in the conveyor system. Two fire panels have been installed, in the jetty substation and the service platform substation, with both reporting signals to NCA-2.

A nimble end-to-end integrated solution
ATP’s extensive experience in hazardous and non-hazardous environments set the team up for success amidst a multitude of challenges. To ensure seamless approval prior to execution, it was critical to ensure the solution was designed in line with local code requirements. This was a mighty challenge for ATP’s Australia-based team, who had to learn American NFPA Standards in order to meet the project’s precise requirements.

During the engineering stage, ATP arranged a meeting with FQML’s representative engineering firm to methodically discuss the process of execution, the deliverables of the project and their expectation of the Fire Detection System Solution. This ensured the correct products were incorporated into the design to meet the correct requirements, airflow environments, pipes and fittings, saving the client a great deal in time and money by preventing design failures from the outset.

Overall, ATP’s attention to detail, fused with a flexible approach to changes in job scope, resulted in a comprehensive solution tailored to FQML’s exact needs. By leaving no stone unturned, ATP has set up the three packages for a seamless rollout that exceeds deadline and cost expectations.

Download the Panama Case Study PDF

Advanced Technology Products was contracted by a tier-1 oil and gas client known to be Australia’s largest natural gas producer and recognised for their world-class capabilities as an integrated upstream supplier of energy around the world. As a pioneer in the industry, our client began their first trial of VESDA (Very Early Smoke Detection) units in 1991, setting up a watertight relationship with Advanced Technology Products that has spanned the last 25 years.

In early 2016, the client began discussions with us regarding previous and potential issues with smoke detection at a large gas plant. As such, Advanced Technology Products proposed an audit in two phases to investigate any shortfalls in their existing fire detection. The gas plant project would thus involve providing smoke detection to new cabinets and upgrading old systems. With Advanced Technology Products’ vast expertise and long working relationship, the client was confident we could pinpoint their unique detection and protection objectives. The goal was to then deploy a hand-selected project team to mitigate the risk of a fire event by providing better coverage, higher sensitivity systems for the detection of smoke and engineering solutions to reduce maintenance costs.

The site had outsourced two different companies to design and install their fire detection, warning, control, and intercom systems. ATP Solutions was asked to come to the site and complete compliance checks on 16 individual systems. The desired outcome was our Third Party System Verification Certificate to meet Australian Standard 1670.1:2018.

To ensure our clients met this standard, we checked for compliance in design, installation, commissioning, configuration, components, and baseline data of their fire systems. Inspections were carried out using our Third Party Verification Punch List Report, with one for each system. This documentation identified any defects and outlined corrective actions to rectify any issues before certification was possible.

Defects were ranked by how hazardous they were. Critical defects required the client to correct them before they were signed off on the punch list. Non-critical defects were a recommendation to rectify in the near future but were not required to be completed before certification.

We pride ourselves on being a credible source, and as such, we provided the client with templates of the four certifications required – design, installation, commissioning certificate, and commissioning report. Once all 16 systems had been checked for compliance, the outcome was positive with each one achieving our Third Party System Verification Certificate.

As the Nickel mine-to-market business’ first choice for asset safety systems, ATP has been awarded the contract at another site. Work is scheduled to commence in November 2022 and this time, our seasoned experts are responsible for both the design and the third-party certification.

Extending our third-party certification services to the oil and gas industry, we are also currently completing compliance checks for Woodside Energy.

Compliance checks that ensure fire detection, warning, control, and intercom systems meet 1670.1:2018 are being pursued more frequently by FPA Australia, Australia’s peak industry body for fire safety. In the eastern states, it is mandatory to have a third-party certification. Previously, being witness to commissioning was not a formalised requirement, however, third-party certification can now be provided.

Our third-party certification services are relatively new to ATP Solutions but are growing in demand. We offer all-inclusive compliance checks to ensure your fire systems receive our Third Party System Verification Certificate. If the system design is not our own, then we are required to conduct a design review (or baseline data review) to ensure all drawings and documentation are confirmed for sufficiency, accuracy, and compliance.

To learn more about how to protect your people and assets, as well as our third-party certification services please call our trusted team on 08 9479 1266 or contact us here.

The operator’s Digital and Geospatial Teams extended their relationship with Advanced Technology Products (ATP) after completing business development work with Extronics. This Tier 1 operating company was looking to capture improved data on the location and associated intelligence of vehicles, equipment and personnel on-site. Extronics presented the IoT technology to the company, which developed into the proof-of-concept project.

Proof of concept – what does that mean?

A proof-of-concept project allows us to demonstrate in a small-scale installation that the technology does what it says it will do, and that it works in the environment as intended. The benefit of the proof-of-concept project is that potential clients can essentially ‘try before you buy’ on a much smaller scale and budget before deciding to commit to a full-scale deployment.

Delivering a proof of concept also helps us set out the full scope of the job and allows us to address any security or privacy concerns that anyone may have on-site before committing to a more wide-scale project.

What was the issue that needed to be addressed?

The use of location intelligence at the gas facility was to investigate enhancements in current health and safety practices, emergency response (including security) in and around the operational facility as well as improved asset performance via improved intelligent insights.

Use cases included improved safety for mustering, critical area management and locating personnel. With a 2km2 gas plant, determining if everyone is where they should be, becomes far more critical.

Using an online asset manager, the system allows for automatic mustering and the ability to locate personnel that did not appear at a specific mustering point. The site critical area management requires that specific areas are fenced off to certain personnel, for example, visitors are not allowed in process areas, or non-HV trained personnel are not allowed in HV switch rooms.

The new technology would give the ability for the operator to geofence an area off and provide alerts and reporting to ensure the right people remain in the right areas. Locating personnel and assets would also allow for improved tracking of productivity and efficiency, allowing accurate reporting on the time it took to complete a task and identifying any hold-ups in the flow of work.

The ATP solution

The project was delivered in two distinct streams, using Personnel and Asset Monitoring, as well as a Plant and Equipment Monitoring system combined with Workforce Intelligence. It was determined that using GPS-based tags (instead of just Wi-Fi tracking) was the best option to address the location accuracy required by the client. The iTAG X30 from Extronics was the perfect solution offering GPS location positioning to meet the client’s requirements. Supported with the enterprise-class MobileView Visibility Platform, the client was able to easily track the location of personnel in real time from a central location. In addition, the client used the API to extend their analytics capabilities with an existing third-party platform meaning the solution was fully integrated with the clients existing systems.

The solution involved deploying everything remotely on Amazon Web Service (AWS) which is a secure cloud service while interfacing with the onsite Wi-Fi. After this was completed, we could deploy to the site with tags in hand. We then ran a collection of user case scenarios to demonstrate the functionality of the system and ensure the product was working as intended.

Outcome and future plans

The pilot system developed by our team exceeded our client’s expectations. Working with GPS tags is a relatively new technology for ATP and this project was one of the first deployments using the tags. However, working with Extronics as a technology partner meant we were able to provide the client with all the necessary support and expertise to deliver a successful proof-of-concept using a GPS solution. Following the success of the proof-of-concept project, we would be looking to continue to develop the relationship with the client and explore similar or upscaled projects to execute.

Like any large mining operation, the client’s business has strict protocols to adhere to when it comes to ensuring the safety of their teams, and implementing state-of-the-art fire detection systems is a non-negotiable for OH&S. They required smoke detection systems for the built infrastructure including warehouses, heavy machinery workshop (with a height of 23m) and office buildings – that was reasonably straightforward. The real challenge was the environment. We had to ensure the fire detection system could withstand the incredibly dusty conditions of the region and minimise false alarms that would disrupt production.

ATP was selected by Primero Group through a referral from their staff member who had worked with us previously when they were at another company. Our dedication to diligent project management, transparency throughout our processes and commitment to innovation to provide our clients with the best outcomes gave them confidence in our abilities for optimal results on this job too. And, at the end of the day, price matters – ATP offers unrivalled experience and technical expertise, but we’re also committed to providing our solutions at a reasonable price for our clients.

Discovery and research backs ATP fire detection solution success

Fire detection solutions are our core delivery service, so we followed our usual protocols to ensure no stone was left unturned when it came to the research and design of this project’s solution. We also needed to consider the specific requirements to meet both the client and Primero Group’s specifications as well as all Australian safety and quality standards. And, we can’t reiterate enough the dusty conditions that required specific consideration for the success of the project.

We designed the fire detection system, general arrangements and layouts with schematic drawings and data sheets to meet all engineering deliverables. This planning then went through a process of review and approval with Primero before we moved into the procurement stage.

Utilising innovative technologies for optimum safety

Despite supply delays – specifically the production of microchips – due to the COVID-19 pandemic, we utilised our strong supplier relationships to source the required products on schedule for our client. From Xtralis, we sourced Open-air Smoke Imaging Detection (OSID) Beam Detectors which provide a reliable source of detection in open areas. This works by using imaging technology to shoot a beam from an imager to a receiver, [1] alerting when the beam is obscured by smoke. We sourced fire panels and alarm systems from AMPAC which were installed within their IP 66 enclosures to withstand the harsh environment. The monitoring tech and field devices were also enclosed to protect them from the elements.

We collaborated with Primero in the installation phase, with ATP supervising the installation of the equipment, and Primero installing the cables. Then, we moved into testing and commissioning the fire system for use.

End-to-end project management to fulfil project promises

There’s nothing we take more seriously than people and asset protection. That’s why ATP protects client interests and investments with a diligent project management process from project start to finish. It feeds into our technical expertise, transparency throughout your project and commitment to supplying innovative solutions to meet your objectives.

The success of this project in terms of timeline, deliverables met and innovative solution achieved gives both ATP and Primero confidence in our partnership for mine works projects. Now that we know we work well together, we look forward to many more projects with the Primero Group in the future.