Project Background and Problem
A leading natural gas producer required a cost-effective fire and gas detection layout for a new wellhead facility. The original standard design was over-engineered and costly, and the client needed help determining a performance-based minimum to ensure compliance without excessive spend. The initial scope focused on flammable gas detection only.
Equinox Automation was engaged to develop a compliant, high-performance layout that balanced safety, standards, and cost.
Solution
We developed two design options—one including a large sand-catcher cyclone for start-up and another for ongoing operations without it. The goal was to ensure either configuration would remain functional if the sand catcher was removed after initial commissioning.
Using 3D fire and gas mapping software, we applied a performance-based design approach to set detector coverage targets and optimise placement. Both point and open-path gas detectors were used to meet requirements. The analysis verified that one point detector could be safely decommissioned if the sand catcher was removed—without compromising coverage.
During the design, we also identified a separate fire hazard linked to a flammable chemical used for injection into the production stream. We recommended the addition of an IR flame detector, and validated its placement using software tools to ensure full hazard coverage.
Results
Cost Savings: We saved our client ~$80,000 by reducing detector count and optimising equipment selection.
Improved Safety: Enhanced detection by addressing unrecognised hazards and reducing leak response time.
Simplified Construction: Detector mounting aligned with existing structures, minimising trenching.
Flexible Design: Verified performance in both start-up and standard operations.
By combining risk-based design, specialist tools, and proactive hazard identification, Equinox Automation delivered a fit-for-purpose detection solution that met safety, compliance, and budget goals.
Contact Equinox Automation to design your next fire and gas detection system project.
Figure 1: IR3 flame detector coverage map visualizes the detector coverage to assist with design verification against coverage targets.
Figure 1: Our engineers use specialist 3D fire & gas mapping software tools for compliant and effective detector layouts.
Figure 2: Working from the project 3D model enabled the design to be optimised for construction efficiencies.
Figure 5: Verifying flame detector coverage and field of view.