Case Study: ESD and Fire Detection

CASE STUDY: ESD and Fire Detection

Design & Construction

Project at a Glance


Marcellus, PA

Project Type:

Facility Safety Upgrades

Challenges Identified

  • Multiple stations each with a different design
  • Gas, Fire Detection & ESD
  • Tying systems into SCADA
Results Met deadline adding all safety upgrades and PM oversight of installation contractors

Project Overview

In Early 2015 a major Marcellus midstream operator requested GCC to review 11 unmanned compressor stations and NGL pumping station sites in the Marcellus – Utica region for Fire and Gas Detection. The project was initiated following an incident where a broken tubing line resulted in a significant undetected leak, which continued to release natural gas for an extended period of time; the leak was found only after operators arrived at the site for other purposes.


GCC design began with a site walkdown to determine current ESD and F&G monitoring device locations, operational processing equipment locations, available structural support locations, and any future plans for expansion. F&G monitoring and ESD devices installed were cataloged to later determine their capability. The scope included a parallel OPP project and BMS conversion. A site layout of F&G monitoring, warning beacons / horns, ESD buttons, OPP monitoring devices, solar/battery powered BMS systems on flare and dehys, and other safety equipment locations were generated to show the effective ranges of the devices in correlation with site obstructions in each plant. The layout was used to identify compliance with our clients’ and industry standards. GCC specified all F&G monitoring devices, beacons, horns, junction boxes, and ESD buttons and generated detailed BOM. GCC also identified optimal conduit/ cable tray routing, calculated cable counts and conduit sizing, managed structural design and drawings, and generated IFC drawings. The IFC drawing package included PLC I/O Redlines, including recommendations or additional PLC cards, card slot locations, fused terminal boards, and connecting cables; loop drawings of all additional and existing F&G detection and indication devices including wire numbering assignments, field junction box design / sizing, layout, drawings, and BOM’s, interconnect drawings (detailing all field j-box connections); ESD P&ID’s for additional and existing F&G detection and indication; and P&ID redlines for OPP monitoring installation locations.


The construction phase was completed on all sites; including new MCC buildings with a different site placements and complete replacement of the station PLC systems. All upgrades provided substantial safety improvement to meets our client’s requirements.

10200 E. Girard Avenue
303.400.4300 MAIN OFFICE

For more information contact:

Wayne Sartori
303.378.7911 Mobile
303.325.2100 Office