Gas Chromatograph and Sulphur Analyser Upgrade

Brief

Situation

AJ Stack Solutions (AJSS) undertook works to remove obsolete gas composition monitoring equipment and install new equipment at a major compressor station. The works needed to be completed in a limited outage window within the upstream suppliers planned shutdown.

Task

The project consisted of the mobilisation of three AJSS personnel to site, including a Project Engineer, Mechanical and Electrical Field Technician, and an Industrial Electrical Engineer sub-contractor. The task included the removal and decommissioning of the obsolete system and installation of an upgraded all in one, gas chromatograph (GC) and sulphur analyser (SA) system within the customer specified timeline to the specification required by the industrial electrical code.

Action

The AJSS Project Engineer led the removal of the redundant system, and decommissioning of all tubing and electrical components relating to the system. The AJSS team provided solutions for the modification of the outdated system to allow integration of the new system into the existing configuration. This involved the fabrication of brackets and mounts to accommodate the new equipment and tubing. A new junction box and respective wiring was installed and connected to the new GC and SA integrated system, as well as to already present systems. Throughout the duration of the project AJSS ensured the safe execution of works under strict safety protocols and ensured adherence to all required standards and laws. The AJSS team worked with operators and technicians on site to ensure the works were performed as intended and in accordance with OEM requirements.

Result

The successful completion of the works in April, 2025 saw the new GC and SA integrated system installed in accordance with customer specifications, regulations and regulatory body approval. The electrical works passed EEHA and H Class inspections as per industry standards. The site was cleaned and restored to its original state, ensuring all hazards were contained and means were implemented to mitigate any persisting risks.

Personnel

Lead

Operations Director

Paul McMullen

Paul is a seasoned operations, commercial, and sales leader with over 18 years of experience in both traditional and renewable energy industries. He holds a Master’s Degree in Mechanical Engineering from the University of Edinburgh and has served in key roles with leading companies, including Solar Turbines, General Electric (GE Vernova), and Vestas Wind Systems. Paul built a strong technical and commercial foundation developed from over 14 years at Solar Turbines (A Caterpillar Company). He has held various roles including Commissioning Engineer, After Market & New Equipment Sales Leader, LTSA Operations Manager, and RM&D Sales Leader across ANZ, Pacific, and the USA. He expanded his leadership expertise in the utility power sector serving as GE Service Sales Director in the ANZ region, where he oversaw sales, commercial activities, and execution handover for all customer service, parts, LTSA, and major outages involving GE and legacy Alstom Gas Turbine and Steam Turbine Generators. Paul then translated his experience into the renewables industry as ANZ Sales Manager at Vestas Wind Systems managing project development, sales, and execution handover of full EPC and S&I major wind farm infrastructure projects exceeding 1GW+. Paul's career reflects his belief in the power of constructive collaboration and communication to drive customer success, from basic annual services to large-scale infrastructure projects. As a valuable member of the AJSS leadership team, Paul leverages his extensive experience in project development, commercial viability, technical & logistical scoping, project management, and hands-on execution to deliver exceptional results.

Lead

Rotating Equipment Engineer

James Stack

James is a marine engineer completing his degree at Australian Maritime College (University of Tasmania) and his cadetship with Teekay shipping Australia in 2017. After which he went on to work as an engineer officer on a variety of vessels including oil tankers, FSO’s, bulk carriers, and offshore supply vessels. He has also been involved in sea trails and ship deliveries for the Royal Australian Navy as well as roles on Navy training and support vessels. James has been part of AJSS on a casual basis since 2014 working on various rotating equipment projects as part of the office support team and more predominantly in the field. In 2023 James took on a full-time role as rotating equipment engineer at AJSS.

Lead

EEHA & Quality Manager

Damien Ford

In 2017 Damien joined AJSS as an offshore EEHA supervisor in the Timor Sea. Since joining AJSS, Damien has provided leadership to the AJSS EEHA team for all projects and today manages a team of EEHA specialists across Australasia. Damien began his career as a qualified electrician in 1992 entering the O&G industry in 2003 starting with DLNG construction swiftly moving to commissioning and inspection arena. 2007 saw the beginning of his offshore industry career with Rig Inspection Services (RIS) where invaluable experience was gained within operations, maintenance and service of E&I equipment onboard jack-ups, Semi Subs, FPSO’s internationally, producing independent facility condition reports for owners and potential lease clients alike. Additional activities included Chief electrician duties, Senior maintenance electrician and EEHA campaign coordinator. From 2012 to present Damien has focused on EEHA E&I inspection campaigns, most recently involved with the QA/QC teams involved with delivering the ground-breaking Gorgon modules, Prelude FLNG, and Inpex CPF projects based in South Korean shipyards. Since returning to Australia E&I commissioning coordinator on the SCM17 project for BHP at Roxby Downs and Lead EEHA inspector on 2 FPSO’s located in the North west shelf (NWS).

Lead

Senior Field Engineer

Neil Walters

Neil started his professional career as an Electrician with the West Australian Government Railways in 1980. Since then, he has worked in a diverse range of industries including Manufacturing, Service, Heavy Mining, Alumina, and Oil and Gas, specifically on rotating equipment and Gas Turbine Engines. As a Regional Field Engineer with Solar Turbines Australia, he specialised in commissioning, troubleshooting and servicing Solar’s full product line, both centrifugal compressors and generators. During Neil’s 10+ years with Solar, he spent considerable time in the USA working with the Performance Test Department, exposing him to the very complex field of turbine engine performance. After leaving Solar in 2006, Neil spent some time with the Victorian Energy Corporation – now AEMO where he worked with the Gas Sector as a Gas Systems Engineer. In 2007 Neil accepted an offer to take up a fly in–fly out position in Papua New Guinea as a Reliability Engineer with Oil Search PNG Ltd. This position utilised his skills with instrumentation and controls, as well as his extensive knowledge of Solar Turbines to service Oil Search’s fleet of 20 plus Solar Turbines. It also utilised Neil’s skills as a trainer and mentor for the PNG citizen workforce. In 2012 Neil joined Invensys Turbo-machinery Division as a Turbo-Machinery Controls (TMC) Consultant, based out of Clayton Victoria. Neil played a key role in developing, implementing and executing Invensys’ turbine, compressor and generator upgrade projects. Specialising in turbines, rotating equipment and hazardous area electrical installations, Neil’s experience covers everything from maintaining and troubleshooting high voltage systems to hydro-mechanical and everything in between.Neil has been working with AJSS since 2014 in various Project Management, Technical Auditing and Field Support roles. He is a TÜV certified safety instrumented systems engineer. He also has a Type B Gas fitting licence in Victoria, SA, WA and NT.