Adapting to Complex Environmental and Technological Challenges

By Keeshan Wadia, General Manager – Engineering and Projects 

Chevron’s Gorgon and Jansz-Io compression projects represent not only the ambition of a major energy development but also the challenges of working within one of Australia’s most protected environments – Barrow Island. The project’s environmental significance is matched by the cutting-edge technological innovation it demands, particularly as Chevron looks to ensure long-term gas supply from the Jansz-Io field. 

The Jansz-Io Compression Project involves complex subsea technology and infrastructure that will stabilise gas flow to the Gorgon gas plant, extending the life of this world-class natural gas project. Aerison was brought in to overcome one critical challenge: providing a customised STATCOM (Static Synchronous Compensator) solution that could withstand the extreme conditions of Barrow Island while complying with stringent environmental and safety requirements. 

The Role of Innovation in Environmental Stewardship 

Aerison’s work on this project began with ABB’s request to design, manufacture, and supply electrical buildings that would house the STATCOM equipment for Chevron’s development. Unlike ABB’s previous commercial and infrastructure projects, the Zone 2 Hazardous Area classification of the Barrow Island site made the standard STATCOM solution unfit for the project’s needs. 

In response, Aerison took a fresh approach, proposing a complete solution that would meet these strict specifications. The design of the building was meticulously developed from the ground up. Working alongside local and international vendors, we conducted thorough research to find suitable products that could meet the operational and environmental requirements. 

Beyond technical specifications, we understood the unique environmental sensitivity of Barrow Island. Aerison’s design didn’t just meet functional needs; we also ensured that every detail—from the building’s structural design to the exterior finishes—adhered to Barrow Island’s strict environmental protocols. This attention extended to choosing lighting that would minimise wildlife attraction, ensuring our work contributed to preserving the island’s fragile ecosystem. 

The Customisation of the STATCOM Solution 

The Aerison-designed buildings were fabricated using over 70 tonnes of steel for a single module, a solution that was certified to meet Oil & Gas industry QA/QC standards. The modular buildings housed all STATCOM equipment, including HVAC, fire and gas detection systems, and electrical components—designed for operation in hazardous environments. 

Our scope of services didn’t stop at design. Aerison was responsible for procurement and installation of HVAC systems, safety equipment, and the fire & gas detection infrastructure, as well as the installation and testing of third-party equipment, including the STATCOM units and associated panels. 

This solution ensured that Chevron’s Jansz-Io compression project could operate seamlessly within the high-risk, high-standards environment of Barrow Island, meeting all safety regulations while maintaining the long-term reliability of critical energy infrastructure. 

Outcome and Lessons Learned 

The success of this project not only reinforced Aerison’s role as a trusted partner in engineering and fabrication but also expanded our portfolio to include highly specialised offerings in the Oil & Gas sector. The completion of this project proved that innovation, cross-disciplinary expertise, and tailored solutions can transform the way complex engineering challenges are approached. 

Lesson Learned #1: Tailoring Solutions to Meet the Unique Challenges of Each Project is Crucial 

Barrow Island’s Zone 2 Hazardous Area classification meant that a standard STATCOM system couldn’t be used without significant modifications. The need for a tailored solution was clear, and Aerison was engaged to develop a solution that met the technical specifications and regulatory requirements. By taking a flexible, customised approach to the design and fabrication process, we were able to address the specific challenges of Barrow Island and ensure that the final product exceeded the client’s expectations. 

Lesson Learned #2: Cross-disciplinary Expertise is Essential for Addressing Complex Projects  

For complex and large-scale projects, having an in-house team with a wide range of technical expertise allows for faster problem-solving and more effective coordination. By collaborating internally, we were able to leverage the strength of our multi-disciplinary capabilities to deliver a complete solution that met both technical and environmental demands. 

Lesson Learned #3: High Safety and Quality Standards are Essential for Long-Term Reliability 

The STATCOM solution we delivered for the Jansz-Io Compression Project wasn’t just a technical achievement—it was designed to set a new benchmark for reliability in extreme conditions. With a 50-year design life, every aspect of the project required a meticulous focus on quality, durability, and safety to ensure long-term performance. Barrow Island’s high temperatures and hazardous environment meant that standard solutions wouldn’t suffice; instead, we had to engineer a system built to withstand decades of exposure while maintaining operational integrity. This project reinforced that when safety and quality are prioritised from the outset, the result is a resilient solution that delivers sustained performance in even the harshest conditions. 

Building for the Long Term: A Vision for the Future 

As the energy sector continues to face increasing pressure to balance growth with environmental responsibility, projects like the Jansz-Io Compression Project are setting new benchmarks. At Aerison, we are committed to providing engineering solutions that don’t just meet current requirements, but lay the foundation for sustainable, efficient infrastructure for the future. 

Partner with Aerison for Innovative Engineering Solutions 

Aerison provides real-world, multi-disciplinary engineering solutions, delivering safe, well-considered, and highly valued outcomes for our clients. If you’re ready to take on complex challenges with a partner that understands the balance between innovation, quality, and sustainability, get in touch with us today at sales@aerison.com.