Orica HTS Upgrade – Kooragang Island

The Challenge

As part of a major upgrade to the High-Temperature Shift (HTS) unit at its ammonia plant, Orica needed to install critical new equipment deep within a highly restricted and volatile area of the facility.

Key challenges included:

• Extremely limited access in a densely packed operating plant
• Strict shutdown timelines and operational safety requirements
• The need to work adjacent to active chemical systems with zero tolerance for error

“IFS and Milleen delivered exactly what this site needed — discipline, flexibility, and technical control.” — Orica Project Manager

The IFS Solution

IFS worked in close collaboration with the Milleen Group Construction division and Orica’s project and safety teams to co-develop a bespoke construction methodology tailored to the site’s operational constraints.

Drawing on IFS’s extensive screw pile expertise, our solution included:

• Precise foundation planning in tight-access areas
• Customised installation sequencing aligned to shutdown windows
• Engineering-led risk mitigation for work near volatile systems

Our familiarity with heavy industrial protocols ensured seamless integration into Orica’s control environment — executing works safely, efficiently, and without disruption.

The Outcome

All works were completed to specification, within shutdown timing, and in full compliance with Orica’s safety and environmental standards. The project demonstrates IFS’s capability in engineering-led, high-risk environments where collaboration and precision are paramount.