The Challenge
Molson Coors Ltd asked Altitude Safety to review and enhance their fixed gas detection system, which was causing problems with constant false alarms. Since their site runs 24/7, any fixes had to be made without interrupting production. Additionally, the system had been originally installed by another company, so we first needed to get hold of all the wiring diagrams to figure out how everything was set up and where things were going wrong.
Our Approach
The team spent a few days on-site digging into the setup and quickly found one of the main issues: the beacons and sounders weren’t triggering at the right time. Specifically, the sounders were set to go off at a second-stage alarm, but Molson Coors only wanted them to activate at the third stage. That mismatch was a big part of the false alarm problem, so we rewired the system to correct it.
Another issue involved how the system reported alarm data. Previously, alarm signals went to two PCs in different offices, which were often vacant during night shifts. This setup meant that shift managers could miss an alarm unless they were physically nearby. To solve this, we introduced a web-based portal that allows the system to be accessed from anywhere. We also set up automated email and SMS alerts, so both shift managers and the SHEQ team are notified straight away if something’s wrong—no matter where they are on-site.
To further optimise safety and accuracy, the team recalibrated each sensor in the detection system, setting a precise zero-point to improve reliability.
The Result
Since implementing these changes, Molson Coors has seen a dramatic reduction in false alarms, improving both operational efficiency and on-site safety. The cloud portal has been highly effective, as it lets the team monitor the system in real time from any device and automatically sends out a report every two weeks with a summary of sensor activity and alarms. This gives Molson Coors a clear picture of what’s happening and helps them stay ahead of any issues, keeping their site safe and compliant.