Home Page > Case Studies : Safety and Monitoring System

Safety and Monitoring System Upgrade

The MoD gave Assystem the go ahead to design and install a major upgrade package valued at £300k for the Safety and Monitoring (S&M) System used to control Integrated Weapons Complexes (IWC) at the MoD Defence Munitions Centres.

Image showing an integrated weapons complex. IWCs provide a test capability for a variety of weapon systems. Each IWC incorporates 4 Weapons Assembly and Check Rooms (WACR) and a central Test Equipment House (TEH). Multiple weapons can be accommodated in each WACR with test stimuli patched to each in sequence from the TEH.

The S&M System consists of a set of control consoles linked to CCTV, Audio, Intercom and Fire Alarm Systems. It provides access control and monitoring, and can be used to isolate all energy sources from the weapons under test to ensure that an unsafe fault condition cannot escalate into an explosive incident.

Image showing the mark 2 safety system. The original system was developed by the MoD 30 years ago. Assystem designed the improved Mark 2 version in the early 1980's and since then has provided full support, including design improvements and supply of new equipment. Although the system continued to provide its users with the functionality they require, component obsolescence was becoming a major problem.

Assystem undertook a complete system review to identify the components and sub-systems most at risk. These included access control (swipe card) units, CCTV cameras, VDUs, and the central control computers. A programme was formulated to identify suitable replacements and integrate them into the S&M system whilst causing minimum disruption to the client's ongoing weapons test programmes. The Assystem activities included:

Project management
Technical and commercial evaluation of alternative sub-systems
Equipment procurement
Electrical and mechanical design to integrate new sub-systems into the S&M
Software development
Prototype demonstration
Installation and commissioning of new equipment at the client's sites
Update of equipment documentation and handbooks
Revision of long-term spares provisioning requirement

The installation of updated equipment has realised the intended benefits of improved system availability and reduced long-term maintenance costs. It has also reduced the need to hold a large spares inventory. Other benefits include improved functionality, which enhances both productivity and safety. By bringing together disciplines from several Assystem divisions and sites, Assystem provided the client with a one-stop-shop service.