Extending laboratory alarm coverage in a live facility

A high containment scientific research facility operated an independent critical alarm system to monitor environmental and safety conditions across multiple laboratories. The system provided alarms for parameters such as freezer temperature and differential pressure to maintain safe working conditions.

The client required an upgrade to extend the system capability to include oxygen depletion and hazardous gas monitoring, alongside improvements to system reliability, scalability and operator visibility.

Challenge

The project required enhancement of a safety critical alarm system within a live laboratory environment. The solution needed to maintain operational integrity while introducing new monitoring capabilities. Challenges included working with legacy systems, distributed infrastructure, and ensuring alarm availability during system or network failures.

Approach

A structured engineering approach was adopted, beginning with development of a detailed functional design specification. The architecture was expanded to include additional remote terminal units and integration of new monitoring devices. Control strategies were implemented using a central PLC with distributed I/O, supported by upgraded SCADA systems. Particular focus was placed on resilience through network design, UPS backed supplies and local alarm capabilities.

Solution

A fully integrated control and alarm system was delivered. This included installation of new sensing equipment, deployment of additional RTUs with local indication, and upgrade of SCADA systems with increased capacity and improved interfaces. The system provided multi layer alarm annunciation including local visual and audible alerts and centralised monitoring.

Testing

A comprehensive testing programme was undertaken including inhouse testing, factory acceptance testing and site acceptance testing. This validated control logic, communications, alarm functionality and fail safe operation under fault conditions.

Outcomes

The upgraded system significantly improved safety monitoring capabilities and system resilience. The modernised platform delivered improved operational visibility and scalability, providing a robust foundation for future expansion while maintaining continuous protection of laboratory environments.