Protecting Innovation: A Safety System Enabling Fusion Research at the University of Liverpool

Project Overview

Client: National Physical Laboratory

Market Sector: R&D

Pioneering Safety in Fusion Research

The University of Liverpool, in collaboration with the National Physical Laboratory (NPL), is at the forefront of fusion materials research. As part of the SBRI Fusion Innovation (Phase 2) programme, the University required a robust, laboratory-scale test rig to explore the performance of newly developed organic materials under industrial conditions.

AMS was entrusted to design, build and deliver the project’s Safety Instrumented System (SIS) panel, a safety-critical component ensuring the rig could operate reliably under tightly controlled parameters. The system needed to protect both people and equipment — automatically shutting down the rig within one second of detecting unsafe conditions. With a proven reputation for delivering dependable, safety-critical EC&I systems on time and right first time, AMS approached the project with technical precision and commitment to accountable delivery.

The test rig’s operation relied on precise and safe control of complex systems, including pumps, cryostats and containment systems. Any interruption or loss of control could risk valuable data, equipment and time. To enable research continuity and uphold the highest standards of safety, the University needed a solution that could not only meet the technical specification but also instil complete confidence in the system’s reliability.

Cage capture safety instrumented system panel

The Challenge. Engineering Precision Under Pressure.

The challenge was to design and deliver a bespoke SIS panel capable of integrating seamlessly with existing laboratory infrastructure, ensuring rapid trip response times (within one second), complete reliability and compliance with the latest British and European standards.

The project carried additional constraints:

A tight delivery window, aligned to laboratory commissioning milestones.
The need to balance innovation with proven reliability, using Commercial Off-The-Shelf (COTS) components.
Coordination across multiple stakeholders.

“Our Engineering Department were impressed with your work.” – National Physical Laboratory

This feedback encapsulated the collaborative and disciplined engineering approach AMS Nuclear brought to the project. Despite challenging specifications and timescales, AMS Nuclear’s experience in safety-critical environments ensured a solution that met every expectation.

Our Engineering Department were impressed with your work.

National Physical Laboratory

Our Solution. A Tailored Solution Built on Collaboration.

AMS Nuclear was commissioned to design, manufacture, test and deliver the complete Safety Instrumented System panel, including a dedicated Low Voltage (LV) power distribution section, to control and protect the test rig’s critical systems.

AMS Nuclear developed a solution that met or exceeded all technical specifications detailed in the project scope, including:

Integration of multi-sensor safety logic using thermocouple, gas detection and oxygen monitoring inputs.
Fail-safe architecture designed to enter a safe shutdown state upon power loss or abnormal readings.
Comprehensive Human – Machine Interface (HMI) with visual and audible indicators, E-stop functionality, and manual reset controls.
High-quality construction and documentation, compliant with BS EN 61439, BS 7671 and EMC Directive 2014/30/EU.

Throughout fabrication and Factory Acceptance Testing (FAT), AMS Nuclear’s engineers worked with the client and contractor to ensure that every design element – from wiring terminations to control logic verification – adhered to the project’s SIL1 reliability targets and quality assurance standards.

AMS Nuclear’s commitment to “owning the outcome” was central to the project’s success. The team provided not only engineering expertise but also proactive coordination, ensuring all documentation, test records, and lifetime quality packages were delivered to the exacting standards required by the end user.

Cage capture safety instrumented system panel opened

Our Delivery. Empowering Future Innovation.

By providing a safety-critical system tailored to fusion research, AMS Nuclear enabled the University of Liverpool to conduct complex experiments with confidence and precision. The project not only ensured safety compliance and equipment reliability but also contributed to the UK’s broader ambition of advancing clean, sustainable fusion energy.

Through this work, AMS Nuclear demonstrated why they are the right choice for safety-critical EC&I systems, delivering dependable engineering solutions that safeguard both people and progress.

The AMS kit is working perfectly, big thanks to the team for their hard work!