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September 2026 - Ken O'Malley - I recently completed a couple of ethics training courses to renew my Professional Engineering license, and they got me thinking about ethics and leadership—not just in engineering decision-making, but in everyday leadership situations. That thinking led me back to a paper written by my former colleague Chris Powell, PE, CFSE, The Courage to Intervene: Developing Ethical Leadership in the Next Generation of Process Safety Professionals, prepared for the 2026 AIChE Global Congress on Process Safety. Chris opens with a story that has stuck with me. A safety-critical system had been commissioned and, from a procedural standpoint, the project was ready to move into startup. But a senior safety leader concluded that some of the work, performed under significant schedule pressure, had not been completed with the rigor it deserved. There was no regulatory violation, and there was no clear technical failure. The leader simply wasn't comfortable that the work met the standard of his organization. So, he required the most critical portions of the commissioning to be performed again under more controlled and thoughtful conditions. That decision delayed startup; it cost real money. And the decision had to be justified to his leadership team without a clear and compelling safety case that made the choice obvious. There is an important lesson in that story that extends well beyond process safety. Our values are most tested when honoring them costs us something. Today's leaders operate under tremendous pressure to perform. Grow revenue. Protect margins. Move fast to win market from competitors. Hit quarterly goals. Do more with less. These are all legitimate responsibilities of leadership. When Small Compromises Start to Look Reasonable Problems creep in, though, when small compromises begin to look reasonable in service of those goals. "We're technically compliant." "It's good enough." "We'll address it later." "It's only this once." Chris describes how individually defensible decisions like these can begin to normalize deviation. The extraordinary becomes acceptable, and eventually, it becomes normal. There is another dimension that I think is easy to overlook: When a leader faces a difficult decision, there can be real value in letting the team see some of the forces at work behind the scenes. Help them understand and appreciate the financial and schedule pressure, the reasons why the easier choice might have been attractive and technically defensible, and then why the harder path was chosen anyway. This visibility is important. If the team only sees the outcomes and consequences of a difficult decision, they miss an important part of learning what it means to be a leader. They need to see experienced leaders wrestle with competing responsibilities and ultimately decide where the line is. Certainly, not every leadership discussion can be shared broadly. But some difficult decisions can become great teachable moments, and those opportunities should not be wasted. The Takeaway Chris closes his paper with an idea I think is worth reflecting on: the most enduring legacy of experienced leaders may not be their technical or commercial knowledge, or even their ability for strategic thinking, but rather the examples they set for others to follow. I agree. Someday, the people being developed today will face their own versions of these decisions—when doing what's right has a real and immediate cost and the justification is opaque. What are tomorrow’s leaders learning from watching us today? Credit: Chris Powell, PE, CFSE, The Courage to Intervene: Developing Ethical Leadership in the Next Generation of Process Safety Professionals, prepared for the 2026 AIChE Spring Meeting and 22nd Global Congress on Process Safety.

Updated August 2026 — During my 24+ years in alarm management, I have collaborated with various companies on their distributed control systems (DCS) across the United States and throughout 20 other countries. Although every system is different, there are more commonalities than you might imagine. I am consistently asked what my favorite and least favorite control systems are to work on. My answer is always the same, “my favorite system is the one I just finished for obvious reasons, and my least favorite is the one I’m working on right now.” This is because all alarm management systems have issues, but naturally, these issues are different from system to system. That is why I felt it was important to discuss how to prevent the five most common industrial alarm management issues. Avoiding Unnecessary and Misused Alarms for Effective Industrial Alarm System Management One tenet of alarm management is that alarms will only be used for abnormal situations. I cannot tell you the number of times that I have found alarms configured on systems for things that should never have an alarm. Some of these were obviously designed for convenience. A typical example of a convenience alarm is a low-temperature alarm on an ambient sensor located just outside the control room door. Although there are a few circumstances when this could be necessary (e.g., an extremely low ambient temperature could adversely affect the viscosity of a process fluid), most of the times that I have encountered this type of convenience alarm, it is simply to let the operator know if it is cold outside. Once, a senior operator in upstate New York actually told me that without the alarm, he wouldn’t know if he should put on a coat or not. The alarm was removed. Another relatively common misuse of industrial alarm systems occurs when a system timer alarm set up thirty (30) to sixty (60) minutes before the end of the shift in order to remind personnel to fill out shift changeover paperwork before going home. In situations where I have found these, the alarms have descriptions like “Time for Turnover Paperwork” or “Call-in Reading to Foreman.” In one of these cases, the description was “Wake Up and Pack Up to Go Home.” In this case, not only was the alarm removed from the system, but the tag was removed as well, and the person this applied to was told to buy an alarm clock. Ultimately, avoiding unnecessary or misused alarms will improve your industrial alarm system’s effectiveness. Ensuring Operator Action — Proper Alarm Criteria and the Use of Alert Systems Another principle of alarm management is that every alarm requires an operator action. When designing an alarm philosophy, one of the steps is to determine the time to respond (how much time is available to take action to avoid the consequences) vs. the severity of consequences matrix, as shown in Table 1 below. Table 1 - Alarm Priority Determination - aeSolutions As you can see in the table above, if there are no consequences or the time available is more than thirty (30) minutes, the parameter does not qualify to be an alarm. Although the operator may need to know that an instrument has reached a certain point, that does not mean that it should necessarily be an alarm. This condition can cause concern when these points support operations and do not meet the necessary qualifications of an alarm but still need to be viewed or accessed as part of operational efficiency. For those items that do not qualify as an alarm, there should be a separate mechanism to inform the operator (e.g., an alert system). I have encountered many types of alert systems, and there are numerous ways to implement them. One of the most common is to set up an alert as a separate “priority” on the DCS that has no visual or audible actions tied to it. This will result in the alerts going to a separate screen designated just for them. The operators will have to become accustomed to checking the screen multiple times during a shift, however these alerts should not be short-time critical (e.g., <1 hour or the potential to be a HIGH priority). If the alarm has the potential to be a HIGH priority, then it should be re-engineered to the point that the time available is 30 minutes or less. Implementing Effective Single Alarms for Each Cause or Action | Industrial Alarm Management Creating a single alarm for each cause or corrective action is another doctrine of effective industrial alarm management. In other words, you should not have to be told more than once to do something. This issue most often occurs with multiple levels of alarming (e.g., High (H) & High-High (HH) or Low (L) & Low-Low (LL)). Below is an example of multiple level alarming being used correctly and incorrectly. Correct use of multiple levels of alarming example: A tank is ten feet in height and will overflow at that ten-foot level. There is a high-level alarm (H) set at nine feet with a HIGH priority to notify the operator to take action, stopping the level rise. There is a high-high level alarm (HH) at the do not exceed height of 9.5 feet, with a LOW priority and a corresponding automated action that stops filling the tank. The alarm located at nine feet notifies the operator that action is needed. The alarm at 9.5 feet notifies the operator that the action taken was not effective and the DCS — or in some cases — the safety instrumented system (SIS), has shut the process down to avoid over-filling the tank. Incorrect use of multiple levels of alarming example: A client had a 40-foot naphtha tank with a high-high alarm set at 39 feet, designated with emergency priority, and a high alarm set at 38 feet, designated with high priority. There were no automated shutdown systems on this tank, and during operations, they overfilled the tank and had a loss of containment (LOC) incident. In an attempt to remedy this issue, the client contacted the DCS vendor and had a custom code written to add a high-high-high (HHH) alarm at 39 feet with an emergency priority, a high-high alarm at 38 feet with an emergency priority, and a high alarm at 37 feet with a high priority. Much to the chagrin of the client, this attempted resolution left their problem unresolved, and once again, they overfilled the tank and had a subsequent loss of containment (LOC) incident. This cycle repeated several times until they performed an alarm rationalization project. At the beginning of this project, the client’s setup was: High-High-High-High-High (HHHHH) Alarm at 39 ft with an EMERGENCY priority High-High-High-High (HHHH) Alarm at 38 ft with an EMERGENCY priority High-High-High (HHH) Alarm at 37 ft with an EMERGENCY priority High-High (HH) Alarm at 36 ft with an EMERGENCY priority High (H) Alarm at 35 ft with a HIGH priority Not only was this bad practice for industrial alarm system management, but the operators became so numb to the alarms that they were ignoring them and setting themselves up to run the tank over again. The results of their alarm rationalization study findings suggested reverting back to the original two (2) alarms and adding an automated shutdown at 39.5 feet with a LOW priority to notify the operator that control has been taken away from the operator and that an automated shutdown has occurred. Preventing DCS Alarm Floods with Advanced Suppression Techniques Another common issue in industrial alarm system management is the prevention of DCS alarm floods (e.g., having more than ten alarms in ten minutes). A leading cause of alarm floods is the absence of the configuration of advanced alarming techniques such as suppression. Many of the newer DCS systems now have some form of suppression built into them; however, this feature is often underutilized. Automated suppression is when the DCS automatically disables (suppresses) an alarm’s audible and visual indicators and sends the alarm to an event log or journal instead. Suppression can be used to support alarm flooding in multiple ways; one way is that it allows a single indication of an issue to be alarmed while hiding all the similar alarms the issue causes. An example of this would be a compressor trip. When the compressor is running, it has numerous alarms configured and enabled, such as the run status, high & low suction pressure, high & low discharge pressure, bearing temperatures, and vibrations — just to name a few. If the discharge pressure goes high while the compressor is running, it can be a big issue. You may have a plug downstream or someone may have accidentally closed a wrong valve. These things need to be taken care of quickly. However, if the compressor shuts down without suppression configured, the result each time will be a run status alarm along with alarms for the high suction pressure, low discharge pressure, all the bearing vibrations as it spools down, and potentially many other alarms. Typically, the only alarm needed is the run status alarm because if the compressor shuts down, a good operator knows that all of these secondary issues are due to the shutdown. If they are allowed to alarm, they become a distraction and hindrance to the mitigation of the issue. Enhancing DCS Security — The Importance of Firewalls and Controlled Internet Access Lastly, the largest issue in industrial alarm system management — which thankfully is seen less and less these days — is the lack of firewalls between the DCS and the outside world. Ideally, a control system would be “air-gapped” in order to minimize the possibility of introducing intrusions or viruses. However, this is not always possible. Typically, the DCS will be protected by firewalls, and often, those firewalls will be in their own layer between the control system and the rest of the company assets. The firewalls will only have a minimum number of obscure ports opened, and those ports will only allow one-way (outbound) traffic. This helps to minimize potential hijacking and infections. The most egregious example of not having firewalls that I have encountered was a few years ago on a project outside the US. One of the client’s complaints was how slow their DCS was running, and they were asking for suggestions on how to improve it. Upon entering the control room, my colleague and I were greeted by what is inarguably the nicest control room I’ve ever seen. The room was brightly lit and immaculately clean. The two (2) main operator stations were laid out in a huge arch in the middle of the room with sixteen (16) monitors each. Sitting perpendicular on the right end was the foreman’s station with four (4) monitors. In the back left corner was the utilities operator station with another twelve (12) monitors, and dead center of the front wall were eight (8) 55” monitors that networked together to make two (2) giant screens that were each two screens high by two screens wide. It was impressive, to say the least — until I realized that the giant screen on the right had more flashing red alarms than I have fingers to count. No one was paying attention to them because the operator on the left was using his giant screen to play an online video game. That’s right, the DCS had a direct connection to the internet. My first suggestion was to disable the internet connection and establish firewalls and the second was to delete all non-business required software from the system. Amazingly, within a week of implementing the suggestions, the system speed had more than doubled. While there are many more issues that could be discussed, these are the five most common issues that stand out in my career. Does your plant suffer from any of these issues or others not mentioned here? The Takeaway | Common Industrial Alarm Management Issues Addressing the most common industrial alarm management issues is crucial for ensuring operational efficiency, safety, and system reliability. By avoiding unnecessary and misused alarms, setting proper alarm criteria, implementing single alarms for each cause or corrective action, preventing alarm floods through advanced suppression techniques, and securing the DCS with firewalls and controlled internet access, companies can significantly enhance their alarm management systems. These ISA-approved best practices not only streamline operations but also empower operators to respond effectively to true emergencies, thereby minimizing risks and maintaining optimal system performance. Implementing these strategies will lead to a more robust and responsive alarm management framework, ultimately contributing to the overall success and safety of industrial operations. If your alarm system issues have you scratching your head, the experts at aeSolutions are always available to help identify and mitigate your industrial alarm system problems.

Introduction | Process Hazard Analysis Revalidation Carolyn Bott, Process Safety Group Manager — In the world of industrial operations, hazards are a given — but unmanaged hazards are a risk no facility can afford. A well-executed Process Hazard Analysis (PHA) is a vital safeguard, helping teams identify potential risks and define the controls needed to mitigate them. But a PHA isn’t a one-time event. As facilities and operations evolve, so must the analysis. That’s where a PHA Revalidation comes in. What is a PHA Revalidation? A PHA revalidation is a systematic update of an existing PHA study to ensure that it accurately reflects current operations, risks, and safeguards. Mandated under OSHA’s Process Safety Management (PSM) standard (29 CFR 1910.119), PHA revalidations are required at least once every five years. This ensures that facilities consistently assess whether existing safeguards and Independent Protection Layers (IPLs) are still appropriate and effective. Unlike a first-time PHA, a revalidation starts with reviewing the previous study. The team evaluates modifications — be it process design, control systems, staffing, procedures, or incident history — and determines whether those changes introduce new risks or warrant updates to the previous Process Hazard Analysis study. It should be noted that in some cases, a facility may determine that the existing PHA is no longer a reliable baseline — perhaps because of major modifications, process redesign, or poor quality in the original study. In these situations, a full PHA redo may be the better option. Methodologies Commonly Used in PHA Revalidations Several risk assessment methodologies are used during PHA revalidations, depending on process complexity and organizational preference. These include: HAZOP (Hazard and Operability Study): A systematic, guideword-based approach for continuous and batch processes LOPA (Layers of Protection Analysis): A method for evaluating the effectiveness of protection layers in reducing the frequency or consequence severity of hazardous events What-If and Checklist Analyses: Useful for simpler systems or as supplementary tools HAZID (Hazard Identification Study): Often applied in the early design phase or as a high-level review FMEA (Failure Modes and Effects Analysis): Focuses on component-level failure scenarios Bowtie Analysis: Visual mapping of causal pathways and safeguards for major hazards These methodologies are not mutually exclusive — they are often used in combination. The chosen methodology(s) should match the process and risk profile. Regulatory Requirements and OSHA Expectations for PHA Revalidations According to OSHA, a PHA must be revalidated at least every five years to ensure it remains consistent with the current process. The revalidation must be conducted by a team with expertise in engineering, operations, and hazard analysis methodology. The team should evaluate changes in equipment, procedures, and materials; verify that recommendations from previous PHAs have been resolved; and confirm that documentation and drawings (such as P&IDs) are current. OSHA further clarifies that a PHA revalidation doesn’t need to start from scratch. It can build upon the previous PHA, provided the review is thorough and documented. Failing to properly revalidate — whether by missing the five-year deadline or conducting an insufficient review — can lead to citations and increased risk exposure. Should I Revalidate Sooner Than Five Years? While the five-year cycle is the regulatory minimum, some facilities choose or need to revalidate more frequently. Situations that may warrant earlier review include: - Significant process changes such as new equipment, revised control strategies, or major throughput adjustments - Facility expansions or new unit operations - Introduction of new chemicals or process conditions - Recurring incidents or near misses suggesting underlying hazards were missed - Internal audits that identify PHA gaps or non-compliance - Evolving industry standards or new safety guidance that impact existing risk assessments In such cases, updating the PHA before the five-year mark can strengthen safety performance and demonstrate due diligence to regulators and insurers. Five Common Challenges in PHA Revalidations Executing a quality PHA revalidation takes planning, expertise, and cross-functional engagement. Below, we describe five common challenges that facilities face when conducting a Process Hazard Analysis Revalidation. 1. Inadequate Documentation and Information Management A revalidation is only as good as the information available. If the previous PHA scenarios were poorly documented or if process safety information (P&IDs, chemistries, etc.) hasn’t been kept current, the team will struggle. Without complete, up-to-date data on what has changed since the last PHA, important scenarios might be overlooked, or the team may waste time reconfirming basic facts. 2. Loss of Key Knowledge and Stakeholder Engagement It isn’t uncommon to find that the team who performed the initial PHA has transferred, retired, or simply moved into new roles by the time of revalidation. If a PHA Reval is not documented effectively, nor involves the appropriate process experts, understanding of the process risks can be lost. This type of insufficient stakeholder engagement can result in missing insights into how the process truly operates or deviates. Every PHA relies on the collective knowledge of its team and if that’s weakened, the revalidation may miss hazards or misunderstand the adequacy of IPLs. 3. Poor or Inconsistent Methodology Application If your PHA revalidation isn’t executed with consistent and up-to-date methods, gaps can occur. In some cases, the prior PHA might have used a different method or risk criteria than what the company uses now, causing confusion. For example, if the initial PHA methodology was misapplied or too simplistic for the process, it can result in the need for substantial correction down the road. Ensuring a comprehensive and systematic approach is applied during revalidation is vital to avoid leaving gaps. 4. Underestimating Time and Resources Required PHA revalidations can be resource intensive. A common mistake is assuming a revalidation will be quick since “we’ve done this before”, and then not allocating enough time or personnel knowledgeable in the process. The result can be rushed sessions, incomplete reviews, or missing documentation. If an organization doesn’t budget adequate time (including for pre-work and team meetings), the five-year deadline can sneak up. 5. Failure to Close Gaps from Previous PHA Recommendations A situation that many face during a PHA revalidation is discovering that some recommendations or gaps from the last PHA were never implemented or fully resolved. Not only does this pose an ongoing risk, but it also complicates the analysis — the team might find themselves re-discussing hazards that should have been mitigated. OSHA expects that existing PHA recommendations are tracked and completed before revalidation​. If that hasn’t happened, your facility faces both compliance issues and potentially repetitive findings. This issue often stems from lack of a robust management system for PHA action items. Anticipating and addressing these challenges early can significantly improve the quality of your PHA revalidation process. Best Practices for an Effective PHA Revalidation To mitigate the challenges described above, facilities should adopt several best practices for PHA revalidations: Prepare thoroughly: Update your process safety information, drawings, procedures, and incident history before the first team meeting. Performing this type of “mini audit” of changes and process safety performance since the last PHA will help drive the revalidation scope. Engage experienced facilitators: Facilitators with expertise in the methodology selected for the reval can guide the process and ensure consistency across nodes and scenarios. Ultimately, your PHA Reval team should consist of experienced operations personnel, engineers familiar with the process, and a competent facilitator. Additionally, involving members from the original PHA team and/or certified PHA leaders can benefit the effort. Involve stakeholders: Cross-functional support from those in operations, engineering, maintenance, and even management stakeholders who understand the process will increase your ability to maintain consistency and accuracy throughout the revalidation process. Verify implementation of past recommendations: A revalidation is an opportunity to check the status of all previously identified hazards. Best practice is to explicitly review how each risk scenario identified last time has been addressed. The team should verify that no known hazard has been forgotten. If some recommendations were deferred or not resolved, this is the time to reassess those risks and decide on an action. Additionally, incorporate any relevant incident learnings (from your site or industry) to enhance the prior analysis​. By looping back on past findings and new learnings, the revalidation closes gaps and solidifies your facility’s risk baseline. Document and track everything: Just as you review old recommendations, establish a strong process for following through on new PHA recommendations coming out of the revalidation. This includes clearly prioritizing them (e.g. using a risk matrix or LOPA results to rank urgency), assigning responsibility, and setting deadlines. Remember, OSHA requires documented resolution of PHA recommendations​ — having a tracking system not only aids safety but keeps your facility compliant. Consider partnering with a qualified PHA facilitator: One of the best investments for a successful PHA revalidation can be partnering with a skilled facilitator. An experienced, third-party PHA facilitator can provide a litany of benefits — including chemical and process knowledge across industries. Beyond providing expert guidance, facilitators can also serve as an objective, unbiased perspective. When considering an external PHA facilitator, look for a provider who goes beyond “checking the boxes.” Facilitators should also offer effective prioritization of risks and recommendations. Additionally, a facilitator should be able to present an actionable gap closure game plan that includes recommendations for trusted engineering solutions providers who can support resolving identified issues. You’ve Completed Your PHA Reval — What Next? A successful PHA revalidation doesn’t end when the last worksheet is signed. The real value comes from implementing recommendations and closing identified gaps. At this stage, facilities should: - Prioritize recommendations using risk matrices or LOPA to focus efforts on high-consequence scenarios - Develop actionable plans for implementation, assigning ownership, and tracking progress - Work with a facilitator or engineering partner who can help close common recommendations such as SIS upgrades, BPCS changes, Alarm Management improvements, BMS modifications, Facility Siting enhancements, and Fire & Gas system updates. - Document closure, including verification of effectiveness and updates to procedures or training as needed Without follow-through, a PHA revalidation becomes a compliance checkbox rather than a meaningful tool for reducing risk. The Takeaway | Turn Your PHA Reval Findings into Forward Motion Process safety isn’t static — and your PHA shouldn’t be either. Regular, well-executed PHA revalidations are essential to staying compliant with OSHA, maintaining operational continuity, and safeguarding personnel and assets. For facilities navigating complex changes, aging infrastructure, or resource constraints, engaging with experienced PHA facilitators can bring structure, insight, and measurable outcomes to the revalidation process. When done right, PHA revalidations don’t just ensure compliance — they create a roadmap for safer, smarter operations.

aeSolutions - A consulting, engineering and system integration company that provides industrial process safety, fired equipment and automation lifecycle solutions and tools. We can help with Toxic Gas Detection, Machinery Safety, Alarm Management, Safety Instrumented Systems, and more. An engineering and systems integration company specializing in automation and industrial process safety. — Resilience Isn't a Bonus, It's a Benchmark — We provide critical system solutions that empower our clients through more resilient operations and safer communities where they operate. Our unique approach is to pair risk-focused industry experts with a proven project delivery team. Speak With One of Our Experts Today About Your Facility's Resilience — If It’s Critical, We Have it Covered — At aeSolutions we help clients reduce project chaos and strengthen performance by integrating the safety lifecycle with the full project lifecycle, and our PMO professionals ensure structure, accountability, and measurable progress. We work with your team to close gaps, clarify responsibilities, and convert fragmented practices into a unified approach that protects people, assets, and uptime. We help you move from risk to resilience with clarity and confidence. — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Click Here to Chat With Our Industry Experts — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production View More Case Studies Here — News & Resources — What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals aeSolutions Recognized with 2026 CSIA Social Responsibility Award Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study — Let's Discuss Your Facility's Needs —

Process safety and automation for fertilizer and agricultural chemical plants, helping you protect people, stay compliant, and keep production running. Ag Chem Facilities Partner With Us For Anhydrous Ammonia Exposure Let's Discuss Your Facility's Needs — Integrated Solutions for Ag Chem Operations — Safety Systems Automation & Control Agricultural chemical production sits at the intersection of highly hazardous materials, continuous public exposure, and relentless seasonal demand. Facilities producing ammonia, urea, nitric acid, and finished crop inputs operate under OSHA PSM 1910.119 and EPA RMP, often on assets that have changed hands, expanded in phases, and years of modifications. Add anhydrous ammonia inventories with offsite consequence potential, combustible dust in dry blending and bagging, and control systems well past vendor support, and the breadth of risks become difficult to manage from any single discipline. aeSolutions helps ag chem producers understand where their real hazards are, size the protection those hazards actually require, and then we design, build, and support commissioning of the automation and safety systems. Process safety, functional safety, alarm management, combustion systems, fire and gas detection systems, and automation all come from the same team, so the hazard identified in a PHA is the same hazard traced through the SIF, into the panel on our shop floor, and out to a commissioned system on your unit. — Ag Chem By the Numbers — 25+ Years Serving Ag Chem Clients 35 Ag Chem Sites Supported 348 Ag Chem Projects Delivered View More Success Stories Here — Where We Work in Ag Chem — Nitrogen & Fertilizer Production Ammonia synthesis, urea, nitric acid, and UAN units, where high-pressure reaction, fired equipment, and toxic release potential converge. Crop Input Formulation & Packaging Batch formulation, solvent handling, and filling operations that combine reactive chemistry with recipe-driven production. Anhydrous Ammonia Storage & Terminals Pressurized and refrigerated storage, rail and truck loading, and bulk transfer, where the dominant risk is offsite consequence. Fired Equipment & Steam Utilities Boilers, process heaters, kilns, dryers, and thermal oxidizers governed by NFPA 85, NFPA 86, and NFPA 87. Dry Blending, Granulation & Bagging Granulators, dryers, coolers, screening, and packaging lines, where combustible dust and material handling drive the hazard profile. Legacy & Acquired Facilities Recently acquired or long-tenured plants carrying incomplete process safety information and undocumented control systems. Click Here to Speak with an Ag Chem Expert — The Challenges We Solve — And The Capabilities We Bring FIRE & GAS DETECTION Anhydrous ammonia with offsite consequence potential Ammonia storage and transfer near property lines makes worst-case release modeling a business question, not just a compliance exercise. We run dispersion and consequence modeling, map detector coverage against it, and design detection, isolation, and mitigation systems sized to the scenario rather than to a rule of thumb. Learn more about our Fire & Gas Capabilities → DUST HAZARD ANALYSIS Combustible dust in blending, granulation, and bagging Dry fertilizer handling generates dust in dryers, coolers, elevators, screens, and baghouses. A Dust Hazard Analysis under NFPA 652 identifies where deflagration is credible, and the resulting protection has to be engineered into the equipment and the control system, not bolted on afterward. Learn more about our Dust Hazard Analysis capabilities → FUNCTIONAL SAFETY Safety functions nobody can prove still work Interlocks accumulate across decades and expansions, often without a Safety Requirements Specification, SIL verification, or proof test record. Our CFSEs determine required SIL, verify achieved SIL, write the SRS, and build the proof test procedures that make the claim defensible under ANSI/ISA 61511. Learn more about our Functional Safety capabilities → BURNER MANAGEMENT Burner management systems running past their support life Dryers, kilns, and waste heat boilers often run on burner management logic that predates current NFPA 86 practice, with hardwired interlocks nobody has verified in years. Nuisance trips cost production during the seasons you can least afford them, and a real demand may not find a working safety function. We design, fabricate, and commission BMS and combustion control systems to code, and factory acceptance test them before they reach your site. Learn more about our Burner Management System capabilities → PROCESS SAFETY PSM and RMP obligations on a plant you inherited Acquired sites frequently arrive without complete process safety information, current P&IDs, or a defensible PHA. Closing that gap under a corporate deadline requires more than a document review. We rebuild the process safety basis, facilitate the PHA and LOPA, and carry the findings into engineering so the compliance case is supported by real design. Learn more about our Process Safety capabilities → AUTOMATION AND CONTROL Control systems past vendor support during peak season Ag chem demand is seasonal, which compresses every outage window and raises the cost of an unplanned trip. We plan DCS and PLC migrations around production reality, with I/O cutover planning, staged commissioning, and documentation that survives the people who built it. Learn more about our Automation & Control capabilities → ALARM MANAGEMENT Operators buried under alarms during upsets When a nitric acid or ammonia unit upsets, alarm floods take away the situational awareness operators need most. Alarm philosophy development, rationalization facilitation, and advanced alarming restore a manageable alarm load and a clear operator response for each one. Learn more about our Alarm Management capabilities → — One Team, Not Five Vendors — Most firms serving ag chem do one thing. A process safety consultant facilitates your PHA and hands you a report. An integrator programs your PLC. A panel builder ships you a cabinet. Each is competent and none of them owns the seam between the others, which is exactly where projects fail and where risk quietly survives. aeSolutions covers the full lifecycle with one accountable team. The hazard scenario identified in your PHA becomes a Layer of Protection Analysis, which sets the required SIL, which drives the Safety Requirements Specification, which becomes a design, which is fabricated and factory acceptance tested in our own UL and FM certified panel shop in Greenville, South Carolina, and then installed and commissioned on your unit. No handoff between companies. No requirement lost in translation. One party responsible for the outcome. DISCIPLINE APPLIED IN AG CHEM Process Safety PHA, HAZOP, LOPA, QRA, PSM/RMP auditing, facility siting, Dust Hazard Analysis, electrical area classification, mechanical integrity Learn more → Functional Safety SIL determination and verification, Safety Requirements Specifications, Functional Safety Assessments, proof test procedures, functional safety management Learn more → Automation & Control DCS and PLC migration, I/O cutover planning, systems integration, HMI design, control narratives, instrument and electrical conceptual design Learn more → Combustion Systems Burner management and combustion control system design for boilers, process heaters, kilns, dryers, incinerators, and thermal oxidizers Learn more → Fire & Gas Plume dispersion modeling, detector coverage modeling, conceptual and detail design, FM approved system fabrication, commissioning Learn more → Alarm Management Alarm philosophy, rationalization facilitation, program audits, advanced alarming, implementation support Learn more → Project Development FEL 1 through 3, total installed cost estimating, scope definition, risk planning, PMO-led execution Learn more → Click Here to Speak with an Ag Chem Expert — Automation & Control Systems for Ag Chem — An ag chem site is rarely one kind of plant. A nitrogen complex runs continuously. The formulation building next to it runs recipes in batches. The bagging and palletizing line at the end runs discrete. Each demands a different control strategy, and the integration between them is where visibility and traceability are usually lost. MODE 01 Continuous Ammonia synthesis, nitric acid, and urea units run steady-state with tight interaction between pressure, temperature, and composition loops. Our work centers on regulatory control performance, safe operating limits, and the interface between the BPCS and the SIS, so the protective layer stays independent of the layer doing the controlling. TYPICAL SCOPE DCS and PLC migration with staged I/O cutover Control narrative and functional requirements Advanced regulatory control and loop performance BPCS and SIS independence verification Safe operating limit definition Learn more about our Automation & Control Capabilities → MODE 02 Batch Formulation, reaction, and blending operations run to recipe, where the sequence itself carries the hazard. Charge order, temperature ramp, and hold time are safety parameters, not just quality parameters. We build batch control that is structured, auditable, and able to fail safe mid-sequence. TYPICAL SCOPE Structured batch control and recipe management Sequence and phase logic with interlock alignment Reactive chemistry review feeding control strategy Batch reporting, electronic records, genealogy Safe-state definition and sequence hold or abort Learn more about our Systems Integration Capabilities → MODE 03 Discrete Granulation, screening, coating, bagging, and palletizing behave like discrete manufacturing lines, with the added complications of combustible dust and equipment that is difficult to guard. Machine safety, dust-rated design, and throughput reliability all have to hold at once, particularly during seasonal peaks. TYPICAL SCOPE Machine safeguarding and safety-rated control design Robotic and automated system risk assessment Packaging and material handling integration Dust hazard controls in the control system Line performance and downtime analysis Learn more about our Machine Safety Capabilities → — Platforms and Fabrication — — Siemens — aeSolutions has been a Siemens Solution Partner since 1999 and was the first company in the Americas to earn Siemens' PCS 7 Safety Specialist certification. Learn more about our Siemens Solution Partner credentials → — Rockwell — aeSolutions is a certified Rockwell Systems Integrator. This allows us to ensure we can provide the best possible solution and exceptional support with the least amount of risk for your company. Learn more about our Rockwell Systems capabilities → We work across Siemens, Rockwell, and other major platforms, and we fabricate, configure, and factory acceptance test complete systems in our own certified panel shop before anything ships to your site. Learn more about our panel fabrication capabilities → — The aeSolutions ResiliencePath™ Method — We’re an integrative specialist with a proven methodology that we call ResiliencePath ™ that embeds safety into every stage of the project lifecycle — from concept to closure — for compliance today and resilience tomorrow. Empowering — Not Enforcing Rather than checking boxes, we help you identify the right questions early to prevent costly late-stage corrections and avoid years of OpEx fixes. Each ResiliencePath™ step is driven by one goal: empowering resilient, value-aligned decisions that stand the test of time. EPC & Subcontractor Integration ResiliencePath™ is adaptable to collaborate seamlessly with EPCs and subcontractors, integrated into a structured workflow designed to adapt to real-world project dynamics without compromising on results. Your Process, Our Expertise At aeSolutions, we help clients reduce project chaos and strengthen performance by embedding safety into the full project lifecycle. This is enhanced by our PMO professionals who ensure structure, accountability, and measurable progress. Our integrated services span PHA facilitation, compliance audits, facility siting, and risk management planning, supported by domain expertise and a focus on practical implementation. We work with your team to close gaps, clarify responsibilities, and convert fragmented practices into a unified approach that protects people, assets, and uptime. Whether you're navigating a revalidation or rethinking your strategy, aeSolutions helps you move from risk to resilience with clarity and confidence. Learn More About the aeSolutions ResiliencePath ™ Methodology — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Success Stories Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production View More Success Stories Here — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Click Here to Chat With Our Industry Experts — Let's Discuss Your Ag Chem Facility Needs —

Discover how aeSolutions delivers cutting-edge process safety and industrial automation solutions across process industries like oil & gas, chemicals, pharmaceuticals, batteries, and more. Explore our expertise today! Industries Served — Solutions For Critical Industries — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem aeSolutions provides deep expertise in the control and process safety management for the agrochemical industry, ensuring production stability and compliance with stringent environmental and safety regulations. We help clients manage the processes and hazards associated with fertilizers, pesticides, and other agricultural chemicals, including the safe handling of anhydrous ammonia and highly reactive substances. Learn More Battery Materials & Mineral Processing The production of battery materials requires safe handling of critical minerals, chemical processing, and fire/explosion risk management. aeSolutions delivers expertise in thermal runaway prevention, gas detection, and process hazard analysis to help clients mitigate risks and maintain regulatory compliance in lithium, nickel, and cobalt processing operations. Chemical Manufacturing Chemical production involves hazardous materials, stringent regulations, and high-risk processes. aeSolutions provides process automation, burner management, fire and gas detection, and process hazard analysis (PHA) to improve safety, efficiency, and regulatory compliance in bulk and specialty chemical production. Energy & Power Generation Energy production facilities, including traditional power plants, cogeneration units, and emerging alternative energy facilities, face complex control and safety challenges. aeSolutions provides fire and gas system design, combustion control and safety, and process hazard analysis to help clients maintain stable control, mitigate risks, enhance system reliability, and comply with industry standards. Hydrogen Production & Processing The hydrogen industry faces flammability risks, high-pressure storage challenges, and evolving regulatory requirements. aeSolutions specializes in the control, fire and gas detection, explosion protection, and quantitative risk analysis (QRA) to support the safety and efficiency of blue, green, and gray hydrogen production and processing facilities. Learn More Metals & Mining Processing Heavy industrial operations in metals refining, mineral extraction, and processing require robust control and safety solutions to address risks like combustible dust, high-temperature reactions, and hazardous material handling. aeSolutions provides dust hazard analysis (DHA), fire and gas detection, and process risk assessment to ensure safe and stable operations. Oil & Gas Production & Processing From upstream extraction to downstream refining, the oil and gas industry must navigate complex safety and regulatory challenges, including high-pressure systems, flammable materials, and mechanical integrity risks. aeSolutions delivers expertise in layers of protection analysis (LOPA), safety instrumented systems (SIS), and emergency relief system evaluation to enhance operational integrity and regulatory compliance. Petrochemicals & Hydrocarbon Processing Petrochemical plants handle highly hazardous chemicals that require advanced control and safety measures to maintain process stability and to prevent fires, explosions, and toxic releases. aeSolutions provides process automation, consequence modeling, relief system evaluation, and process safety engineering to improve reliability, protect personnel, and ensure compliance with safety regulations. Pharmaceutical & Life Sciences Manufacturing The pharmaceutical industry must balance product purity, process safety, and regulatory compliance while handling flammable solvents, high-potency chemicals, and strict environmental controls. aeSolutions delivers ventilation system design, containment strategies, and process hazard analysis (PHA) to support safe and compliant manufacturing. Renewable Fuels & Bioenergy Renewable fuel production — including biofuels, biogases, synthetic fuels, and waste-to-energy processes — introduces safety challenges such as combustion risks, toxic gas emissions, and complex reaction chemistry. aeSolutions provides process control, hazard identification (HAZID), fire and gas detection, and safety instrumented systems (SIS) design to mitigate these risks and enhance operational efficiency. Specialty Chemicals & Advanced Materials Specialty chemicals require precision in process control and stringent safety management to prevent hazardous incidents. aeSolutions provides continuous and batch control, process hazard analysis (PHA), fire and gas system design, and SIS implementation to protect personnel, optimize operations, and maintain regulatory compliance. Utilities & Critical Infrastructure Utility providers — including power generation, water treatment, and industrial gas distribution—must manage safety risks related to combustion systems, hazardous gas handling, and emergency response. aeSolutions delivers expertise in burner management systems (BMS), alarm management, and process safety engineering to ensure reliable and secure operations. Why aeSolutions? Trusted Go-To Partner for Our Clients' Tough Challenges Innovative, Sustainable Solutions to Create Client Value Professional Project Management to Drive Client Business Results Consistent Performance and Delivery on Our Commitments Recognized Extensively Credentialed Professionals (PE, CFSE, PMP) Active in Leadership of Professional Organizations (ISA, AIChE, CSIA) Involved in Development of International Standards & Industry Best Practices Deep Technical Acumen, Thought Leadership