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214 items found for ""

  • DCS/PLC Migrations and Upgrades - Automation Engineering | Systems Engineering

    DCS/PLC Migrations and Upgrades System Integration Solutions Upgrading a Distributed control system (DCS) is a complex task that requires careful planning, coordination, and testing to mitigate risks such as downtime and data loss. Site requirements, regulatory compliance, and minimizing disruptions must be considered to ensure a smooth cutover. However, the security and functionality benefits of newer technologies can outweigh the costs, making it a valuable process for industrial operations. ​ aeSolutions can provide the methodology, technical services, resources, personnel, and field support to accomplish your goals and objectives working with you from project inception to final commissioning. Through a proven project delivery model, aeSolutions integrates diverse hardware, software, and services from multiple vendors and client stakeholders into a unified, integrated system. Our full range of services will lead you through the controls integration process to deliver a fully integrated, cohesive control system in a well-executed project. aeSolutions' Integration Services Conceptual & Preliminary Engineering - Front-End Loading (FEL) / Front-End Engineering Design (FEED) ​ PFD/P&ID Development ​ Control System Platform Evaluation Continuous and Batch Design ​ TIC Estimate Development Instrument and Electrical Design (I&E) ​Instrument Index, Specs & Installation Details Plan Drawings Controls Electrical - Field Wiring MCC Specification & Design Cable Schedules Construction SOWs Systems Integration Control Hardware Design Control System Server Virtualization PLC, DCS, SIS, SCADA Configuration Network Architecture Layout/ Design Control Panel Fabrication & Testing Construction Oversight Commissioning/Startup Support Expanded "Design, Implement, & Commission" Our clients are increasingly challenged to produce more with less. The productivity of yesterday’s most efficiently operated facilities is not acceptable for even mid-pack performance today. We understand the economic pressures the industry faces —and our industrial automation services can help. Our teams are skilled in all aspects of process control engineering because we all understand that the greatest influence over project success or failure comes from the earliest stages of conceptual design, long before the actual programming effort ever begins. ​ The overall result is a facility is both back online faster so you see the financial advantages of the new DCS faster. Automation Applications Our industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Safety Instrumented Systems (SIS), Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas Systems (FGS). The result is a totally integrated automation lifecycle, from project inception to operation. Process Automation Systems ​ Modernizing for Productivity and Profit Factory Automation Systems Mechanizing in Real Time Safety Instrumented Systems Delivering Safety on Demand Fire and Gas Systems Furnishing the Last Line of Defense Advanced Regulatory Control (ARC) Enlisting More Variables Burner Management Systems (BMS) Mitigating Fired System Hazards Combustion Control Systems (CCS) Optimizing Fuel Air Operation Human Machine Interfaces (SCADA) Interacting with Intuitive Information Alarm Management Systems Alerting Appropriate Action Migration Solutions ​​ Moving up with Modernization Conceptual & Preliminary Engineering Project Management Shaping a Successful Result from the Start ​ Project Assessment and Conceptual Design Articulating the Project Vision and Characterizing the Control System ​ Preliminary Engineering Converting Concept to Design Basis ​ Lifecycle and Upgrade Planning Looking Ahead Hardware Design Hardware Design Specifications Developing Hardware Details ​ Electrical and Instrumentation Design Connecting to the Process ​ Hardware Design and Panel Fabrication Supplying World-Class Panels ​ Construction, Installation, Commissioning Realizing the Vision ​ ​ ​ Systems Integration Software Design Specifications​ Developing Software Details Network Design Distributing Monitoring and Control Control System Configuration Creating Consistently Correct Control Simulation and Factory Acceptance Testing Approving the Configurations Site Acceptance Testing and Startup Testing and Turnover Maintenance and Support Supporting Client Successes

  • aeSolutions - Process Safety, Fired Equipment & Automation

    Improving industry by guiding our clients to increasingly resilient operations and safer communities. How We Can Help Our Story Engineering Company Integrating Process Safety, Automation & Fired Equipment Success Stories +25 Years Strong +40 Certified Experts +2000 Clients Served +600 Projects per Year Our Services Alarm Management Machinery Safety Migrations and Upgrades Process Safety Fired Equipment Project Management Combustible & Toxic Gas SIS Engineering Feature Stories You Need a Process Safety Roadmap! Structuring Your Process Safety Programs aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Improve Your Process Safety Culture to Drive Improved Safety Performance Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS Evolution of Fired Equipment Protective Systems in the Chemical Sector Client Success Built With Trusted Expertise aeSolutions is an engineering consulting and systems integration company that provides industrial process safety and automation products and services. We specialize in helping industrial clients achieve their site’s risk management and operational excellence goals. Process Safety As a supplier of complete process safety management (PSM) solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities. Alarm Managem ent Our clients recognize the relationship between the process safety performance of their facilities and the implementation of effective alarm management techniques and alarm philosophy. Our alarm management services help clients improve the performance of their alarm systems and increase the situational awareness of their operators. Machinery Safety Clients who operate and maintain machinery and robotics list safety is a top priority. We help manufacturing facilities achieve safe machine operation through risk assessments, application of the hierarchy of control, and sensible safeguard design. Our scalable programs address client’s specific needs and the machinery lifecycle to provide tailored solutions aligned with international and United States’ standards. DCS/PLC Migrations and Upgrades aeSolutions can provide the system integration methodology, technical services, and resources to accomplish the objectives of your automation project. We work with you from project inception to final commissioning through a proven project delivery model integrating diverse hardware, software, and services from multiple vendors and stakeholders into a unified, integrated system. Safety Instrumen ted Systems aeSolutions has a unique process to design and implement ISA84/IEC 61511-compliant safety instrumented systems (SIS). We integrate our knowledge and experience in PHA/LOPA along with control system hardware and field instrumentation to ensure that Safety Instrumented Functions (SIFs) are clearly defined. We define, design, and document the safety functions to meet your safety and online reliability requirements for 61511 and regulatory compliance. Fired Equipment From up-front engineering to end-user compliance testing, aeSolutions has helped clients create and maintain safe, efficient fired equipment and associated processes. With our extensive engineering knowledge of the National Fire Protection Agency (NFPA) and other regulations, aeSolutions is uniquely qualified to advise on virtually all combustion-related codes and other hazard assessments. Combustible & Toxic Gas The aeSolutions Fire and Combustible & Toxic Gas Detection team deliver a unique blend of experience in philosophy, technology selection, and geographic/scenario-based modeling. Beginning with a Gas Detection Philosophy development or review and update, we design a system that is fit for purpose, cost-effective, and has a defined basis that can be updated as the plant evolves.

  • Network Design

    Network Design Distributing Monitoring and Control aeSolutions designs industry standard as well as vendor specific networks for distributing controllers, I/O, data servers, and operator stations. Networks like Industrial Ethernet can be a composite of cables, fiber optics, and wireless systems, with managed switches and routers. aeSolutions recommends products and standards that we have tested for reliability, bandwidth, redundancy, distance, and industrial environments. Access points between the wide area enterprise networks and the critical control system networks must be managed carefully. Installation quality and signal testing are critical to achieving a fast, reliable control network. • Distributed I/O networks • Controller communication networks • HMI servers and client networks • Switches, routers, and firewalls • Single mode and multimode fiber optics • Coaxial and twisted pair cables • Drawings and Bills of Material Automation Services Previous Next

  • Fire and Gas Philosophy : Terms and Acronyms

    Acronyms & Terms Glossary <- More Definitions Fire and Gas Philosophy The Fire and Gas philosophy drives the design basis of the entire gas detection system. The philosophy should provide general direction, intent, specific performance goals, and effective strategies on how to implement the gas detection system. It clearly specifies the chemicals of concern and the intended purposes, i.e., detection of toxic or combustible levels, voting requirements, alarm rationalization, and control actions. aeSolutions' Fire and Gas team can support gas detection systems from conceptual design through field installation. This includes developing a Fire and Gas philosophy, technology selection, ensuring an appropriately sized system, and fire and gas mapping using the Geographic coverage approach and/or Computational Fluid Dynamics (CFD) scenario-based modeling to determine gas detector placement. Our Services You Need a Process Safety Roadmap! A systematically written document outlining the process safety elements and systems that apply at your facility. Structuring Your Process Safety Programs Each foundational block includes the pillars that support the overall structure, including all of the PSM and RMP elements. aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor.

  • HIPPS System : Terms and Acronyms

    Acronyms & Terms Glossary <- More Definitions HIPPS System High Integrity Pressure Protection Systems (HIPPS) is designed and built in accordance with IEC 61508 and IEC 61511 standards to detect high pressure events and close off a process independently of shutdowns (ESD/PSD) thus protecting lower-rated downstream equipment. Our Services You Need a Process Safety Roadmap! A systematically written document outlining the process safety elements and systems that apply at your facility. Structuring Your Process Safety Programs Each foundational block includes the pillars that support the overall structure, including all of the PSM and RMP elements. aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor.

  • Latching Alarm : Terms and Acronyms

    Acronyms & Terms Glossary <- More Definitions Latching Alarm An alarm that remains in the alarm state after the process has returned to normal and requires that an Operator reset it before it will clear. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Our Services You Need a Process Safety Roadmap! A systematically written document outlining the process safety elements and systems that apply at your facility. Structuring Your Process Safety Programs Each foundational block includes the pillars that support the overall structure, including all of the PSM and RMP elements. aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor.

  • Latent Failure : Terms and Acronyms

    Acronyms & Terms Glossary <- More Definitions Latent Failure Refer to Covert Failure. Our Services You Need a Process Safety Roadmap! A systematically written document outlining the process safety elements and systems that apply at your facility. Structuring Your Process Safety Programs Each foundational block includes the pillars that support the overall structure, including all of the PSM and RMP elements. aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor.

  • “Fit for Purpose” Solution Reduces Planned Downtime by 66%

    “Fit for Purpose” Solution Reduces Planned Downtime by 66% aeSolutions’ hybrid safety system design enabled the client to maintain safe continuity of their fired equipment, meet NFPA compliance, and significantly lower planned downtime. Challenge Several challenges related to strict National Fire Protection Association (NFPA) requirements arose as part of our client’s multi-stream waste incinerator’s annual leak testing. Any solutions would include navigating between NFPA-compliant and SIS-based systems and could lead to loss of revenue associated with destabilizing shutdowns, the likelihood of spurious trips, and planned downtime. Solution aeSolutions’ team of engineers and subject matter experts customized a “Fit for Purpose” engineering and equivalent risk-reduction solution that would meet or exceed NFPA codes as well as engaged the Authority Having Jurisdiction (AHJ) for approval of this customized approach. Among other efforts, our experts performed detailed configuration and integration of the client’s new Triconex process safety system with their existing DCS (distributed control system). Results Our approach enabled the client to select a hybrid, compliance/risk-based solution. aeSolutions identified and engaged the AHJ for approval of this customized approach, which proved to: • Implement compliance solutions that encourage system-wide risk reduction • Sustain reliability and availability of equipment to maintain operations • Increase leak test intervals with online testing reducing planned downtime by 66% Learn more about how aeSolutions could help you with a similar Combustion project. Industry: Chemicals Geography: Gulf Coast Unit Operation: Thermal Oxidizer Governing: NFPA 86 Take a look at our Success Stories page for more ways aeSolutions has helped our clients. Previous Story Next Story

  • Node : Terms and Acronyms

    Acronyms & Terms Glossary <- More Definitions Node Sections of equipment with definite boundaries within which process parameters are investigated for deviations. The concept of dividing a process into nodes for analysis is commonly, but not exclusively, used in HAZOPs. Nodes are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Our Services You Need a Process Safety Roadmap! A systematically written document outlining the process safety elements and systems that apply at your facility. Structuring Your Process Safety Programs Each foundational block includes the pillars that support the overall structure, including all of the PSM and RMP elements. aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor.

  • Maximum Credible Event (MCE) : Terms and Acronyms

    Acronyms & Terms Glossary <- More Definitions Maximum Credible Event (MCE) A hypothetical explosion, fire, or toxic event that has the potential maximum consequence to the occupants of the building under consideration from among the major scenarios evaluated. The major scenarios are realistic and have a reasonable probability of occurrence considering the chemicals, inventories, equipment and piping design, operating conditions, fuel reactivity, process unit geometry, industry incident history, and other factors. Each building may have its own set of MCEs for potential explosion, fire, or toxic material release impacts. Maximum Credible Events (MCEs) are considered during facility siting studies conducted by aeSolutions' experienced modelers. to help companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Our Services You Need a Process Safety Roadmap! A systematically written document outlining the process safety elements and systems that apply at your facility. Structuring Your Process Safety Programs Each foundational block includes the pillars that support the overall structure, including all of the PSM and RMP elements. aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor.

  • Fire & Gas Detection Detailed Engineering

    Fire and Toxic & Combustible Gas - Detailed Engineering aeSolutions utilizes first-hand industry experience to design clients' Fire and Gas Systems to the latest FM Approved standards. Our system design services include developing wiring plans, functional test plans, factory acceptance and site acceptance test plans and facilitation(FAT/SAT Plans). During the Factory Acceptance Testing (FAT) we confirm that all aspects of the control system are in full compliance with the final design documentation. Field Design Deliverables ​ Written Narrative Riser Diagram Floor Plan Layout Sequence of Operation ​ ​ Manufacturer’s Published Instructions Battery Calculations Voltage Drop Calculations Detailed Design Deliverables Detector Final Placement End Device Selection I/O Assignment Panel Design Architecture Block Diagram Cable Schedule / Cable Block Diagrams ​ ​​ Installation Details for End Devices Engineering and Design calculations Completion Test Forms HMI screen requirements ​ Installation Support Fire & Gas Pr oducts ​ NRTL Approved Fire Panels NRTL Approved Power Supplies NRTL Approved Proprietary Supervisor Stations Ensure toxic gas detection ​ Fire & Gas Lifecycle Services Ongoing Maintenance Training - to Operate, Maintain, and More Contact Us

  • Water Cannons Protect Community from Anhydrous Ammonia Leaks

    Water Cannons Protect Community from Anhydrous Ammonia Leaks Client needed to reduce liability and risk associated with anhydrous ammonia storage tanks. aeSolutions provided a leak detection and suppression system that alerts personnel and provides the means to contain the resulting vapor cloud to the storage tank area using high-pressure, high-volume water cannons integrated with the control system. Challenge A global manufacturer of agricultural chemicals stores 30,000 tons of anhydrous ammonia on-site in two large storage tanks. A large leak from one of these tanks would be hazardous and potentially fatal to on-site personnel and to the public in the surrounding areas. The client needed the ability to detect and alert personnel of leaks and allow operators to contain the resulting vapor cloud from a safe remote location. Solution After a thorough corporate safety review of the pressurized ammonia storage facility, aeSolutions provided an innovative safety shutdown and suppression system utilizing water cannons capable of manual or automatic operation from the safety system. Fourteen 2000 GPM water cannons capable of knocking the ammonia cloud to the ground and neutralizing its caustic characteristics were integrated, giving control room operators control over each cannon: • 340 Degree rotational movement • Vertical movement • Nozzle pattern control from fog to stream • Water flow control Results The client now has an effective means of monitoring and controlling an accidental release of ammonia and minimizing the impact to personnel, the public, and to the environment. aeSolutions increased the safety by providing leak detection and notification, equipment isolation, and large-scale leak dispersion containment through perimeter water cannons. Learn more about how aeSolutions could help you with a similar gas detection project. Industry: Agricultural Chemicals Geography: Southeast US Unit Operation: Beam type gas detectors, point type gas detectors, product isolation valves, and electronically operated water cannons Governing: FM Approvals Take a look at our Success Stories page for more ways aeSolutions has helped our clients. Previous Story Next Story

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