Upcoming Events April 6-10, 2025 Hilton Anatole in Dallas, TX 2025 Spring Meeting & 21st Global Congress on Process Safety This is the essential technical conference for chemical, process and process safety engineers, offering unparalleled coverage of the industry's critical needs and providing excellent networking opportunities with a diverse audience of professionals. Read All More Info October 21-23, 2025 The Westin Memorial City, Houston, TX 2025 Mary Kay O'Connor Safety & Risk Conference Safe Artificial Intelligence: Theory, Understanding, & Application - Making Safety Second Nature The 2025 Conference will host: 28th MKO Process Safety Symposium 80th Instrumentation & Automation Symposium 4th Ocean Energy Safety Symposium Read All More Info This calendar shows our upcoming events such as trade shows we are participating in or upcoming training classes. Trade fairs or trade shows play important roles in marketing as well as business networking in market sectors that use them. Our team is usually presenting our engineering expertise as aeSolutions strives for excellence and perseveres to deliver on our commitments. Whitepapers are often presented at these events. Check the aeSolutions’ blog for more details or to view our whitepapers and/or recordings that we are able to share from the events. aeSolutions’ social media accounts are also a great way to keep up to date with ou r upcoming events and speaking engagements. You can find us on LinkedIn or on X/Twitter . At aeSolutions, we push through challenges with passion and purpose.

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 Process Safety Automation & Control Functional Safety Fired Equipment Alarm Management Fire & Combustible Toxic Gas Feature Stories Making a Difference: Our 2024 Charitable Giving Initiative Safety Culture: Examining Common Shortcomings | Industrial Equipment News Unplanned Shutdowns as Proof Test Credits: What to Know and Steps to Take | OH&S Control System Migrations | Part 4 | Managing Scope, Schedule, Budget Control System Migrations | Procurement Specification & Vendor Selection FSA Stage 2: Evaluating the Safety Instrumented System (SIS) Readiness for Field Installation 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.

aeSolutions' Email Newsletter The latest online content from aeSolutions, an integrated lifecycle partner in process safety, automation and fired equipment, emailed straight to you every other month. Past Month's Newsletters: aeSolutions January 2025: Control System Migrations - Part 4 | Safety Culture: Examining Common Shortcomings | Unplanned Shutdowns as Proof Test Credits aeSolutions November 2024: Are You Ready for Your Next Facility Siting Study? | Control System Migrations - Part 3 | Integrating PHA LOPA Outputs into Effective SIS Engineering aeSolutions September 2024: Discover SIS Flaws With Stage 1 FSA | 2024 Mary Kay O'Connor Safety & Risk Conference | Success Story: Hydrogen Production Plant F&G System Design & Implementation aeSolutions August 2024: Preventing Common Alarm Management Issues | Expertise in Hydrogen Safety | Process Safety Roadmap aeSolutions May 2024: Decoding SIS | New FGS Product | Layer of Protection Analysis (LOPA) R egister to Receive Monthly Emails Sign Up Now By providing this information, you agree to the processing of your personal data as described in our Privacy Policy. Sign Up Today! Keep up with aeSolutions Industry articles, upcoming events, and new ideas. Examples include topics such as Regulatory Compliance with Fire and Gas, Alarm Rationalization Whitepapers, Videos on Systematic Failures and what that really means, taking credit for protection layers, understanding protection layers and risk layering, and gas detection front end loading project management. What is LOPA and Lopa safety? Random failure of operator error due to human factors. Expert Engineers in Process Safety Management Services answers these with a PHA LOPA audit. We also often feature content on Burner Management systems. Our team understands the market and vendors.

Facility Siting Studies & Modeling Solutions Facility siting studies are advised as part of new projects (green or brown field) and modification of existing facilities (buildings, population and process changes, introduction of new chemicals or products). In cases where a facility has applicability to the OSHA PSM and/or EPA RMP standards, conducting baseline and revalidation facility siting studies are required by these regulatory authorities to assess the consequences of potential incidents such as fires, explosions, or toxic exposure on individuals both onsite and off. Evaluating the impact of these facility operational risks is vital when creating a comprehensive safety plan. aeSolutions' facility siting and consequence modeling experts work hand in hand with your team to identify potential process hazards, accounting for your operation's specific siting protocols and goals. aeSolutions is an industry-trusted provider of risk-based and consequence-based facility siting studies in addition to gas dispersion modeling, gas sensor mapping, and gas detector placement. Why Partner With Us? At aeSolutions, we believe one of the greatest influences on operational excellence is a comprehensive, sustainable risk management program that addresses both conformance and compliance. For over 25 years, aeSolutions has served as a multi-faceted safety solutions provider across a wide gamut of industries. When it comes to facility siting studies, we leave no stone unturned. aeSolutions' team of trained facilitators execute the hazard recognition and risk reduction process while our experienced modelers apply the appropriate methodology in line with API 752/753/756 in addition to industry best management practices. In short, we provide results that enable effective allocation of resources to minimize facility siting risks by your site leadership team. Trust Built On Experience Years of Combined Experience In Facility Siting Studies Facility Siting Studies Completed Years Serving the Industry Facility Siting Study & Analysis Our Facility Siting Capabilities Risk-Based & Consequence-Based Studies Gas Dispersion Modeling Fire Modeling Computational Fluid Dynamics (CFD) Modeling Gas Sensor Mapping Gas Detector Placement Explosion Modeling In accordance to API 752, 753, 756 recommended practices and the Center for Chemical Process Safety (CCPS) Guidance. The aeSolutions Six Step Approach Identify chemicals of concern Identify site-specific conditions Identify potential hazard event scenarios from review of site data Identify & classify occupied buildings Perform the hazard and consequence analysis Perform the risk management analysis aeSolutions utilizes DNV-GL's PHAST to provide quantitative fire and toxic effect data for pool fires, vapor cloud fires, vapor cloud explosions, jet fires, and toxic vapor clouds. Results are illustrated on a site plot plan with hazard endpoint circles for radiant heat, toxic concentrations, and pressure/impulse waves. Additionally, aeSolutions may perform computational fluid dynamics (CFD) models for highly hazardous scenarios upon request. Industries Served Chemical Metals & Mining Renewable Energy Hydrogen Agriculture Petrochemical Specialty Chemical Energy & Alternative Energy Oil & Gas Pharmaceutical Utilities LNG About Facility Siting Studies A Facility Siting Analysis is intended to evaluate the potential hazards and consequences of uncontrolled releases of flammable and toxic substances; to assess their potential for injuring the occupants of fixed and temporary structures on or offsite; to identify existing safeguards; and to determine measures to reduce the risk posed by these potential events. Within the United States, facility siting is required as an element of Process Hazard Analysis (PHA) for sites covered by the Occupational Safety and Health Administration's (OSHA) Process Safety Management (PSM) Standards under 29 CFR 1910.119 (e)(3)(v). aeSolutions' Facility Siting Studies are conducted in accordance with methods listed in the American Petroleum Institute's (API) Recommended Practices 752, 753, and 756, and published guidance from the Center for Chemical Process Safety (CCPS). Facility Siting is a multi-faceted analysis of potential fire, explosion, and toxic hazards to personnel from releases of hazardous chemicals. These chemicals of concern include those that vaporize quickly, are highly toxic to personnel or the environment, have low flash points and boiling points, are highly reactive, and/or are present at temperatures, pressures, and/or in quantities significant enough to pose a hazard of concern. Ready to Discuss Your Facility Siting Study? Recent Posts Understanding How Burner Management Systems Work Understanding how burner management systems (BMS) work and how they can benefit your facility's safety and regulatory compliance. Evolution of Fired Equipment Protective Systems in the Chemical Sector Several years ago, aeSolutions started our fired equipment business. This business is focused on safeguarding burners and furnaces,... Enhanced Reliability and Safety Through Standardization Fired equipment such as industrial boilers, incinerators, process furnaces, and fluid heaters are used everywhere. They are a crucial, compl

Project Success Stories Learn how aeSolutions was able to help our clients overcome their challenges. Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility A multi-fuel boiler project for a chlor alkali production facility resulted in significant modernization and operational improvements. The client's legacy relay-based Burner Management System (BMS) was upgraded to a DeltaV CHARM Safety Logic Solver, providing enhanced visibility, safety, and operational flexibility. This project not only modernized the client's system but also ensured compliance with NFPA 85 codes and met all Safety Instrumented Systems (SIS) requirements. Read More Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities aeSolutions was tasked to provide Front-End Loading (FEL) and Detail Design for a newly acquired legacy agricultural chemical facility in order to meet full compliance with PSM OSHA 1910.119 standards and the client’s corporate safety requirements. Read More Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant aeSolutions was challenged to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Read More A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Implementing Safety Instrumented Systems (SIS) and Burner Management Systems (BMS) within tight deadlines and supply chain disruptions is challenging. A recent project converting boiler fuel from coal to natural gas with a Safety Instrumented BMS met strict safety standards despite these hurdles. Read More Alarm Management for a Greenfield LNG Facility A Liquefied Natural Gas (LNG) facility was being newly constructed (i.e., Greenfield) and the company wanted to conduct an alarm rationalization on the process prior to initial startup. Existing facilities (i.e., Brownfield) have the benefit of historical operating trends and data during a rationalization session to recognize whether setpoints are effective and which alarms might give troubles. Read More Pharma Company Detecting Natural Gas Leaks in Boiler House A pharmaceutical client determined they needed a natural gas leak detection and isolation system for a utility building based on a PHA recommendation. aeSolutions installed a combustible gas leak detection system to shut off the gas supply to the boiler, bringing the facility into compliance with the safety program requirements. Read More Large Specialty Chemical Company Reduces Alarm Floods A large specialty chemical company was facing alarm floods in their utility unit. With aeSolutions guidance, the site was able to effectively prioritize and reduce alarms through the rationalization process, which includes reviewing, validating, and justifying alarms needed for avoiding potential process upsets or abnormal deviations from normal operation. Read More Simplified, Cost-Effective, and Consistent Acidic Compound Detection New acid detector placement philosophy led to reduced maintenance , lowered costs, a reduced the likelihood of confusion during leaks, and helped create a uniform response strategy. Read More Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million A client was facing a lengthy compliance process to upgrade a fleet of fired heaters. With aeSolutions guidance, the client reduced their compliance scope by 50%. Focusing on the NFPA 86 prescriptive design applicable to waste gas thermal oxidizers and applying our experience in Process Safety Management (PSM)... Read More 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. Read More Pharmaceutical Company Required Toxic & Combustible Gas Detection System A large-scale pharmaceutical manufacturing facility needed to develop and implement a gas detection system at their site to mitigate risk to personnel and equipment from a potential combustible or toxic gas leak. The project progressed from the assessment stages of developing a gas detection philosophy to ultimately integrating an industrially designed GDS 1400 MK II panel for the gas detection control and alarm system. Read More Complex Hot Cutover of Large Natural Gas Processing Facilities Due to facility siting factors, control rooms of one of the world’s largest natural gas (NG) processing and compression facilities were relocated from a possible blast zone to a Blast Resistant Modules (BRMs). This complex cutover for personnel relocation needed to be accomplished without a shutdown (S/D) of either interdependent ... Read More Specialty Chemical Site’s Increasingly Complicated Cutover When a project that began with standard safety system upgrades quickly expanded to a much broader scope of engineering with tight deadlines, aeSolutions responded with an experienced engineering workforce to deliver above-quality expectations while meeting key deadlines. Read More “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. Read More Protecting Personnel with Practical Gas Detector Placement A pharmaceutical company needed to implement gas detectors at their facility to protect personnel from potential leaks of toxic and combustible gases. aeSolutions evaluated the gas detector placement and number of detectors that would provide the earliest warning to personnel based on the expected dispersion and behavior of specific gas release scenarios. Read More Alarm System Rationalization and Safe Operating Limit for Energy Production A current client was adding a new energy production unit with an innovative process to an existing site and wanted to ensure the new design incorporated the site’s existing alarm management practices that were previously set up by the aeSolutions alarm management team. Read More

Large Specialty Chemical Company Reduces Alarm Floods A large specialty chemical company was facing alarm floods in their utility unit. With aeSolutions guidance, the site was able to effectively prioritize and reduce alarms through the rationalization process, which includes reviewing, validating, and justifying alarms needed for avoiding potential process upsets or abnormal deviations from normal operation. Challenge As a result of the alarm floods, the Operators were reluctant or delayed in responding to the current alarm system because they were unable to determine which alarms were important and which were much less urgent or unnecessary. This reduced the time that staff had to respond to urgent or high priority operating conditions and diverted their attention from other important duties. The site had not yet performed alarm rationalization of their utility unit. As a result, the control room Operators were overwhelmed with nuisance alarms, incorrectly prioritized alarms, and alarms with no Operator action. This produced an operating environment susceptible to safety or environmental hazards that could have resulted in an incident. Solution aeSolutions facilitated a rationalization process with site operations and engineering staff to identify and prioritize the most effective alarms to detect a process upset within the utility unit while ensuring alarms met the definition and requirements defined within the client’s existing site Alarm Management Philosophy. By using the aeAlarm™ Rationalization Tool, the team was able to efficiently and functionally perform the following tasks: • Incorporate Process Hazard Analysis (PHA) and Layers of Protection Analysis (LOPA) data, such as required Operator responses used as Independent Protection Layers (IPLs) to reduce scenario risk to a tolerable level • Document alarm attributes based on the International Society of Automation (ISA) 18.2 and the Alarm Philosophy which addresses how alarms will be managed throughout the ISA 18.2 lifecycle • Review alarm parameters and setpoints to ensure they were aligned with the unit’s safe operating limits • Create templates for similar alarms within similar equipment trains Results The client’s control room achieved a two-thirds reduction in alarms configured for the utility unit which increased operator performance and production efficiency. The optimization of the alarm system also returned the client to compliance with Recognized and Generally Acceptable Good Engineering Practices (RAGAGEP) for Alarm Management. Overall, the operating staff became more focused on safe and effective operations because Operators were finally able to trust that the alarms they were addressing were accurate, necessary and important. Learn more about how aeSolutions could help you with a similar Alarm project. Industry: Chemicals Geography: Gulf Coast Unit Operation: Utilities Governing Authority: ISA 18.2 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities A globally recognized chemical producer that had recently acquired a legacy plant used to produce highly hazardous agricultural chemicals turned to aeSolutions’ multi-disciplinary capabilities for a comprehensive solution to bring their legacy plant into compliance. The client was faced with a tight schedule to meet their corporate process safety standards through a functional safety upgrade, with the goal of bringing the facility into PSM OSHA 1910.119 compliance. Once awarded the project, aeSolutions successfully delivered the client’s FEL3 and Detail Design goals. As part of the FEL3 project, aeSolutions collaborated with the client to establish an estimate basis. This helped ensure the accuracy of the total installed cost estimate, with the project coming in slightly under the estimated value. The success and quality of this project’s outcome serves as an example of aeSolutions’ unrivaled capabilities as a comprehensive lifecycle solutions provider within the industry. Challenge This complex project posed numerous challenges during the Front-End Loading (FEL) phase for the client’s newly acquired agricultural chemical production facility. The legacy facility did not meet the client’s corporate process safety standards, nor was it PSM OSHA 1910.119 compliant. aeSolutions was tasked with providing Front End Loading (FEL) level III engineering design services for the Process Control Technology (PCT) discipline. Basic design for Phase 1 at the legacy facility was to cover a kiln, a hydro clarifier, a waste heat boiler, and multiple coal mills. The final challenge was developing an accurate total installed cost estimate that the client then used to secure funding. Solution • By implementing processes and project sponsorship to promote efficient communication between the client’s remote stakeholders and the management team of the legacy facility, aeSolutions was able to foster an environment that proved to be essential in meeting the client’s goals of achieving PSM OSHA 1910.119 compliance within their schedule. • aeSolutions successfully provided cross-discipline deliverables within the client’s timeline, while accommodating several scope revisions from the client. • aeSolutions’ recognition of the importance of not only being aware of a project’s information but having the experience to also know where the information needs to flow helped facilitate the overall success of the project. • By utilizing aeSolutions’ team of experienced subject matter experts across multiple disciplines, we were able to provide the level of knowledge, understanding, competency, and dedication required to meet the client’s strict requirements. • By educating the client’s operations team about the rationale of actions throughout the project, aeSolutions helped to facilitate better alignment between the client’s corporate/capital project team and the facility operations team. • Through the meticulous attention to detail and quality of services provided, aeSolutions’ was able to bring a highly hazardous chemical production facility into PSM OSHA 1910.119 compliance. - aeSolutions worked closely with the client to establish a comprehensive and accurate total installed cost estimate for the project. • The accuracy of aeSolutions’ estimate meant that the client did not have to request supplemental funding, that no change orders were required, and that the project was ultimately completed slightly under the total installed cost budget. • Adherence to the client’s aggressive timeline relied on the versatility of aeSolutions to integrate with the client’s newly implemented document control system. This adaptability proved to be an integral part of aeSolutions’ ability to complete the project roughly two months ahead of schedule — relative to other groups that were working in parallel. • In the face of the complexities and evolving requirements of this project, aeSolutions was able to deliver FEL3 and the Detailed Design results that the client was thrilled with. • aeSolutions’ assignment of appropriate resources based on alignment with the requirements of the project’s complexity and risks — contributed to the high productivity rate realized during this project. Results This project’s successful execution serves as a textbook example of the results clients hope for. From the initial development of front-end loading (FEL3), a highly accurate total installed cost estimate, and Detail Design deliverables, every aspect of our contribution to this project helped bring the client’s legacy facility into compliance with PSM OSHA 1910.119 regulations as well as the client’s own corporate safety standards. The aeSolutions multi-disciplinary team and their ability to adapt to the client’s evolving needs played a pivotal role in achieving the project’s success. By integrating seamlessly with the client’s document control system and maintaining strict adherence to safety and regulatory requirements, aeSolutions delivered results that represented an — according to the client — excellent quality of deliverables. Industry: Hazardous Agricultural Chemical Production Geography: West Unit Operation: Front End Loading Level III (FEL3), Detail Design Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Pharmaceutical Company Required Toxic & Combustible Gas Detection System A large-scale pharmaceutical manufacturing facility needed to develop and implement a gas detection system at their site to mitigate risk to personnel and equipment from a potential combustible or toxic gas leak. The project progressed from the assessment stages of developing a gas detection philosophy to ultimately integrating an industrially designed GDS 1400 MK II panel for the gas detection control and alarm system. Challenge This pharmaceutical facility had a large number of uncommon toxic and combustible gases and vapors. The gas detection philosophy document needed to account for the physical properties of the gases present at the site. The previously developed gas detection philosophy document did not account for the required gas detection alarm levels and sensor ranges. It also did not account for the limitations of the available detection technologies. Additionally, the document needed to describe how to address cross-sensitivity when multiple gases are present in the same area. Solution We developed a gas detection philosophy in compliance with the latest industry standards. The document addressed all of the following: • The physical characteristics of the gases and vapors at the facility • Industry-recognized exposure levels for the gases • Preferred gas detection technologies • Minimum requirements for gas detection including leak sizes • Addressed gas detection cross sensitivities aeSolutions designed and provided a comprehensive gas detection system to monitor all of the toxic and combustible gases and alert personnel to the hazards. Once established, the gas detection philosophy was used as the basis for integrating the GDS 1400 MK II gas detection control and alarm system. This unit utilizes the Siemens Simatic PCS7 series hardware/software platform and interfaces to the facility’s building management system and fire alarm panel. Its SIL 3-capable logic solver was scalable to a large I/O count, which ended up totaling 650 I/O counts distributed among seven (7) remote I/O panels for the large number of chemicals. The following were delivered: • Gas Detection Philosophy Document • Gas Detection Plot Plan and placement within the client 3D model • GDS 1400 MK II Gas Detection System • Specified and procured all of the gas detectors • Interface with building management system for HVAC control (e.g., overriding the HVAC control to dilute and/or remove explosive gases from the facility) • Interface with Fire Alarm panel for mass notification messaging • Interface with process control system for process shutdowns, where applicable Results The pharmaceutical company now has a scalable gas detection system capable of reducing the risk to personnel and equipment and complying with their corporate safety program requirements. The system also provides long term data collection of gases that have been measured in the facility. Learn more about how aeSolutions could help you with a similar project Industry: Pharmaceuticals Geography: Southeast Unit Operation: GDS 1400 MK II, Gas Detection System, PCS7, SPHA I/O, FGS Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Complex Hot Cutover of Large Natural Gas Processing Facilities Due to facility siting factors, control rooms of one of the world’s largest natural gas (NG) processing and compression facilities were relocated from a possible blast zone to a Blast Resistant Modules (BRMs). This complex cutover for personnel relocation needed to be accomplished without a shutdown (S/D) of either interdependent ... Challenge At the time it was built, the NG facility was the largest in the world. Some sections of piping are approximately 5 foot diameter and compression is achieved with enormous gas turbines - jet engines. The number of drawings, valves, wires, and control schemes that needed to be evaluated and understood was extensive and complex. Additionally, the magnitude and complexity of migrating the controls was tremendous. Normal gas operation controls such as turbine controls, panel boards, and valve interfaces needed to be migrated, as well as process safety controls such as the Basic Process Control System (BPCS), safety systems, Fire & Gas (F&G) systems, Halon fire suppressant circuits, and Emergency Shutdown (ESD) circuits. Furthermore, the NG facility equipment spanned 50 years of modifications and many upgrades were needed to universalize and modernize the many generations of equipment, including digitalizing hardwired signals into a the BPCS and installing a new PLC-based BPCS Honeywell C300 control system. Yet the biggest challenge was migrating the hard-wired emergency stop (E-stop) button from the old to new control room with minimal transition time and without a widespread outage. The circuit was designed fail-safe, meaning if the circuit opened up the relay, an activated emergency event could result in several effects: relieve gas pressure to flare, isolate system in place, or a plant S/D. Solution aeSolutions not only designed the new control room but took responsibility for all stages of the project, managing tasks from the conceptual and preliminary engineering to detailed design to managing on-site activity and personnel during the complex cutover. Specifically, aeSolutions: • Developed detailed cutover procedures and checklists and an integration schedule that identified specific people and detailed daily tasks for the next year for both NG facilities • Performed a detailed option analysis to evaluate potential best solutions • Analyzed every wire to understand what it does and temporary bypasses to be put into place; maintained a well-documented log to track what had been completed • Developed a contingency plan to guard against emergency events and mitigate risk of valve position changing during cutover process for safety purposes • Set up a local integration center, i.e., Factory Acceptance Test (FAT) lab, to convene equipment and everyone involved; determined ways to install additional panels; designed, fabricated, and tested the new control panels that were needed for the E-stops and F&G system and provided cabinets that were needed; developed a scheme of transitioning existing terminations to new termination locations without causing a S/D • Managed on-site activities helping direct the cutover process while implementing the cutover plan, including directing facility operators, engineers, support staff, construction, and even IT staff Results aeSolutions’ role evolved from system integrator and helping move the control rooms to becoming the focal point of coordinating schedules and staffing and choreographing the entire cutover project. We developed an execution strategy and found ways to integrate multiple teams into the plan. The FAT lab particularly provided a tremendous benefit to establish how components worked, verify detailed FAT plans and test procedures, and develop methods to quickly (dis)connect test panels with everyone in the same room. This integration strategy saved time and travel costs to successfully cutover the controls on a NG operating plant without impact to production. Learn more about how aeSolutions could help you with a similar project. Industry: Natural Gas Geography: Pacific Northwest Unit Operation: Control Center, Compressed Gas Valves Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

“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 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Specialty Chemical Site’s Increasingly Complicated Cutover When a project that began with standard safety system upgrades quickly expanded to a much broader scope of engineering with tight deadlines, aeSolutions responded with an experienced engineering workforce to deliver above-quality expectations while meeting key deadlines. Challenge The initial project scope included providing the client with instrumentation specifications and wiring and cutover plans to facilitate the cutover to a new system. Due to incomplete and outdated instrument lists, a significant and unexpected change in scope became required to include instrument specification services, which nearly doubled the time and manpower needed to reach the goal by the client’s deadline. Solution aeSolutions efficiently identified and conveyed the necessary adjustments to the project with clear and concise communication, enabling the client to swiftly make informed decisions, modify the scope, and adjust staffing accordingly. Our team quickly deployed resources to provide the following deliverables within the original schedule: • Instrument Specifications • Instrument Field Wiring • Cutover Mapping • Cutover Wiring In addition, aeSolutions designed custom cabinets for the cutover at the request of the client once it became apparent that the field loops would be doubled. During construction, aeSolutions assisted the client with locating and providing quality drawings for cutover installation and commissioning. Results Upon completion, the clients informed aeSolutions that the provided support was indispensable for a smooth start-up, and the subcontractors confirmed that aeSolutions specifically contributed to one of the most efficient cutovers they’ve ever commissioned. The client had large projects going on, and aeSolutions was able to save them costs by hitting their shutdown dates and not requiring additional shutdown time. Learn more about how aeSolutions could help you with a similar a Systems Integration / Migration & Upgrade project. Industry: Specialty Chemical Geography: Southeast Unit Operation: Safety System Upgrade Governing: ISA/IEC 61511 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story