Acronyms & Terms Glossary <- More Definitions Compliance Auditing "An evaluation of compliance with Process Safety Management (PSM) and Risk Management Plan (RMP) regulations at least every three (3) years to verify that the procedures and practices developed under the standard are adequate and are being followed. Audits are executed to meet local regulatory requirements, to comply with internal company standards, and as a good business practice. In the U.S., audits are required every 3 years per OSHA 29 CFR 1910.119(o) PSM and US EPA 40 CFR 68 RMP. Compliance with evolving regulatory requirements, industry standards, and corporate initiatives can be overwhelming. aeSolutions offers a comprehensive approach to address the definition of scope and objectives, develop workflow process, and coordinate onsite activities detailed with protocols and reports. We provide a cross functional team of process safety and risk management elements to perform this essential part of the process safety lifecycle. Auditing services include defining requirements for preparation, site visits, and reporting. aeSolutions works with the client to obtain, review, and evaluate required documentation and data, conduct a site visit at the facility for employee interviews and debriefs, and compile a report documenting all audit protocols. The selection of the type of audit to be performed shall depend on the applicable regulatory requirements and level of detail the site has requested to be performed." Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Project Success Stories Learn how aeSolutions was able to help our clients overcome their challenges. 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 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 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 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 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 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 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 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 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 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 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 “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

Acronyms & Terms Glossary <- More Definitions Safety Instrumented System (SIS) Safety Instrumented System is a system of hardware and software controls engineered to perform "specific control functions" in order to prevent or mitigate hazardous events by taking a process to a safe state when predetermined conditions are violated. What and how the system should perform may be determined via HAZOPS (Hazard and operability studies) or LOPA (layers of protection analysis). aeSolutions' engineering specialists will design, configure, test, and install documented Safety Instrumented Systems that verifiably meet the client's Safety Requirements Specifications. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Acronyms & Terms Glossary <- More Definitions Inherently Safer Design (ISD) A way of thinking about the design of chemical processes and plants that focuses on the elimination or reduction of hazards, rather than on their management and control. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Acronyms & Terms Glossary <- More Definitions Safety Controls, Alarms, and Interlocks (SCAI) Process safety safeguards implemented with instrumentation and controls, used to achieve or maintain a safe state for a process, and required to provide risk reduction with respect to a specific hazardous event. These are sometimes called safety critical devices or critical safety devices. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Acronyms & Terms Glossary <- More Definitions Flash Fire A fire that spreads by means of a flame front rapidly through a diffuse fuel, such as a dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. Flash fires produce relatively short term thermal hazards with negligible overpressure (blast wave) and burn through a pre-mixed vapor cloud largely horizontally as a vertical ""wall of flame"". Flash fires are considered during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Acronyms & Terms Glossary <- More Definitions Sequential Function Chart (SFC) Sequential Function Charts (SFCs) are an example of logic diagrams that can be used to illustrate the functioning of a Safety Instrumented System (SIS). SFCs are frequently used to document the various operating modes of fired equipment. The aeSolutions staff is capable of selecting the best format, or combination of formats, to best meet the requirements of our clients. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Acronyms & Terms Glossary <- More Definitions What is PSM PSM is an acronym for Process Safety Management (PSM), a system that helps prevent/reduce risk of hazardous chemical releases Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Acronyms & Terms Glossary <- More Definitions Control Panel An enclosed unit that users can access to control or monitor instruments and equipment. Each panel is designed for a specific equipment arrangement and includes devices that allow an operator to control specified equipment. aeSolutions operates its own 10,000 square foot FM-approved and UL 508a-certified panel fabrication and testing facility. The aeSolutions team designs and builds sophisticated panels both for a wide variety of projects, from small operator PLC cabinets, to large multi-bay safety and control systems designed to run large facilities. Process simulation test beds are built to prove that controls and operator interfaces will function in accordance with project requirements. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

Machinery Safety Guard Against Injuries. Decrease R isk. aeSolutions is proud to offer Machinery Safety Services to reduce the risk of injury in the manufacturing industry. For our clients who operate and maintain machinery, safety is a top priority. ​ We help manufacturing facilities achieve safe machine operation through risk assessment, application of the hierarchy of control, and sensible safeguard design. In addition, our program helps reduce exposure to liabilities that can lead to unmanageable costs. ​ Our comprehensive, scalable program addresses client’s specific needs and the machinery lifecycle to provide tailored solutions aligned with international and United States standards. Service Description The following services are offered: Screening to prioritize corrective actions Risk A ssessment to discover hazards, classify risk, and identify safeguarding objectives - Specializing in Robots & Packaging machinery Evaluation of facility compliance and the State of Conformity to address areas of improvement for installed safeguards, including performance level verification Safeguard Specification and implementation to make certain risk reduction is achieved, including selection and design, functional safety analysis, safety function requirements, and implementation Training on hazard identification, risk assessment execution, and standard interpretation Contact One of Our Experts Top Mistake to Avoid in Machinery Functional Safety In the machinery industry, a safety function is a control function that reduces the risk of injury, exposure to hazards, or harm to the... Machinery Safety – Is it a Safety Function? Determining this is not always straightforward and requires a hazard assessment to identify safety functions (e.g., equipment, devices, ... Ten Fingers and Ten Toes: Applying Machinery Safety Principles in a Process Plant When performing risk assessments on process equipment, are you reviewing machinery as well? Machinery Safety Standards – The What and Why The machinery safety standards positively recompense designers, integrators and users along with providing a framework for achieving OSHA co Robotic Systems Risk Assessments An effective RA starts with including knowledgeable employees with expertise in the operations, specific robotic application, RA methodology Analysis Robot Integration Risk Assessments ​ Safety Function Performance Level Verification & Validation ​ Machine Guarding Assessments ​ Machine Safety Risk Assessments ​ ​ ​ ​ Design/Specification Design/Specification ​ Safe Machinery​ Design ​ Robotic Safety ​ ​ Light Curtain Positioning ​ Guarding Design ​ Interlock Design ​ ​Circuit Design Qualitative Training Procedures ​ Reduce Injuries ​ Mitigate Risk ​ Safeguard Hazards ​ Protect Employees ​ ​ ​ ​

Acronyms & Terms Glossary <- More Definitions Combustion Control System (CCS) Also known as the Boiler Control System (BCS) The subsystem of instrumentation and controls that manages the firing rate and air/fuel ratio of the burner in response to load demand. The Combustion Control System works in conjunction with the Burner Management System (BMS). aeSolutions' family of products includes industrial Combustion Control Systems in several packages. The pre-engineered packages are configurable to meet the client's operational requirements and is readily configured to implement a variety of fuel-saving optimization techniques, including fully metered / cross-limited fuel air control with oxygen trim, and interfacing to a wide variety of field sensors, analyzers, and valves. The CCS is often supplied as an integrated Combustion Management System package, which includes a BMS for safe startup, shutdown, and interlocking. Our Services Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety Case Study in Navigating Tight Schedules and Supply Chain Challenges in SI and BMS The strategies and insights gained from overcoming these challenges offered valuable lessons for future similar projects.The ability to asse 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,...

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