The highest concentration of a vapor or gas that will produce a flash of fire when an ignition source is present. At concentrations higher than the UFL, the mixture is too rich to burn. It is often referred to as the Upper Explosive Limit (UEL). Upper Flammability Limit (UFL) concentrations are considered for endpoint distances 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. Acronyms & Terms Glossary <- More Definitions Upper Flammability Limit (UFL) The highest concentration of a vapor or gas that will produce a flash of fire when an ignition source is present. At concentrations higher than the UFL, the mixture is too rich to burn. It is often referred to as the Upper Explosive Limit (UEL). Upper Flammability Limit (UFL) concentrations are considered for endpoint distances 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 Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

A propagating chemical reaction of a substance in which the reaction front advances rapidly into the unreacted substance, but at less than sonic velocity in the unreacted material. Acronyms & Terms Glossary <- More Definitions Deflagration A propagating chemical reaction of a substance in which the reaction front advances rapidly into the unreacted substance, but at less than sonic velocity in the unreacted material. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

An independent protection layer (IPL) is a a system of logic solvers, a human action, or a device that reduces risk of a chemical /energy release while being independent of the initiating event. The Center for Chemical Process Safety (CCPS) requires a protection layer to achieve the following seven core attributes to be considered an IPL: independent, functional; integrity; reliable; validated; maintained and audites; access security; and management of change. Acronyms & Terms Glossary <- More Definitions Independent Protection Layer An independent protection layer (IPL) is a a system of logic solvers, a human action, or a device that reduces risk of a chemical /energy release while being independent of the initiating event. The Center for Chemical Process Safety (CCPS) requires a protection layer to achieve the following seven core attributes to be considered an IPL: independent, functional; integrity; reliable; validated; maintained and audites; access security; and management of change. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Common Mode Failure is a Failure causing coincident failures in multiple systems on two or more separate channels in a redundancy system, leading to system failure. This state may result from one or more failure events. Acronyms & Terms Glossary <- More Definitions Common Mode Failure Common Mode Failure is a Failure causing coincident failures in multiple systems on two or more separate channels in a redundancy system, leading to system failure. This state may result from one or more failure events. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

The tool used to analyze STAMP. It uses a control-theory based hazard analysis technique similar to PHA but works top-down (i.e., top event to specific causes). Acronyms & Terms Glossary <- More Definitions Systems Theoretic Process Analysis (STPA) The tool used to analyze STAMP. It uses a control-theory based hazard analysis technique similar to PHA but works top-down (i.e., top event to specific causes). Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Optimizing Fuel Air Operation Combustion Control Systems - Automation Application Optimizing Fuel Air Operation 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. The CCS 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 an aeSolutions BMS for safe startup, shutdown, and interlocking. • Graphical HMI common to CCS and BMS • Alarming, tuning, and diagnostic displays • Communications to BMS and DCS • Multiple fuel optimization • Cross-limiting, Oxygen trim • Boilers, heaters, dryers, thermal oxidizers • Combustion Management Engineering Automation Services Previous Next

The cause of failure is the specific reason or condition that leads to the malfunction or breakdown of a system, component, or process. Identifying the cause of failure is essential for implementing corrective actions and improving reliability. Acronyms & Terms Glossary <- More Definitions Cause of Failure The cause of failure is the specific reason or condition that leads to the malfunction or breakdown of a system, component, or process. Identifying the cause of failure is essential for implementing corrective actions and improving reliability. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

A substance possessing toxic, reactive, flammable, or explosive properties. Acronyms & Terms Glossary <- More Definitions Highly Hazardous Chemical (HHC) A substance possessing toxic, reactive, flammable, or explosive properties. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Area classification is the process of determining and designating specific zones within a facility where flammable gases, vapors, or combustible dusts may be present, potentially leading to hazardous conditions. These classified areas help guide safety measures and equipment installation, ensuring compliance with safety standards and reducing the risk of explosions or fires. Acronyms & Terms Glossary <- More Definitions Area Classification Area classification is the process of determining and designating specific zones within a facility where flammable gases, vapors, or combustible dusts may be present, potentially leading to hazardous conditions. These classified areas help guide safety measures and equipment installation, ensuring compliance with safety standards and reducing the risk of explosions or fires. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

An audible and/or visible means of indicating to the operator an equipment malfunction, process deviation, or abnormal condition requiring a response. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Acronyms & Terms Glossary <- More Definitions Alarm An audible and/or visible means of indicating to the operator an equipment malfunction, process deviation, or abnormal condition requiring a response. 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 Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

NFPA 87 is the standard from the National Fire Protection Association that provides safety guidance for fluid heaters and related equipment to minimized fire and explosion hazards that can endanger the equipment, building, or personnel. A piece of equipment is considered to be a fluid heater if it includes any of the following features: fluid is flowing under pressure, fluid is indirectly heated, and/or a release of energy from combustion of a fuel or an electrical source occurs within the unit. Acronyms & Terms Glossary <- More Definitions NFPA 87 NFPA 87 is the standard from the National Fire Protection Association that provides safety guidance for fluid heaters and related equipment to minimized fire and explosion hazards that can endanger the equipment, building, or personnel. A piece of equipment is considered to be a fluid heater if it includes any of the following features: fluid is flowing under pressure, fluid is indirectly heated, and/or a release of energy from combustion of a fuel or an electrical source occurs within the unit. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Our system design services include developing wiring plans, functional test plans, factory acceptance and site acceptance test plans (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. Gas detection compliance  toxic gas detection and toxic gas monitoring 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. Written Narrative Riser Diagram Floor Plan Layout Sequence of Operation Field Design Deliverables Manufacturer’s Published Instructions Battery Calculations Voltage Drop Calculations Detector Final Placement End Device Selection I/O Assignment Panel Design Architecture Block Diagram Cable Schedule / Cable Block Diagrams Detailed Design Deliverables Installation Details for End Devices Engineering and Design calculations Completion Test Forms HMI screen requirements Installation Support Fire & Gas Products NRTL Approved Fire Panels NRTL Approved Power Supplies NRTL Approved Proprietary Supervisor Stations Ensure toxic gas detection Ongoing Maintenance Training - to Operate, Maintain, and More Fire & Gas Lifecycle Services Contact Us