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aeSolutions systems integration services support moving industrial manufacturing facilities from Risk to Resilience by integrating control systems and ensuring reliable performance. Systems Integration Services Click Here to Chat With Our Systems Integration Experts Connecting Control Systems for Reliable, Consistent, and Scalable Operations Outdated systems, inconsistent configurations, or poorly integrated components introduce risk, reduce visibility, and create challenges for operations and maintenance teams. aeSolutions works with clients to integrate control systems in a way that supports consistency, reliability, and long-term maintainability. aeSolutions provides Systems Integration services to help industrial manufacturing facilities connect and align control systems, platforms, and field devices into a cohesive, functional environment. Effective integration is essential to ensuring that automation systems operate reliably, data flows accurately, and system performance meets operational expectations. Our Systems Integration services include: Integration of control systems, including DCS, PLC, and HMI platforms Configuration and alignment of system communications and data exchange Integration of field instrumentation and control devices into automation systems Support for system interoperability across new and existing platforms Coordination of system interfaces and data flow between components Verification of system functionality and alignment with project requirements Documentation of integrated system architecture and configurations Development of I/O lists, control narratives, and logic documentation Design of HMI interfaces and operator displays aeSolutions works closely with your engineering, operations, and project teams to deliver integrated control systems that function as intended in real-world environments. Whether supporting new system deployments or upgrades to existing infrastructure, our systems integration expertise helps ensure reliable performance, improved visibility, and a more connected operational environment. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Learn More About aeSolutions — Let's Discuss Your Systems Integration Needs —

aeSolutions' has been a trusted provider of facility siting study and modeling needs for over 25 years. Let's discuss how we can positively impact your sustainable risk management program. 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. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results 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. — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Click Here to Chat With Our Industry Experts 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

Articulating the Project Vision and Characterizing the Control System Project Assessment and Conceptual Design Articulating the Project Vision and Characterizing the Control System aeSolutions engages clients to determine project goals, scope boundaries, assumptions, and customer requirements. A common conceptual design for the project is formulated in a project assessment report. The conceptual design includes a budgetary estimate and schedule. • Site and field investigations • Current state quantification • Client requirements • Scope and boundaries • Project assumptions • Conceptual design • Assessment report • Conceptual system architecture • Preliminary I/O counts • Project cost and schedule estimates aeSolutions' experienced professionals work closely with the client's engineers to map out the preliminary scope of work for the project and propose a high-level view of the system requirements. The conceptual design includes a budgetary estimate and schedule to support the feasibility and business case reviews. • Conceptual system architecture • Migration strategies • Operational philosophy • Preliminary I/O counts • Preliminary Bill of Material • Wiring philosophy • Project cost and schedule estimates +/- 30% 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 What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland.

A function of the expected frequency and severity of a single potential incident or group of incidents. Acronyms & Terms Glossary <- More Definitions Risk A function of the expected frequency and severity of a single potential incident or group of incidents. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland.

Immediately dangerous to life or health (IDLH) means an atmospheric concentration of any toxic, corrosive or asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse health effects or would interfere with an individual's ability to escape from a dangerous atmosphere. IDLH 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 Immediately Dangerous to Life and Health (IDLH) Immediately dangerous to life or health (IDLH) means an atmospheric concentration of any toxic, corrosive or asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse health effects or would interfere with an individual's ability to escape from a dangerous atmosphere. IDLH 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 What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland.

Strengthen process safety and maintain compliance with aeSolutions’ Process Hazard Analysis (PHA) services. Our expert-led studies identify risks, improve safeguards, and support safer operations. Process Hazard Analysis (PHA) Services Click Here to Chat With Our PHA Experts Expert Hazard Analysis for Comprehensive Risk Management aeSolutions provides detailed, rigorous Process Hazard Analysis services designed to proactively identify, evaluate, and mitigate process safety risks across diverse industries and facilities. Our PHA experts facilitate studies tailored to your specific operational context, whether for existing assets, capital projects, or management-of-change (MOC) scenarios. Our extensive process hazard analysis capabilities include: PHA Studies (Meeting regulatory compliance and/or client requirements) Existing Facilities, Capital Projects, and MOCs Fixed Facilities, Pipelines, Offshore, Transportation, and Specialty Process PHAs, Procedural PHAs, and PHA Revalidations Burner Management Systems, Chemicals, Oil and Gas, Manufacturing, Pharmaceuticals, and More Customized Methodologies for Specific Processes & Equipment Recognizing that each facility and process presents unique hazards, aeSolutions applies industry-recognized methodologies matched to your specific operational environment. Our hazard analysis specialists select the most effective techniques to comprehensively assess risks, ensure regulatory compliance, and enhance safety performance. Our hazard analysis methodologies include: Methodologies Appropriate to the Specific Process and Equipment Hazard Identification (HAZID) and Hazard Register Development Hazard and Operability Analysis (HAZOP) What-If / Checklist Analysis Failure Modes and Effects Analysis (FMEA) Control System Hazard and Operability Analysis (CHAZOP) With our tailored approach to hazard analysis, your organization can confidently manage risks, protect assets, and maintain a resilient safety culture. Risk Matrix Development Support aeSolutions can also help clients develop clear, defensible PHA risk matrices by facilitating management‑led workshops that define risk tolerability criteria and ensure consistent, risk‑based decision‑making across PHA and LOPA studies. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Learn More About aeSolutions — Let's Discuss Your Process Hazard Analysis Needs —

aeSolutions facilitates alarm rationalization to reduce alarm flood, improve operator response, and align with ISA 18.2 and IEC 62682 standards. Alarm Rationalization Facilitation Service Click Here to Chat With Our Alarm Rationalization Facilitation Experts Defining Meaningful, Actionable Alarms Through Structured Rationalization aeSolutions provides Alarm Rationalization Facilitation services to help organizations systematically evaluate and define their alarm set to ensure each alarm is necessary, prioritized correctly, and actionable by operators. Our structured approach aligns key stakeholders on alarm intent, response, and performance expectations using consistent, standards-based methodologies. Rationalization is where alarm management gets real, and where most programs stall. Reviewing thousands of alarms with cross-functional teams is time-intensive, politically complex, and technically demanding. Without experienced facilitation, workshops lose momentum, criteria drift between sessions, records become inconsistent, and the resulting alarm set doesn’t hold up during implementation or audits. aeSolutions facilitates rationalization workshops that keep teams productive, criteria consistent, and records audit-ready. We guide your operations, engineering, and process safety stakeholders through structured, standards-based review of every alarm’s necessity, priority, setpoints, deadbands, cause, consequence, and required operator response, aligned with ANSI/ISA-18.2, EEMUA 191, or IEC 62682. Proven Results from Large-Scale Alarm Rationalization Our rationalization methodology and aeAlarm platform were central to the results documented in our award-winning research presented at the 2025 Mary Kay O’Connor Process Safety Conference. Working with cross-functional teams at a midstream LNG facility, we rationalized over 55,000 alarm points across two process units on Honeywell Experion, achieving 84–92% reductions in urgent alarm activations. Unit A reduced urgent alarms from 45% of total alarm load to just 7%. Unit B reduced urgent alarms from 62% to 5%. Over 7,800 nuisance urgent alarms were eliminated, and 100% of remaining alarms now have documented operator response procedures. These results demonstrate what structured rationalization looks like when methodology, tooling, and facilitation expertise come together. Read the full paper here . What to Expect from a Typical Alarm Rationalization Engagement A typical rationalization engagement for a medium-sized process unit involves 2–4 weeks of facilitated workshop sessions, with preparation, data collection, and documentation extending the overall timeline to 8–12 weeks. We work with your team to define scope, establish session schedules that minimize production impact, and deliver implementation-ready rationalization records. For multi-unit or site-wide campaigns, we structure phased approaches that maintain consistency across the program. Our Alarm Rationalization Facilitation services include: Facilitation of structured alarm rationalization activities with cross-functional teams Review and validation of existing alarms for necessity and purpose Definition of alarm priorities based on consequence and required response time Documentation of alarm causes, consequences, and operator response actions Establishment of alarm setpoints, deadbands, and classification criteria Identification and elimination of duplicate, nuisance, or low-value alarms Development of rationalization records to support implementation and auditability Alignment with alarm philosophy and lifecycle requirements aeSolutions works closely with your operations, engineering, process safety, and control system teams to ensure rationalization outcomes are practical, consistent, and aligned with real-world operating conditions. Whether supporting a new alarm management initiative or improving an existing system, our facilitation expertise helps create a streamlined alarm set that enhances operator effectiveness and supports safer, more resilient operations. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Learn More About aeSolutions — Let's Discuss Your Alarm Rationalization Facilitation Needs —

Please use this form. We'd like to hear from you. info@aesolutions.com Phone: 864-676-0600 Greenville, South Carolina Corporate Headquarters Contact aeSolutions Contact us regarding your pr oject or question and the appropriate team member will be in touch. Emal Us 864-676-0600 Email: info@aesolutions.com Greenville, SC Corporate Headquarters 250 Commonwealth Drive Ste 200 Greenville, SC 29615 Regional Office Phone numbers: Houston, TX 713-292-0000 757 N Eldridge Parkway Ste 520 Houston, TX 77079 aeSolutions offers performance-based process safety PSM engineering, and automation (system integration) solutions with proven processes that ensure consistent project execution, while helping clients optimize safety, quality and production. We are committed to providing services that enable our clients to sustainably own, operate, and maintain their process facilities. Following its original vision of providing Value-Driven Engineering, aeSolutions continues to anticipate and exceed the expectations of their customers, employees, and the market.

Identify and mitigate process risks with aeSolutions’ HAZOP study services. Our expert-led analyses help facilities improve safety, ensure compliance, and reduce operational risk. HAZOP Study Services Click Here to Chat With Our HAZOP Study Experts Structured Hazard Identification for Safer and More Resilient Process Operations aeSolutions provides expert Hazard and Operability (HAZOP) study facilitation to help industrial manufacturing facilities systematically identify and evaluate process hazards and operability issues. Our experienced facilitators guide your team through a structured analysis that helps uncover potential deviations, evaluate safeguards, and reduce process safety risks. HAZOP studies are a critical component of effective Process Safety Management (PSM) programs. aeSolutions supports facilities throughout the HAZOP lifecycle, from preparation and study execution to documentation and action item tracking, ensuring studies deliver practical insights that strengthen operational safety and reliability. Our HAZOP study capabilities include: HAZOP study facilitation by experienced process safety professionals Node definition and deviation analysis using standard guide words Identification of credible hazard and operability scenarios Safeguard evaluation and risk ranking Documentation of study findings and recommendations Support for capital projects, facility modifications, and management of change (MOC) Integration with broader PHA and process safety programs Revalidation support for existing HAZOP studies With aeSolutions’ HAZOP expertise, organizations can improve hazard visibility, strengthen process safety programs, and ensure operational risks are identified and addressed through a structured and defensible methodology. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Learn More About aeSolutions — Let's Discuss Your HAZOP Study Needs —

An Automatic Shutdown System is a safety mechanism that initiates an automatic process shutdown in response to certain conditions, such as equipment failure or hazardous events. These systems help prevent accidents and protect personnel, equipment, and the environment. Acronyms & Terms Glossary <- More Definitions Automatic Shutdown System An Automatic Shutdown System is a safety mechanism that initiates an automatic process shutdown in response to certain conditions, such as equipment failure or hazardous events. These systems help prevent accidents and protect personnel, equipment, and the environment. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland.

aeSolutions is a total process automation provider with extensive experience in turnkey solutions. We've earned aeSolutions was the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification. ​aeSolutions' President, Ken O’Malley, holds a position on Siemens’ User Advisory Boar Siemens Solution Partner - aeSolutions aeSolutions is a process automation engineering company with extensive experience in delivering turnkey automation solutions and is a leading provider of critical systems such as Safety Instrumented Systems, Fire and Gas Systems, and Combustion Control and Safeguarding Systems in the country. The company maintains a team of experienced Professional Engineers and Certified Functional Safety Experts (CFSE). aeSolutions joined Siemens Solution Partner Program in 1999 and has earned the Solution Partner Specialist designation after achieving technical and commercial milestones associated with year-over-year quality performance delivering solutions in both brownfield migrations and greenfield expansions for over two decades. We're proud to have been the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification. Siemens.com Partner Detail Page aeSolutions' President, Ken O’Malley , holds a position on Siemens’ User Advisory Board as well as Siemens’ national Solution Partner Council. Service Portfolio: Consulting for process safety and automation conceptual design Automation of process manufacturing facilities Training on PSM and process automation and safety systems Integration, Engineering, and Commissioning of DCS, SIS, BMS and fire & gas systems FM and UL certified panel fabrication shop Migrations & upgrades of automation & safety systems aeSolutions: Certificates: Solution Partner Process Control System SIMATIC PCS 7 Advanced Factory Automation PCS 7 Safety Specialist Systems Intergration - Automation Services Combustion - Burner Management Systems aeSolutions & Siemens Media aeSolutions is the First in Americas to earn S iemens SIMATIC PCS 7 Safety Specialist Certifications “As customers require PCS 7 safety instrumented systems, we can recommend aeSolutions, our certified Process Safety Specialist Solution Partner, knowing that they have the engineering and quality practices to execute the project right the first time using best practices,” says Rich Chmielewski, Siemens USA PCS 7 Solution Partner Program Manager. Learn More Using the cloud to secure the cloud https://www.controlglobal.com Best practices for gas detection system design https://www.controlglobal.com aeSolutions is First in the Americas to Earn Siemens SIMATIC PCS 7 Safety Specialist Certification https://www.automationworld.com aeSolutions & Siemens Case Studies Ammonia isolation and mitigation safety system based on FGS 1400 MK II platform. Uses S7-400 safety controllers and S7-300 safety IO. Ammonia suppression safety system that is NRTL approved for toxic gas. FGS 1400 MK II product provides leak detection, occupant notification, equipment isolation, and hazard suppression capability for a pressurized ammonia storage facility. View Details aeSolutions applies our expertise to help you produce Hydrogen safely. Expertise is required to produce hydrogen safely especially indoors with electrolyzers. You are working with a dangerous chemical and with modeling of the gas, especially indoors, you can properly place the detectors. Fire and Gas, Safety Shutdown systems as well as overall process automation best practices, are critical to safely product hydrogen. View Details Optimizing Integration of Life-Saving Gas Detection Systems for the Pharmaceutical Industry Leverage the expertise of Solution Partner aeSolutions to provide plants with turnkey gas detection systems including all control system components, detectors and computational fluid dynamics modeling. Benefits can include: •Ensures OSHA compliance to reduce risk of overexposure, fire or explosion •Simplified integration of gas detection systems into plants •Minimized footprint due to modern I/O technology View Details Siemens PCS7 Implemented as SI-BMS for Utility Boilers at Chemical Plant Designed, fabricated, configured, tested and performed start-up services for seven burner management systems (BMS) on seven coal and gas fired process boilers for a chemical manufacturing plant. View Details Fire & Gas Safety System using SIMATIC S7-400F provides highly scalable flexibility for industrial Fire and Gas applications. FM approved Fire and Gas safety system based on S7-400 safety controllers and ET200MF safety IO. System provides detection, notification, suppression, and process ESD shutdowns. System also has FM approved power supply system capable of supplying OSHA and NFPA 72 power requirements. View Details Meeting Customer Demand by Doubling Production PCS 7 Simatic Batch and PCS 7 Failsafe were used to automate a new reactor and associated equipment to double production View Details Safety Shutdown and BMS needs met with Compliant System Refineries burner management and safety shutdown needs are met with rack-to-rack redundant PCS 7 Failsafe System and Safety Matrix. View Details Siemens PCS 7 TIA Success: Instrumentation and Motor Control Centers as a Modular and Scalable Solution The SEFA Group plant gives a local supply of a premium recycled product available for sustainable construction. Siemens PCS 7 was successfully integrated using TIA with all instrumentation and motor control centers to aid in elimination of up to 400,000 tons of fly ash per year transported to landfills. This also improved reliability with PCS7 tools View Details www.usa.siemens.com/process