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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. Challenge A global pharmaceutical company’s corporate standards mandated a local manufacturing site install a combustible gas leak detection system in its boiler house to mitigate risk to personnel and equipment. The client needed the ability to detect and isolate gas leaks within a utility building containing multiple large natural gas-fired boilers to lessen the risk to personnel and reduce the potential for extended production disruption due to significant equipment damage. Solution aeSolutions designed and provided an FM approved industrial fire alarm and gas detection system to automatically isolate the main natural gas feed to the building when a leak is detected. aeSolutions also provided detector placement consulting services based on the physical location of potential leak sources. Delivered: • FGS 1300 fire alarm and gas detection/isolation system • Automatic isolation valve installed in natural gas supply line • Eight point gas detectors • Detector placement services Results The client now has an industrial grade system for detecting and isolating a release of natural gas, reducing the risk to personnel and equipment, and complying with their corporate safety program requirements. Learn more about how aeSolutions could help you with a similar gas detection project. Industry: Pharmaceuticals Geography: Southeast Unit Operation: FGS 1300 Governing: FM Approvals Previous Story Next Story

As a supplier of complete process safety systems and risk management solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety systems and backgrounds. Our specialists understand process safety. Planning "control systems" & "process controls", and process risk management. - Process Hazard Management HS4, HS5, HS- essential component of any facility. Learn about the importance of process safety management Transforming Your Process From Process Safety Gaps Resource Constraints Lack of Leadership Buy-In Does this sound familiar? Ready for Relief? Let's Chat Stale PHA Reports — Our Process Safety Capabilities — Process Safety Management (PSM) is essential for building operational resilience in complex, high-risk industrial environments. Gaps in process safety, whether due to outdated hazard analyses, unclear ownership, or staff turnover, can escalate risk and create costly disruptions. Without a clear strategy and structured approach, facilities face mounting compliance burdens, greater exposure to incidents, and internal stress that affects team performance. An effective PSM program is more than a regulatory requirement; it is a system for predictability, accountability, and safer, smarter decision-making across the organization. Process Hazard Analysis (PHA) PSM/RMP Audits Facility Siting Studies Dust Hazard Analysis (DHA) SOP Training/Development Pressure Relief Studies Hazard & Operability Study (HAZOP) Layers of Protection Analysis (LOPA) Click Here to Speak with a Process Safety Expert About Your Facility's Resilience — The aeSolutions ResiliencePath™ Method — We’re an integrative specialist with a proven methodology that we call ResiliencePath™ that embeds safety into every stage of the project lifecycle — from concept to closure — for compliance today and resilience tomorrow. Empowering — Not Enforcing Rather than checking boxes, we help you identify the right questions early to prevent costly late-stage corrections and avoid years of OpEx fixes. Each ResiliencePath™ step is driven by one goal: empowering resilient, value-aligned decisions that stand the test of time. EPC & Subcontractor Integration ResiliencePath™ is adaptable to collaborate seamlessly with EPCs and subcontractors, integrated into a structured workflow designed to adapt to real-world project dynamics without compromising on results. Your Process, Our Expertise At aeSolutions, we help clients reduce project chaos and strengthen performance by melding the process safety lifecycle with the project lifecycle. Our integrated services span PHA facilitation, compliance audits, facility siting, and risk management planning, supported by domain expertise and a focus on practical implementation. We work with your team to close gaps, clarify responsibilities, and convert fragmented practices into a unified approach that protects people, assets, and uptime. Whether you're navigating a revalidation or rethinking your strategy, aeSolutions helps you move from risk to resilience with clarity and confidence. Learn More About the aeSolutions ResiliencePath ™ Methodology — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production View More Case Studies Here — 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 — Our Process Safety Whitepapers — Whitepaper - Using Small Data to Support Decision Making When LOPA Fails Whitepaper - Improving Human Factors Review in PHA and LOPA Whitepaper - Process Safety - Using Bayes' Theorem to Establish Site Specific Confidence in LOPA View More Whitepapers Here — Let's Discuss Your Process Safety Needs —

The most recent aeSolutions News Articles, Blogs, Media Releases, Whitepapers all in one spot. We are continuinally engaged in thought leadership, industry groups, and standard steering committees. News and Resources What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals aeSolutions Recognized with 2026 CSIA Social Responsibility Award Blogs Read More Blogs Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Whitepapers Read More Whitepapers News on topics such as PHA, LOPA, systematic failures, Process Safety, Safety Instrumented Systems, SIS, Fire and Gas Systems, Company News aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions Announces Key Leadership Promotions to Support Continued Client Success aeSolutions Announces New Executive Leadership Appointments and Corporate Growth Structure Media Releases Read More Media Releases aeSolutions' News, Blogs, Media Coverage, & Whitepapers. We understand that the industry is constantly evolving. We also understand that, because of this, communication is more important than ever. That’s why it’s our goal to regularly publish technical whitepapers that keep our colleagues and clients informed. Learn about our latest innovations and awards to see how aeSolutions is an industry leader in integrating Process Safety, Industrial Systems Integration, Alarms, Combustion, & Fired Equipment. Keywords : ae solutions, asset inventories, creating network diagrams, systematic failures, systematic failure, iec 61511, isa 84, automation engineering services, site acceptance test, site acceptance testing, burner management systems, siemens combustion controls, bms panels, siemens bms, nfpa 87, aes consulting engineers, isa 84, industrial firewalls, pha safety, dmz design best practices, purdue model for control hierarchy, combustion control solutions, fire and gas detection 61511 (10) 10 posts AIChE (2) 2 posts ANSI/ISA 84 (3) 3 posts ANSI/RIA R15.06 (1) 1 post API 752 (1) 1 post API 753 (1) 1 post API 756 (1) 1 post API RP 556 (1) 1 post Aerosol (1) 1 post Aerosol Explosion (1) 1 post Alarm (4) 4 posts Alarm Philosophy (2) 2 posts Alarm Rationalization (1) 1 post Alarm Rationilization (2) 2 posts Ammonia (2) 2 posts Audit (3) 3 posts Automation (1) 1 post Award (3) 3 posts Awards (1) 1 post BMS Design (2) 2 posts BPCS (2) 2 posts Bayes (5) 5 posts Bayes theory (1) 1 post Boiler Fuel Conversion (1) 1 post Boilers (2) 2 posts Burner Management Systems BMS (12) 12 posts CFD Modeling (3) 3 posts CHAZOP (2) 2 posts CSIA (1) 1 post Carolyn Bott (2) 2 posts Certification (3) 3 posts Chemical Processing (1) 1 post Chris Hickling (1) 1 post Combustible dust (4) 4 posts Combustion (4) 4 posts Common cause (1) 1 post Compliance (6) 6 posts Compliance with Standards (1) 1 post Confidence Interval (1) 1 post Continuous Improvement (1) 1 post Control Panels (1) 1 post Control System (12) 12 posts Control System Integrator (2) 2 posts Control system migrations (4) 4 posts Control system upgrades (2) 2 posts Culture (3) 3 posts DCS (2) 2 posts DHA (1) 1 post David Cochran (1) 1 post David Ivester (2) 2 posts Deluge (1) 1 post Design Philosophy (1) 1 post Detailed Design (1) 1 post Don Connolley (2) 2 posts EPA (6) 6 posts Energy transition (1) 1 post Engineering consultant (4) 4 posts Engineers Week 2024 (6) 6 posts Ethical Leadership (1) 1 post Explosion (2) 2 posts FEL (2) 2 posts FGS 1300 (1) 1 post FGS 5000 (1) 1 post FMEA (1) 1 post FSA (7) 7 posts FSA Stage 3 (1) 1 post FSA stage 4 (2) 2 posts Facility Siting (4) 4 posts Factory Acceptance Testing (1) 1 post Financial (1) 1 post Fire Code (1) 1 post Fire and gas systems (8) 8 posts Fire detection (1) 1 post Fired Equipment (5) 5 posts Flammability Diagram (1) 1 post Flammable Gas/Vapor Release (2) 2 posts Flammable Limits (2) 2 posts Flash Fire (2) 2 posts Front End Loading (5) 5 posts Functional Safety Assessment (FSA) (7) 7 posts GCPS (2) 2 posts Gap Assessments (2) 2 posts Gas Detection (8) 8 posts Gas Detection/Dispersion Prediction (1) 1 post Gas Detector (2) 2 posts Gas detection types (2) 2 posts Geographic Scenario (1) 1 post Green Energy (2) 2 posts Greg Hardin (4) 4 posts Greg Pajak (1) 1 post HAZOP (6) 6 posts Hardware reliability (1) 1 post Hazard Assessment (3) 3 posts Hazard Identification and Risk Analysis (1) 1 post Human Factors (5) 5 posts Human Reliability (3) 3 posts Hydrogen (3) 3 posts IEC 61511 (6) 6 posts IPL validation (4) 4 posts ISA (2) 2 posts ISA 18.2 (2) 2 posts ISA 61511 (4) 4 posts ISA 84 (3) 3 posts ISA/IEC 61511 (6) 6 posts ISO 13849-1 (1) 1 post Independent Protection Layers IPL (7) 7 posts Industrial Automation (2) 2 posts Instrumentation (1) 1 post Interconnected Systems (1) 1 post Interlocks (1) 1 post Jacob Lindler (2) 2 posts Joel Ramirez (1) 1 post Joel Read (1) 1 post Judith Lesslie (9) 9 posts Keith Brumbaugh (8) 8 posts Ken O’Malley (11) 11 posts Ken Whittle (2) 2 posts LOPA - 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Identify gaps in your alarm philosophy with aeSolutions. We assess alignment with ISA 18.2, IEC 62682, and EEMUA 191 to strengthen performance. Alarm Philosophy Gap Assessment Service Click Here to Chat With Our Alarm Philosophy Gap Assessment Experts Identifying Gaps and Strengthening the Foundation of Your Alarm Management Program aeSolutions provides Alarm Philosophy Gap Assessment services to evaluate your existing alarm philosophy against recognized industry standards and best practices, including ANSI/ISA-18.2, EEMUA 191, or IEC 62682. Our structured approach identifies risks, gaps, inconsistencies, and areas for improvement, ensuring your alarm management program is built on a solid, defensible, and resilient foundation. Over time, alarm philosophies can become outdated, incomplete, or misaligned with actual operating practices. This can lead to inconsistent alarm configuration, ineffective prioritization, and increased operator burden. aeSolutions helps facilities assess the current state of their alarm philosophy and provides clear, actionable recommendations to improve alignment, consistency, and overall program effectiveness. Our Alarm Philosophy Gap Assessment services include: Review of existing alarm philosophy documentation for completeness and clarity Benchmarking against ANSI/ISA-18.2, EEMUA 191, IEC 62682, and industry best practices Identification of gaps in alarm design, prioritization, and classification criteria Evaluation of defined operator response expectations and alarm handling guidance Assessment of roles, responsibilities, and program ownership Review of alarm lifecycle processes, including rationalization, implementation, and maintenance Evaluation of performance metrics, KPIs, and monitoring practices Documentation of findings with prioritized, actionable recommendations aeSolutions works closely with your operations, engineering, and process safety teams to identify gaps and provide practical recommendations that align with your facility’s operating environment. Whether preparing for a broader alarm management initiative or improving an existing program, our expertise helps ensure your alarm philosophy supports consistent, effective, and resilient alarm management practices. When Do You Need Alarm Philosophy Gap Assessment Services? It is the right time for this service if your alarm philosophy hasn’t been updated in more than 3 years, your facility has undergone DCS upgrades, console consolidation, or significant process changes since the philosophy was written, or if you’re preparing for an OSHA PSM audit, corporate governance review, or insurance assessment. Multiple sites operate under different alarm management practices and you need a standardized baseline. Your rationalization records no longer align with the philosophy they were based on. Addressing these gaps is a key step in moving your facility from risk to resilience. — 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 Philosophy Gap Assessment Needs —

aeSolutions Corporate Partners Corporate Connections aeShield® automatically maintains the complex relationships among the risk reduction performance, design verification calculations, inspection and test plans for integrity management, and actual plant historical data. aeShield® provides real time alerts and reporting on the process safety health of a single safety loop, a full process area or across an entire multi-site enterprise. aeSolutions is a licensed reseller of aeShield® Safety Lifecycle Management software suite, a comprehensive platform for automating the safety lifecycle in compliance with ISA84.00.01/IEC 61511 and the related requirements of OSHA 1910.119. Cisco Systems, Inc. engages in the design, manufacture, and sale of Internet Protocol based networking products and services related to the communications and information technology industry. The firm operates through the following geographical segments: the Americas, EMEA, and APJC. Its product comprises of the following categories: Switches, Routers, Wireless, Network Management Interfaces and Modules, Optical Networking, Access Points, Outdoor and Industrial Access Points, Next-Generation Firewalls, Advanced Malware Protection, VPN Security Clients, Email, and Web Security. The Mary Kay O’Connor Process Safety Center provides a neutral forum to discuss difficult issues related to process safety. The Chemical Safety Program Assessment Project is a significant effort that brings together a diverse group of stakeholders to identify national chemical safety goals; identify and implement activities necessary to accomplish these goals; and establish a measurement system to help gauge progress toward these goals. The center also serves as an information resource base for process safety, acting as a library and software laboratory. 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've earned aeSolutions was the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification and is now also the first to renew. In 2026, aeSolutions was also named a Chemical Expert within the Siemens Solutions Partner Network. There are currently only a couple of chemical experts within the Siemens Solutions Partner Network in the US. aeSolutions was deemed qualified for this designation based on our expertise in executing and managing complex automation capital projects in the chemicals and oil & gas industries. Siemens Partner Details Site aeSolutions' President, Ken O’Malley , holds a position on Siemens’ User Advisory Board as well as Siemens’ national Solution Partner Council. Click to Learn More about aeSolutions American Petroleum Institute (API) represents all segments of America’s oil and natural gas industry. Nearly 600 members produce, process and distribute most of the nation’s energy, and participate in API Energy Excellence® , which is accelerating safety progress by fostering new technologies and transparent reporting. API was formed in 1919 as a standards-setting organization. In their first 100 years, API has developed more than 700 standards to enhance operational and environmental safety, efficiency and sustainability. aeSolutions is a Member of the American Petroleum Institute. Founded in 1994, the Control System Integrators Association (CSIA) is a not-for-profit, global trade association that seeks to advance the industry of control system integration. Control system integrators use their engineering, technical and business skills to help manufacturers and others automate their industrial equipment and systems. CSIA helps members improve their business skills, provides a forum to share industry expertise, and promotes the benefits of hiring a certified control system integrator. CSIA has over 500 member companies in 35 countries. aeSolutions is an Integrator Member of the Control System Integrators Association Rockwell Automation, Inc. is a global leader in industrial automation and digital transformation. Headquartered in Milwaukee, Wisconsin, Rockwell Automation employs approximately 23,000 "problem solvers" serving customers with automation products, software, and solutions in more than 100 countries. aeSolutions is a certified Rockwell Systems Integrator. This allows us to ensure we can provide the best possible solution and exceptional support with the least amount of risk for your company. CCPS is a not-for-profit, corporate membership organization within AIChE that identifies and addresses process safety needs within the chemical, pharmaceutical, and petroleum industries. CCPS brings together manufacturers, government agencies, consultants, academia and insurers to lead the way in improving industrial process safety. CCPS member companies, such as aeSolutions, work in project subcommittees to define and develop useful, time-tested guidelines that have practical application within industry. aeSolutions is a Member Company of CCPS. Founded in 1945, the International Society of Automation is a leading global, nonprofit organization that is setting the standard for automation by helping over 30,000 worldwide members and other professionals solve difficult technical problems, while enhancing their leadership and personal career capabilities. Based in Research Triangle Park, North Carolina, ISA develops standards; certifies industry professionals; provides education and training; publishes books and technical articles; and hosts conferences and exhibitions for automation professionals. aeSolutions is both an ISA member as well as assists in the creation and delivery of ISA safety and alarm management courses. . Founded in the mid 1830’s in France, the company has its earliest roots in steel foundries, the machine industry, and later ship building. In the late 1800’s the company expanded into the emerging electricity market. Today Schneider Electric is focused on software, critical power, and smart grid applications. aeSolutions’ alliance partnership with Schneider Electric is in the areas of Control Systems and the Modicon Safety System products. The Modicon M580 platform provides a compelling and cost-competitive SIL 3 SIS logic solver with controller and I/O module availability-redundant architectures.

Improve your industrial manufacturing facility's alarm management with aeSolutions. Reduce alarm floods, enhance operator response, and strengthen safety across the full lifecycle. Transforming Your Alarm Management From DCS Alarm Floods Inconsistent Alarm Priorities Nuisance Alarms Does this sound familiar? Overloaded Operators Ready for Relief? Let's Chat — Our Alarm Management Capabilities — Alarm Management is essential for building operational resilience in today’s complex industrial environments. When alarm systems are poorly configured, overly sensitive, or unmanaged over time, operators can face alarm floods, nuisance alerts, and competing priorities that erode situational awareness and increase operational risk. These gaps in alarm performance, whether due to legacy settings, lack of rationalization, or inconsistent practices, can overwhelm teams, undermine compliance efforts, and elevate exposure to system upsets and safety incidents. Without a strategic and structured alarm management program, facilities struggle with alarm fatigue, delayed response times, and unnecessary stress on operations and site personnel. An effective alarm management program is more than a control system feature, it is a vital framework for predictability, clarity, and safer, smarter decision-making under pressure. Achieving system resilience leads to proactive, not reactive behavior. Alarm Philosophy Development Alarm Philosophy Gap Assessment Alarm Management Program Audit Advanced Alarming Techniques Alarm Rationalization Facilitation Alarm Implementation Support Click Here to Speak with an Alarm Management Expert About Your Facility's Resilience — The aeSolutions ResiliencePath™ Method — We’re an integrative specialist with a proven methodology that we call ResiliencePath ™ that embeds safety into every stage of the project lifecycle — from concept to closure — for compliance today and resilience tomorrow. Empowering — Not Enforcing Rather than checking boxes, we help you identify the right questions early to prevent costly late-stage corrections and avoid years of OpEx fixes. Each ResiliencePath™ step is driven by one goal: empowering resilient, value-aligned decisions that stand the test of time. EPC & Subcontractor Integration ResiliencePath™ is adaptable to collaborate seamlessly with EPCs and subcontractors, integrated into a structured workflow designed to adapt to real-world project dynamics without compromising on results. Your Process, Our Expertise At aeSolutions, we help clients reduce operational noise and strengthen performance by integrating an effective alarm management program with day-to-day operations and system change. Our services span alarm philosophy development, alarm rationalization facilitation, alarm program assessments, and sustainability. We work alongside your operations, engineering, and safety teams to eliminate alarm overload, clarify operator response expectations, and transform fragmented alarm practices into a unified program that protects people, assets, and uptime. Whether you are addressing chronic alarm floods or building a sustainable alarm management strategy, aeSolutions helps you move from risk to resilience with clarity and confidence. Learn More About the aeSolutions ResiliencePath ™ Methodology — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Click Here Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production View More Case Studies Here — 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 — Our Alarm Management Whitepapers — Whitepaper - Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation Whitepaper - Breathing Life into the Alarm Management Lifecycle Whitepaper - Process Safety - Using Bayes' Theorem to Establish Site Specific Confidence in LOPA View More Whitepapers Here — Let's Discuss Your Alarm Management Needs —

A probability that accounts for the fraction of time the facility is in a specified condition when the incident sequence arrives at the pertinent consequence severity. Conditional modifiers are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Acronyms & Terms Glossary <- More Definitions Conditional Modifier A probability that accounts for the fraction of time the facility is in a specified condition when the incident sequence arrives at the pertinent consequence severity. Conditional modifiers are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Our Services 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.

Control system that monitors the concentration of combustible gases and initiates alarm and shutdown functions at predetermined concentrations. aeSolutions' Fire and Gas team can support gas detection systems from conceptual design through field installation. This includes developing a Fire and Gas philosophy, technology selection, ensuring an appropriately sized system, and fire and gas mapping using the Geographic coverage approach and/or Computational Fluid Dynamics (CFD) scenario-based modeling to determine gas detector placement. Acronyms & Terms Glossary <- More Definitions Gas Detection System Control system that monitors the concentration of combustible gases and initiates alarm and shutdown functions at predetermined concentrations. aeSolutions' Fire and Gas team can support gas detection systems from conceptual design through field installation. This includes developing a Fire and Gas philosophy, technology selection, ensuring an appropriately sized system, and fire and gas mapping using the Geographic coverage approach and/or Computational Fluid Dynamics (CFD) scenario-based modeling to determine gas detector placement. Our Services 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.

Discover aeSolutions’ proven playbook for successful project development, focusing on achievable scopes, risk management, and seamless transitions to execution. Project Development Efficient & Resilient Project Execution Turning ambitious ideas into successful outcomes demands more than effort — it requires clarity, alignment, and the ability to anticipate challenges before they arise . At aeSolutions, we understand the unique challenges that complex projects bring — from tight budgets and timelines to aligning stakeholder expectations and managing risks. Our project development team will not only guide your project from concept to execution but will also enhance the resilience and efficiency of each phase. Leveraging our 25+ years of industry-trusted expertise, we implement a proven playbook to drive results. We Understand the Drivers for Change Growth Environmental, Social, Governance Cost Competitiveness We Believe Strategic Foresight Drives Flawless Execution aeSolutions has developed proven methods to anticipate, identify, mitigate, and resolve project challenges before they impact your goals. We understand that effective project development demands more than part-time attention or divided focus. In-house operating personnel often face the challenge of balancing their core responsibilities with the demands of project management — a task that requires dedicated expertise and continuous practice. This is where the aeSolutions project development team steps in with structured, methodical approaches to eliminate project pitfalls. We believe project development is a specialized, high-level process focused on setting clear goals, defining scope, aligning resources, and ensuring risk management best practices are in place from the outset. By addressing these critical elements, aeSolutions transforms complex projects into streamlined, successful outcomes. Some of the most often sited reasons for project failure are highlighted in the graph below. With the guidance of our experienced project development team, you will be able to better understand and avoid these pitfalls, while proactively positioning your project for success. Poor Communication Insufficient Resource Planning Unrealistic Schedules Poor Project Requirements Lack of Stakeholder Buy-In Undefined Project Closure Criteria Unrealistic Budgets Insufficient or No Risk Planning Lack of Change Control Process aeSolutions has a Playbook for Successful Project Development Discovery Allocation of Resources Kickoff Execution Study Gap Closure System Definition Detailed Design Procurement Fabrication Test, Deliver, Install Commission, Start-up Discovery Define/Clarify Goals Establish Drivers for Achievement Align Expectations Allocation Kickoff Execution Achievable Scope/Budget/Schedule Risk Management Planning Division of Responsibilities (DOR) Transition from Project Development to Project Execution Team Alignment with DOR Project Development Acts as Quality Assurance Guide Project Team to Client Success Why Partner With aeSolutions? In today’s industrial landscape, the success of complex projects hinges on precise planning, resilient design, and adaptable execution. At aeSolutions, we pair risk-focused experts with a project delivery team that helps industrial facilities overcome common project challenges. Our approach integrates robust risk management and team alignment from the outset, transforming project planning into a strategic advantage. From the initial discovery and gap analysis to detailed system design and final commissioning, our experts ensure that every phase aligns with your business goals, driving efficiency and maximizing ROI. Let aeSolutions elevate your project from concept to completion with a development process built on quality, resilience, and client success. aeSolutions sets the foundation for your project's success from discovery to start-up. Contact Us for More Information About Our Project Development Capabilities

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 —