PSM is an acronym for Process Safety Management (PSM), a system that helps prevent/reduce risk of hazardous chemical releases Acronyms & Terms Glossary <- More Definitions What is PSM PSM is an acronym for Process Safety Management (PSM), a system that helps prevent/reduce risk of hazardous chemical releases Our Services 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.

Mechanizing in Real Time Factory Automation Systems Mechanizing in Real Time aeSolutions has delivered automation solutions with Programmable Logic Controllers for nearly two decades. In the 1970's, a PLC was a programmable emulator of relay ladder logic. Today, a PLC is a scaled down controller, often stand alone, but with much of the power and some of the functions of controllers used in DCS process automation. Multiple PLC's are often networked somewhat like a DCS with fewer features. aeSolutions can provide the right PLC automation system when a client needs highly reliable and very fast real time response to events in a manufacturing cell or an electromechanical panel. Ruggedized operator displays and touch screens allow local HMI control. The PLC can also be interfaced to a supervising DCS. • High speed I/O and processing • Ruggedized environment • Basic networking and communications • Ladder logic programming familiar to I&E staff • Scalable in size and cost Automation Services Previous Next

An interlock system is a safety mechanism that takes certain actions when specific conditions are met (to prevent undesirable or hazardous events). Interlocks are used to control equipment operations, ensuring safe and correct sequencing to prevent accidents. Acronyms & Terms Glossary <- More Definitions Interlock System An interlock system is a safety mechanism that takes certain actions when specific conditions are met (to prevent undesirable or hazardous events). Interlocks are used to control equipment operations, ensuring safe and correct sequencing to prevent accidents. 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 likelihood of occurrence of an event or an event sequence during an interval of time. Probability is expressed as a dimensionless number ranging from 0 to 1. Acronyms & Terms Glossary <- More Definitions Probability The likelihood of occurrence of an event or an event sequence during an interval of time. Probability is expressed as a dimensionless number ranging from 0 to 1. 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 industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Process Control, Safety Instrumented Systems (SIS), Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas, systems integration, Rockwell, Triconex, Safety systems, critical controls DCS/PLC Migrations and Upgrades System Integration Solutions Upgrading a Distributed control system (DCS) is a complex task that requires careful planning, coordination, and testing to mitigate risks such as downtime and data loss. Site requirements, regulatory compliance, and minimizing disruptions must be considered to ensure a smooth cutover. However, the security and functionality benefits of newer technologies can outweigh the costs, making it a valuable process for industrial operations. aeSolutions can provide the methodology, technical services, resources, personnel, and field support to accomplish your goals and objectives working with you from project inception to final commissioning. Through a proven project delivery model, aeSolutions integrates diverse hardware, software, and services from multiple vendors and client stakeholders into a unified, integrated system. Our full range of services will lead you through the controls integration process to deliver a fully integrated, cohesive control system in a well-executed project. aeSolutions' Integration Services Conceptual & Preliminary Engineering - Front-End Loading (FEL) / Front-End Engineering Design (FEED) PFD/P&ID Development Control System Platform Evaluation Continuous and Batch Design TIC Estimate Development Instrument and Electrical Design (I&E) Instrument Index, Specs & Installation Details Plan Drawings Controls Electrical - Field Wiring MCC Specification & Design Cable Schedules Construction SOWs Systems Integration Control Hardware Design Control System Server Virtualization PLC, DCS, SIS, SCADA Configuration Network Architecture Layout/ Design Control Panel Fabrication & Testing Construction Oversight Commissioning/Startup Support Expanded "Design, Implement, & Commission" Our clients are increasingly challenged to produce more with less. The productivity of yesterday’s most efficiently operated facilities is not acceptable for even mid-pack performance today. We understand the economic pressures the industry faces —and our industrial automation services can help. Our teams are skilled in all aspects of process control engineering because we all understand that the greatest influence over project success or failure comes from the earliest stages of conceptual design, long before the actual programming effort ever begins. The overall result is a facility is both back online faster so you see the financial advantages of the new DCS faster. Automation Applications Our industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Safety Instrumented Systems (SIS), Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas Systems (FGS). The result is a totally integrated automation lifecycle, from project inception to operation. Process Automation Systems Modernizing for Productivity and Profit Factory Automation Systems Mechanizing in Real Time Safety Instrumented Systems Delivering Safety on Demand Fire and Gas Systems Furnishing the Last Line of Defense Advanced Regulatory Control (ARC) Enlisting More Variables Burner Management Systems (BMS) Mitigating Fired System Hazards Combustion Control Systems (CCS) Optimizing Fuel Air Operation Human Machine Interfaces (SCADA) Interacting with Intuitive Information Alarm Management Systems Alerting Appropriate Action Migration Solutions Moving up with Modernization Conceptual & Preliminary Engineering Project Management Shaping a Successful Result from the Start Project Assessment and Conceptual Design Articulating the Project Vision and Characterizing the Control System Preliminary Engineering Converting Concept to Design Basis Lifecycle and Upgrade Planning Looking Ahead Hardware Design Hardware Design Specifications Developing Hardware Details Electrical and Instrumentation Design Connecting to the Process Hardware Design and Panel Fabrication Supplying World-Class Panels Construction, Installation, Commissioning Realizing the Vision Systems Integration Software Design Specifications Developing Software Details Network Design Distributing Monitoring and Control Control System Configuration Creating Consistently Correct Control Simulation and Factory Acceptance Testing Approving the Configurations Site Acceptance Testing and Startup Testing and Turnover Maintenance and Support Supporting Client Successes Related Posts Control System Migrations | Procurement Specification & Vendor Selection Mitigating Project Risks through Front-End Loading for Control System Migrations Cost Justification for Control System Replacement Projects

Site Acceptance Testing occurs at a client’s site after equipment delivery to verify whether equipment meets the functionality and performance requirements specified by the client. This testing occurs after all equipment commissioning tasks but before installation. This differs from a Factory Acceptance Test (FAT) since it occurs after delivery. AKA: What is a site acceptance test? or What is a sat acceptance test? Acronyms & Terms Glossary <- More Definitions Site Acceptance Testing (SAT) Site Acceptance Testing occurs at a client’s site after equipment delivery to verify whether equipment meets the functionality and performance requirements specified by the client. This testing occurs after all equipment commissioning tasks but before installation. This differs from a Factory Acceptance Test (FAT) since it occurs after delivery. AKA: What is a site acceptance test? or What is a sat acceptance test? 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.

Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility A critical pipeline transportation facility required a custom Safety Instrumented Burner Management System (SI-BMS) upgrade for their incinerator operations. The project involved implementing a SI-BMS compliant with NFPA 86, integrating alarm and first-out features, and establishing seamless communication with their existing Distributed Control System (DCS). aeSolutions provided an Allen-Bradley control system featuring a GuardLogix controller with POINT Guard Safe I/O, a new Human-Machine Interface (HMI), and extensive on-site support, significantly improving the reliability and safety of the client’s operations. Challenge The client faced numerous challenges with their existing incinerator burner management system. The previous system lacked first-out indications and alarm features, making troubleshooting operational shutdowns time-consuming and inefficient. Additionally, there were challenges in implementing a new BMS. Handling multiple burners and switching fuel sources between fuel oil and waste gas added further complexity to operations. Moreover, integration between the new BMS and existing DCS required extensive on-site testing and validation. The remote geographic location compounded these challenges, requiring extended on-site support due to logistical constraints related to weather and travel. Solution Leveraging dual expertise in safety engineering and control systems integration, aeSolutions implemented a tailored SI-BMS that significantly enhanced operational transparency and control. The new SI-BMS solution provided clear first-out alarms, pinpointing exact causes for shutdowns and drastically reducing troubleshooting time. aeSolutions ensured NFPA 86 compliance and delivered a robust solution capable of managing the complex operational scenarios involving four burners with interchangeable fuel sources. One of the key factors in the success of this project was aeSolutions’ project delivery team, which brought together our risk-focused industry experts and hands-on technical specialists. This enabled real-time responsiveness to client needs during commissioning. Changes to the Safety Requirements Specification (SRS) and system configuration were executed seamlessly, including on-site, in direct response to client feedback and operating conditions. The team’s ability to evaluate safety impacts and implement adjustments quickly, without compromising compliance, demonstrated the strength of integrating safety and controls expertise within one provider. aeSolutions worked closely with the client’s DCS programmer to resolve integration challenges, coordinating communication protocols and aligning system behaviors across platforms. This flexibility not only helped overcome technical hurdles but also ensured that the final system supported the client’s preferred operational practices. Results The client’s operational efficiency, reliability, and resilience substantially improved upon commissioning of the new BMS solution. Operators gained immediate clarity from the introduction of first-out alarms, resulting in quicker resolutions and significantly reduced downtime. The upgraded system consistently achieved reliable startups, eliminating previous issues related to intermittent operational failures. Furthermore, aeSolutions’ flexible and collaborative approach in adjusting and refining system configurations during commissioning directly supported the client’s unique operational needs. This approach not only ensured safety and compliance but also provided tangible time savings, thereby delivering immediate and ongoing value. Following this project’s success, the client has continued to engage aeSolutions for additional critical infrastructure projects, highlighting the sustained value and effectiveness of our tailored solutions. Industry: Oil & Gas Geography: Pacific Northwest Unit Operation: Customized Safety Instrumented Burner Management System (SI-BMS), POINT Guard Safe I/O, Human-Machine Interface (HMI) Previous Story Next Story

An alarm that annunciates excessively, unnecessarily, or does not return to normal after the correct response is taken (e.g., chattering, fleeting, false, or stale alarms). 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 Nuisance Alarm An alarm that annunciates excessively, unnecessarily, or does not return to normal after the correct response is taken (e.g., chattering, fleeting, false, or stale alarms). 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.

Converting Concept to Design Basis Preliminary Engineering Converting Concept to Design Basis aeSolutions works with clients to form preliminary engineering documentation based on the conceptual design and assists clients in choosing an appropriate control system vendor. Client review and approval cycles assure the quality of the functional requirements specification. • Instrument data sheets • Functional requirements specification • Instrument list and I/O count • Operating ranges, alarm and trip setpoints • Plant drawings (P&I, I&E, Loop, LAN, Arrangement) • Preliminary project architecture and migration drawings • Vendor platform evaluations • Bills of Material - hardware and software • Project cost and schedule estimates +/- 10% Automation Services Previous Next

Functional Safety is the process of reducing the risks of both simple and complex systems so that they function safely if a hardware, operational, or human failure occurs. When every safety function is carried out as prescribed and the performance standards for each safety function are met, “Functional Safety” has been achieved. Acronyms & Terms Glossary <- More Definitions Functional Safety Functional Safety is the process of reducing the risks of both simple and complex systems so that they function safely if a hardware, operational, or human failure occurs. When every safety function is carried out as prescribed and the performance standards for each safety function are met, “Functional Safety” has been achieved. 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 Variable Frequency Drive (VFD) is an electronic device that controls the speed and torque of an electric motor by varying the frequency and voltage of the power supplied to the motor. VFDs improve energy efficiency, enhance motor performance, and allow for precise control in applications such as HVAC systems, pumps, and conveyors. Acronyms & Terms Glossary <- More Definitions Variable Frequency Drives (VFD) A Variable Frequency Drive (VFD) is an electronic device that controls the speed and torque of an electric motor by varying the frequency and voltage of the power supplied to the motor. VFDs improve energy efficiency, enhance motor performance, and allow for precise control in applications such as HVAC systems, pumps, and conveyors. 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 small industrial computer originally designed to perform the logic functions executed by electrical hardware (relays, drum switches, and mechanical timer/counters). PLCs have evolved into controllers capable of controlling very complex processes. aeSolutions satisfies a project's safety interlock Safety Integrity Level (SIL) requirements with independent, SIL-certified safety PLC's that can be integrated with the process automation Distributed Control System (DCS) for monitoring and alarming. Acronyms & Terms Glossary <- More Definitions Programmable Logic Controller (PLC) A small industrial computer originally designed to perform the logic functions executed by electrical hardware (relays, drum switches, and mechanical timer/counters). PLCs have evolved into controllers capable of controlling very complex processes. aeSolutions satisfies a project's safety interlock Safety Integrity Level (SIL) requirements with independent, SIL-certified safety PLC's that can be integrated with the process automation Distributed Control System (DCS) for monitoring and alarming. 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.