The systematic application of management policies, procedures, and practices to the tasks of analyzing, assessing, and controlling risk in order to protect employees, the general public, the environment, and company assets, while avoiding business interruptions. Acronyms & Terms Glossary <- More Definitions Process Risk Management The systematic application of management policies, procedures, and practices to the tasks of analyzing, assessing, and controlling risk in order to protect employees, the general public, the environment, and company assets, while avoiding business interruptions. 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 calculation performed to determine the Probability of Failure on Demand (PFD) of a required SIF. SIL calcs are based on failure rate data for the SIF components (i.e., sensors, logic solvers, and control elements) and accounts for factors such as test frequency, redundancy, voting arrangements, etc. The Risk Reduction Factor (RRF) is simply the inverse of PFD (RRF = 1/PFD) and is used to establish the associated SIL rating required to reduce the hazard risk to an acceptable risk tolerance level. Over-specification of devices to be used in a SIF is not uncommon because it is a SAFETY Instrumented Function. However, over-specification does not necessarily improve safety significantly and can reduce the resources available for overall safety. aeSolutions can help you identify the best devices to use in SIFs and assist you in the purchasing process. Acronyms & Terms Glossary <- More Definitions Safety Integrity Level (SIL) Calculations A calculation performed to determine the Probability of Failure on Demand (PFD) of a required SIF. SIL calcs are based on failure rate data for the SIF components (i.e., sensors, logic solvers, and control elements) and accounts for factors such as test frequency, redundancy, voting arrangements, etc. The Risk Reduction Factor (RRF) is simply the inverse of PFD (RRF = 1/PFD) and is used to establish the associated SIL rating required to reduce the hazard risk to an acceptable risk tolerance level. Over-specification of devices to be used in a SIF is not uncommon because it is a SAFETY Instrumented Function. However, over-specification does not necessarily improve safety significantly and can reduce the resources available for overall safety. aeSolutions can help you identify the best devices to use in SIFs and assist you in the purchasing process. 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.

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.

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

An Alarm Philosophy establishes how a company addresses alarm management through all phases of its lifecycle. An effective alarm philosophy document defines the alarm system’s design philosophy as well as how it should be managed and maintained with information such as alarm criteria, specifications, and responsibilities. This document is typically the starting point of any alarm management project. Learn more at https://www.aesolutions.com/alarm-management Acronyms & Terms Glossary <- More Definitions Alarm Philosophy An Alarm Philosophy establishes how a company addresses alarm management through all phases of its lifecycle. An effective alarm philosophy document defines the alarm system’s design philosophy as well as how it should be managed and maintained with information such as alarm criteria, specifications, and responsibilities. This document is typically the starting point of any alarm management project. Learn more at https://www.aesolutions.com/alarm-management 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.

Alarm Rationalization is the process of optimizing alarms at a facility, inhibiting alarm floods, and ensuring alarms perform their function as intended. Both IEC 62682 and ISA/ANSI 18.2 define the requirements for a sustainable Alarm Management Lifecycle. One of the most resource intensive steps in this lifecycle is the documentation and rationalization of potential alarms. aeSolutions' integrated approach can supply expertise for all stages of the alarm management lifecycle specializing in: - Philosophy development - Gap assessment of current alarm philosophy - Alarm management and rationalization training - Facilitation of alarm rationalizations - Including our alarm rationalization tool, aeAlarm™​ - Alarm management program gap assessment Acronyms & Terms Glossary <- More Definitions Alarm Rationalization Alarm Rationalization is the process of optimizing alarms at a facility, inhibiting alarm floods, and ensuring alarms perform their function as intended. Both IEC 62682 and ISA/ANSI 18.2 define the requirements for a sustainable Alarm Management Lifecycle. One of the most resource intensive steps in this lifecycle is the documentation and rationalization of potential alarms. aeSolutions' integrated approach can supply expertise for all stages of the alarm management lifecycle specializing in: - Philosophy development - Gap assessment of current alarm philosophy - Alarm management and rationalization training - Facilitation of alarm rationalizations - Including our alarm rationalization tool, aeAlarm™ - Alarm management program gap assessment 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 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 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 spurious trip refers to an unplanned or unintended shutdown of a system, often triggered by false alarms or erroneous signals from monitoring equipment. These incidents can cause operational disruptions, safety risks, and unnecessary downtime in industrial processes such as power plants, oil and gas facilities, or manufacturing systems. Acronyms & Terms Glossary <- More Definitions Spurious Trips A spurious trip refers to an unplanned or unintended shutdown of a system, often triggered by false alarms or erroneous signals from monitoring equipment. These incidents can cause operational disruptions, safety risks, and unnecessary downtime in industrial processes such as power plants, oil and gas facilities, or manufacturing systems. 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.

Operational readiness refers to the state of being fully prepared and equipped to begin or continue operations safely and efficiently. It involves ensuring that systems, personnel, and processes are in place and functioning correctly before starting operations. Acronyms & Terms Glossary <- More Definitions Operational Readiness Operational readiness refers to the state of being fully prepared and equipped to begin or continue operations safely and efficiently. It involves ensuring that systems, personnel, and processes are in place and functioning correctly before starting operations. 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.

Distributing Monitoring and Control Network Design Distributing Monitoring and Control aeSolutions designs industry standard as well as vendor specific networks for distributing controllers, I/O, data servers, and operator stations. Networks like Industrial Ethernet can be a composite of cables, fiber optics, and wireless systems, with managed switches and routers. aeSolutions recommends products and standards that we have tested for reliability, bandwidth, redundancy, distance, and industrial environments. Access points between the wide area enterprise networks and the critical control system networks must be managed carefully. Installation quality and signal testing are critical to achieving a fast, reliable control network. • Distributed I/O networks • Controller communication networks • HMI servers and client networks • Switches, routers, and firewalls • Single mode and multimode fiber optics • Coaxial and twisted pair cables • Drawings and Bills of Material Automation Services Previous Next

Shaping a Successful Result from the Start Automation Project Management Shaping a Successful Result from the Start aeSolutions manages every project with a comprehensive set of tools for planning and tracking tasks, deliverables, and milestones. Clear communications and rigorous documentation ensure that client expectations are met throughout the project. • Dedicated project management group • Project scheduling and tracking • Resource allocation • Scope and budget control • Project execution planning • Risks, roles, and accountabilities identification • Meetings, action lists, and reporting • Project deliverable approval cycles • Gate reviews between approval stages • Purchasing and shipping Automation Services Previous Next

Pharmaceutical Company Required Toxic & Combustible Gas Detection System A large-scale pharmaceutical manufacturing facility needed to develop and implement a gas detection system at their site to mitigate risk to personnel and equipment from a potential combustible or toxic gas leak. The project progressed from the assessment stages of developing a gas detection philosophy to ultimately integrating an industrially designed GDS 1400 MK II panel for the gas detection control and alarm system. Challenge This pharmaceutical facility had a large number of uncommon toxic and combustible gases and vapors. The gas detection philosophy document needed to account for the physical properties of the gases present at the site. The previously developed gas detection philosophy document did not account for the required gas detection alarm levels and sensor ranges. It also did not account for the limitations of the available detection technologies. Additionally, the document needed to describe how to address cross-sensitivity when multiple gases are present in the same area. Solution We developed a gas detection philosophy in compliance with the latest industry standards. The document addressed all of the following: • The physical characteristics of the gases and vapors at the facility • Industry-recognized exposure levels for the gases • Preferred gas detection technologies • Minimum requirements for gas detection including leak sizes • Addressed gas detection cross sensitivities aeSolutions designed and provided a comprehensive gas detection system to monitor all of the toxic and combustible gases and alert personnel to the hazards. Once established, the gas detection philosophy was used as the basis for integrating the GDS 1400 MK II gas detection control and alarm system. This unit utilizes the Siemens Simatic PCS7 series hardware/software platform and interfaces to the facility’s building management system and fire alarm panel. Its SIL 3-capable logic solver was scalable to a large I/O count, which ended up totaling 650 I/O counts distributed among seven (7) remote I/O panels for the large number of chemicals. The following were delivered: • Gas Detection Philosophy Document • Gas Detection Plot Plan and placement within the client 3D model • GDS 1400 MK II Gas Detection System • Specified and procured all of the gas detectors • Interface with building management system for HVAC control (e.g., overriding the HVAC control to dilute and/or remove explosive gases from the facility) • Interface with Fire Alarm panel for mass notification messaging • Interface with process control system for process shutdowns, where applicable Results The pharmaceutical company now has a scalable gas detection system capable of reducing the risk to personnel and equipment and complying with their corporate safety program requirements. The system also provides long term data collection of gases that have been measured in the facility. Learn more about how aeSolutions could help you with a similar project Industry: Pharmaceuticals Geography: Southeast Unit Operation: GDS 1400 MK II, Gas Detection System, PCS7, SPHA I/O, FGS Previous Story Next Story