Search this site

Creating Consistently Correct Control Control System Configuration Creating Consistently Correct Control aeSolutions' qualified specialists configure control logic and operator stations (HMI) to perform the required process functionality in accordance with industry and project standards. Individual control loops are configured and tested to the software design specifications. Software quality standards lead to consistent, correct, maintainable control systems. • Function block, function chart, ladder, and structured text languages • Engineering workstation configuration and productivity tools • Alarm management logic, summaries, and indications • Displays, faceplates, screen navigation, dynamics, trends • Regulatory and advanced control loops • Process interlocks, alarms, first-outs, and resets • Batch management and phase logic • Process historian, alarm archives, reports • Foreign device interfaces • Asset management and maintenance system Automation Services Previous Next

The Safety Requirement Specification (SRS) (clause 10 of ISA/IEC 61511) takes the results of the hazard and risk assessments and defines the requirements of the Safety Instrumented Functions (SIFs) that have to be performed by the Safety Instrumented Systems (SIS). aeSolutions is qualified with Certified Functional Safety Experts to quantify process hazard risks and develop the Safety Requirement Specification (SRS) for a process. The SRS is an input to the SIS design process but not all of the required information is available when design starts. Our SIS Specialists have configuration, instrumentation, and operations experience, allowing them specify feasible solutions to complex SIF implementation problems. Acronyms & Terms Glossary <- More Definitions Safety Requirement Specification (SRS) The Safety Requirement Specification (SRS) (clause 10 of ISA/IEC 61511) takes the results of the hazard and risk assessments and defines the requirements of the Safety Instrumented Functions (SIFs) that have to be performed by the Safety Instrumented Systems (SIS). aeSolutions is qualified with Certified Functional Safety Experts to quantify process hazard risks and develop the Safety Requirement Specification (SRS) for a process. The SRS is an input to the SIS design process but not all of the required information is available when design starts. Our SIS Specialists have configuration, instrumentation, and operations experience, allowing them specify feasible solutions to complex SIF implementation problems. 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.

Complex Hot Cutover of Large Natural Gas Processing Facilities Due to facility siting factors, control rooms of one of the world’s largest natural gas (NG) processing and compression facilities were relocated from a possible blast zone to a Blast Resistant Modules (BRMs). This complex cutover for personnel relocation needed to be accomplished without a shutdown (S/D) of either interdependent ... Challenge At the time it was built, the NG facility was the largest in the world. Some sections of piping are approximately 5 foot diameter and compression is achieved with enormous gas turbines - jet engines. The number of drawings, valves, wires, and control schemes that needed to be evaluated and understood was extensive and complex. Additionally, the magnitude and complexity of migrating the controls was tremendous. Normal gas operation controls such as turbine controls, panel boards, and valve interfaces needed to be migrated, as well as process safety controls such as the Basic Process Control System (BPCS), safety systems, Fire & Gas (F&G) systems, Halon fire suppressant circuits, and Emergency Shutdown (ESD) circuits. Furthermore, the NG facility equipment spanned 50 years of modifications and many upgrades were needed to universalize and modernize the many generations of equipment, including digitalizing hardwired signals into a the BPCS and installing a new PLC-based BPCS Honeywell C300 control system. Yet the biggest challenge was migrating the hard-wired emergency stop (E-stop) button from the old to new control room with minimal transition time and without a widespread outage. The circuit was designed fail-safe, meaning if the circuit opened up the relay, an activated emergency event could result in several effects: relieve gas pressure to flare, isolate system in place, or a plant S/D. Solution aeSolutions not only designed the new control room but took responsibility for all stages of the project, managing tasks from the conceptual and preliminary engineering to detailed design to managing on-site activity and personnel during the complex cutover. Specifically, aeSolutions: • Developed detailed cutover procedures and checklists and an integration schedule that identified specific people and detailed daily tasks for the next year for both NG facilities • Performed a detailed option analysis to evaluate potential best solutions • Analyzed every wire to understand what it does and temporary bypasses to be put into place; maintained a well-documented log to track what had been completed • Developed a contingency plan to guard against emergency events and mitigate risk of valve position changing during cutover process for safety purposes • Set up a local integration center, i.e., Factory Acceptance Test (FAT) lab, to convene equipment and everyone involved; determined ways to install additional panels; designed, fabricated, and tested the new control panels that were needed for the E-stops and F&G system and provided cabinets that were needed; developed a scheme of transitioning existing terminations to new termination locations without causing a S/D • Managed on-site activities helping direct the cutover process while implementing the cutover plan, including directing facility operators, engineers, support staff, construction, and even IT staff Results aeSolutions’ role evolved from system integrator and helping move the control rooms to becoming the focal point of coordinating schedules and staffing and choreographing the entire cutover project. We developed an execution strategy and found ways to integrate multiple teams into the plan. The FAT lab particularly provided a tremendous benefit to establish how components worked, verify detailed FAT plans and test procedures, and develop methods to quickly (dis)connect test panels with everyone in the same room. This integration strategy saved time and travel costs to successfully cutover the controls on a NG operating plant without impact to production. Learn more about how aeSolutions could help you with a similar project. Industry: Natural Gas Geography: Pacific Northwest Unit Operation: Control Center, Compressed Gas Valves Previous Story Next Story

A way of thinking about the design of chemical processes and plants that focuses on the elimination or reduction of hazards, rather than on their management and control. Acronyms & Terms Glossary <- More Definitions Inherently Safer Design (ISD) A way of thinking about the design of chemical processes and plants that focuses on the elimination or reduction of hazards, rather than on their management and control. 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.

High Integrity Pressure Protection Systems (HIPPS) is designed and built in accordance with IEC 61508 and IEC 61511 standards to detect high pressure events and close off a process independently of shutdowns (ESD/PSD) thus protecting lower-rated downstream equipment. Acronyms & Terms Glossary <- More Definitions HIPPS System High Integrity Pressure Protection Systems (HIPPS) is designed and built in accordance with IEC 61508 and IEC 61511 standards to detect high pressure events and close off a process independently of shutdowns (ESD/PSD) thus protecting lower-rated downstream equipment. 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.

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

A 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 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.

An event or sequence of events that results in undesirable consequences. Scenarios 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 Scenario An event or sequence of events that results in undesirable consequences. Scenarios 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.

ERPGs estimate the concentrations at which most people will begin to experience health effects if they are exposed to a hazardous airborne chemical for 1 hour. A chemical may have up to three ERPG values, each of which corresponds to a specific tier of health effects. The three ERPG tiers are defined as follows: 1) ERPG-1 is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing more than mild, transient adverse health effects or without perceiving a clearly defined objectionable odor. 2) ERPG-2 is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual's ability to take protective action. 3) ERPG-3 is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects. ERPG concentrations are considered for endpoint distances during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Acronyms & Terms Glossary <- More Definitions Emergency Response Planning Guideline (ERPG) ERPGs estimate the concentrations at which most people will begin to experience health effects if they are exposed to a hazardous airborne chemical for 1 hour. A chemical may have up to three ERPG values, each of which corresponds to a specific tier of health effects. The three ERPG tiers are defined as follows: 1) ERPG-1 is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing more than mild, transient adverse health effects or without perceiving a clearly defined objectionable odor. 2) ERPG-2 is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual's ability to take protective action. 3) ERPG-3 is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects. ERPG concentrations are considered for endpoint distances during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland.

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

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

A systematic review to identify and evaluate the potential fire, flash fire, or explosion hazards associated with the presence of one or more combustible particulate solids in a process or facility. Acronyms & Terms Glossary <- More Definitions Dust Hazard Analysis (DHA) A systematic review to identify and evaluate the potential fire, flash fire, or explosion hazards associated with the presence of one or more combustible particulate solids in a process or facility. 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.