Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant In the rapidly expanding field of hydrogen production and storage, safety is paramount. aeSolutions was presented with the complex challenge of designing and installing a fire & gas (F&G) detection system for a greenfield hydrogen production plant. This case study explores how aeSolutions overcame the unique hazards associated with hydrogen to create a robust and efficient detection system, ensuring the protection of both personnel and assets. Through a combination of advanced modeling techniques and strategic detector placements, aeSolutions delivered a solution that not only met safety requirements but also optimized system performance and cost-efficiency. Challenge aeSolutions was tasked with designing and installing a Fire & Gas (F&G) detection system for a new hydrogen production plant, which presented unique challenges due to the flammable nature of hydrogen. The plant included both indoor and outdoor processes, with hydrogen production occurring inside a ventilated building and other processes like filtration, compression, and storage taking place outdoors. The key challenge was to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Solution aeSolutions implemented a multi-step approach to optimize the gas detection system layout. The process began with preliminary geographic placements based on recognized standards and was followed by scenario-based placements using consequence modeling software. When initial models indicated uncertainties regarding potential explosion severity, aeSolutions employed Computational Fluid Dynamics (CFD) modeling to refine detector placements, reducing the number of detectors required while ensuring comprehensive coverage. Additionally, the design included strategic placements of both catalytic bead and ultrasonic gas detectors indoors and outdoors to efficiently detect leaks and mitigate potential hazards. Results The final design resulted in a robust detection system that optimized the placement and number of detectors, ensuring reliable detection of hydrogen leaks with minimal risk of undetected releases. The CFD modeling confirmed that with proper mitigation measures, hydrogen leaks could be controlled, preventing catastrophic explosions. The project concluded with the successful installation of 18 lower explosive limit (LEL) indoor detectors and 7 outdoor detectors, along with additional safety features like ultrasonic detectors and flame detectors. This approach not only enhanced safety but also minimized system costs and maintenance needs, providing a scalable solution for this hydrogen production facility. Learn more about how aeSolutions could help you with a similar project Industry: Hydrogen Geography: Southeast Unit Operation: Hydrogen production including the use of electrolyzers Previous Story Next Story

Simplified, Cost-Effective, and Consistent Acidic Compound Detection New acid detector placement philosophy led to reduced maintenance , lowered costs, a reduced the likelihood of confusion during leaks, and helped create a uniform response strategy. Challenge The client has to contend with detecting a multitude of toxic acidic vapors in order to keep their people safe. Initially, their plan involved using 5 to 6 individual toxic gas detectors in each area to detect these acidic vapors separately in each room. This approach would have led to a high number of detectors, increased maintenance, more I/O (input/output) to contend with, and elevated costs for replacing sensor elements. Additionally, the use of multiple detectors could result in confusion if there was a leak, as all the detectors would respond, making it impossible to pinpoint the specific acidic vapor released. Solution Upon closer review, it was realized that the client did not need to differentiate between the specific acidic vapors The single detector would tell them they had an acid leak, no matter which one. When a detector was triggered, the action was the same, evacuate to a safe area. A more efficient solution was devised by using a single acidic vapor detector in each room instead of multiple individual detectors. This philosophy reduced the number of detectors from 5 to 1 in each room, leading to an 80% reduction in the total number of detectors across the entire facility. Results By implementing the revised gas detection philosophy, the client achieved significant benefits. They collected a comprehensive list of all the chemicals of concern and determined the levels at which they wanted to detect these vapors. This allowed them to model the vapor releases and strategically position the gas detectors in a 3D model for optimal coverage. The client no longer needed to be specific as to the type of acidic vapor being detected, focusing solely on the detection of acidic vapors in general. Furthermore, it reduced possible confusion, ensuring the safety of individuals on the premises by enabling timely evacuation in case of any acid leak, regardless of the specific acidic vapor involved. The new approach resulted in simplified maintenance, cost reduction, decreased risk of confusion in case of a leak, and established a consistent action plan for evacuation. See how we can help you with a similar detector placement project. Keywords: formic acid, hydrocoloric acid, detection, detector, evactuation, acid vapor, acidic compounds, gas detection Previous Story Next Story

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 Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

A system composed of sensors, logic solvers, final elements, and support systems (e.g., utilities, interfaces, and communications). The aeSolutions automation engineering team can design, construct, and implement automation systems. It starts with defining the automation requirements in the Front End Loading (FEL) stages of projects, as 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.​ Our systems group is comprehensive in its capability to provide transmitter-to-value engineering. Acronyms & Terms Glossary <- More Definitions Process Automation A system composed of sensors, logic solvers, final elements, and support systems (e.g., utilities, interfaces, and communications). The aeSolutions automation engineering team can design, construct, and implement automation systems. It starts with defining the automation requirements in the Front End Loading (FEL) stages of projects, as 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. Our systems group is comprehensive in its capability to provide transmitter-to-value engineering. Our Services Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

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: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

Dormant or standby operation where the IPL takes action only when a process demand occurs and is otherwise inactive. High demand mode occurs when the process demands (i.e., when the IPL is challenged) happen more than once per year. High demand mode of an IPL is 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 High Demand Mode Dormant or standby operation where the IPL takes action only when a process demand occurs and is otherwise inactive. High demand mode occurs when the process demands (i.e., when the IPL is challenged) happen more than once per year. High demand mode of an IPL is 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: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

An organization that implemented Section 112(r) of the 1990 Clean Air Act amendments and requires facilities that use extremely hazardous substances to develop a Risk Management Plan (RMP) per 40 CFR 68.150 to 68.185. aeSolutions has the knowledge and experience to assist with all elements of RMP development and implementation required by the EPA RMP Standard, 40 CFR 68, from high level gap and applicability assessments to complete RMP site program development, including drafting procedures and creating mechanical integrity programs. Acronyms & Terms Glossary <- More Definitions Environmental Protection Agency (EPA) An organization that implemented Section 112(r) of the 1990 Clean Air Act amendments and requires facilities that use extremely hazardous substances to develop a Risk Management Plan (RMP) per 40 CFR 68.150 to 68.185. aeSolutions has the knowledge and experience to assist with all elements of RMP development and implementation required by the EPA RMP Standard, 40 CFR 68, from high level gap and applicability assessments to complete RMP site program development, including drafting procedures and creating mechanical integrity programs. Our Services Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

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 Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

Facility siting studies are used to ascertain location based risks for a plant and ensure that occupied buildings are located at a safe distance from process units. A Facility Siting Analysis is intended to evaluate the potential hazards and consequences of uncontrolled releases of flammable and toxic substances; to assess their potential for injuring the occupants of fixed and temporary structures on or offsite; to identify existing safeguards; and to determine measures to reduce the risk posed by these potential events. aeSolutions has trained facilitators to execute the hazard recognition and risk reduction process and experienced modelers that apply the appropriate methodology in line with API 752/753 and industry best management practices for Facility Siting. We provide results that allow your site leadership team to allocate resources more effectively to minimize facility siting risks. Acronyms & Terms Glossary <- More Definitions Facility Siting Study Facility siting studies are used to ascertain location based risks for a plant and ensure that occupied buildings are located at a safe distance from process units. A Facility Siting Analysis is intended to evaluate the potential hazards and consequences of uncontrolled releases of flammable and toxic substances; to assess their potential for injuring the occupants of fixed and temporary structures on or offsite; to identify existing safeguards; and to determine measures to reduce the risk posed by these potential events. aeSolutions has trained facilitators to execute the hazard recognition and risk reduction process and experienced modelers that apply the appropriate methodology in line with API 752/753 and industry best management practices for Facility Siting. We provide results that allow your site leadership team to allocate resources more effectively to minimize facility siting risks. Our Services Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

Refer to Covert Failure. Acronyms & Terms Glossary <- More Definitions Latent Failure Refer to Covert Failure. Our Services Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.

Protecting Personnel with Practical Gas Detector Placement A pharmaceutical company needed to implement gas detectors at their facility to protect personnel from potential leaks of toxic and combustible gases. aeSolutions evaluated the gas detector placement and number of detectors that would provide the earliest warning to personnel based on the expected dispersion and behavior of specific gas release scenarios. Challenge To design a gas detection system for a multitude of uncommon gases and vapors in a pharmaceutical clean environment with the possibility of both indoor and outdoor releases. The goal was to detect a release at a level as low as reasonably possible, taking into account internal ventilation influences on gas releases. Solution Computational Fluid Dynamics (CFD) scenario modeling was performed to justify the number and placement of gas detectors. The CFD models helped ensure the effectiveness of the gas detection system and provided an auditable record of the assumptions made (e.g., leak location, leak size, ventilation rate, etc.) that could be referred to and updated throughout the life of the facility Results The CFD models revealed some unexpected behaviors from the vapors of concern compared to what might have been reasonably predicted by their physical properties. CFD modeling revealed: • Lighter than air gases were pulled downward, and gas detector locations were revised accordingly • Gas leaks dispersed farther than expected and affected originally unprotected warehouse buildings; therefore, gas detectors were placed on the ventilation intakes of the warehouse • An ammonia leak from a sphere under pressure dispersed vertically and was not detected by ammonia detectors around the sphere; coverage was augmented by the use of an open path ammonia gas detector aimed across the top of the sphere The facility owner now has greater confidence that they are protecting their personnel with an optimal number of detectors in the right locations thereby minimizing long-term maintenance costs for the gas detection system. CFD modeling is the best investment for large facilities with specialty gases to ensure gas detectors are appropriately located for optimum performance. Learn more about our gas detection services Industry: Pharma Geography: Pacific Northwest Unit Operation: Gas Detectors Previous Story Next Story

A measure of the expected probability or frequency of occurrence of an event. This may be expressed as an event frequency (e.g., event per year), a probability of occurrence during a time interval (e.g., annual probability), or a conditional probability (e.g., probability of occurrence, given that a precursor event has occurred). Acronyms & Terms Glossary <- More Definitions Likelihood A measure of the expected probability or frequency of occurrence of an event. This may be expressed as an event frequency (e.g., event per year), a probability of occurrence during a time interval (e.g., annual probability), or a conditional probability (e.g., probability of occurrence, given that a precursor event has occurred). Our Services Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability.