Also known as the Boiler Control System (BCS) The subsystem of instrumentation and controls that manages the firing rate and air/fuel ratio of the burner in response to load demand. The Combustion Control System works in conjunction with the Burner Management System (BMS). aeSolutions' family of products includes industrial Combustion Control Systems in several packages. The pre-engineered packages are configurable to meet the client's operational requirements and is readily configured to implement a variety of fuel-saving optimization techniques, including fully metered / cross-limited fuel air control with oxygen trim, and interfacing to a wide variety of field sensors, analyzers, and valves. The CCS is often supplied as an integrated Combustion Management System package, which includes a BMS for safe startup, shutdown, and interlocking. Acronyms & Terms Glossary <- More Definitions Combustion Control System (CCS) Also known as the Boiler Control System (BCS) The subsystem of instrumentation and controls that manages the firing rate and air/fuel ratio of the burner in response to load demand. The Combustion Control System works in conjunction with the Burner Management System (BMS). aeSolutions' family of products includes industrial Combustion Control Systems in several packages. The pre-engineered packages are configurable to meet the client's operational requirements and is readily configured to implement a variety of fuel-saving optimization techniques, including fully metered / cross-limited fuel air control with oxygen trim, and interfacing to a wide variety of field sensors, analyzers, and valves. The CCS is often supplied as an integrated Combustion Management System package, which includes a BMS for safe startup, shutdown, and interlocking. 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.

The process of engineering safety systems or the engineering of safety systems. A safety instrumented system (SIS) is a collection of hardware and software controls that are specifically designed for use on critical process systems. Acronyms & Terms Glossary <- More Definitions SIS Engineering Definition The process of engineering safety systems or the engineering of safety systems. A safety instrumented system (SIS) is a collection of hardware and software controls that are specifically designed for use on critical process 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.

A Fail Closed device, typically a valve, is set to close automatically when a failure state occurs. A Fail Open device works in the opposite way and is set to open automatically when a failure state occurs. These failures are typically can be caused by a power or pressure loss. Acronyms & Terms Glossary <- More Definitions Fail Closed - Fail Open A Fail Closed device, typically a valve, is set to close automatically when a failure state occurs. A Fail Open device works in the opposite way and is set to open automatically when a failure state occurs. These failures are typically can be caused by a power or pressure loss. 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.

Screening, Risk Assessments, Training, State of Compliance, Screening Detailed Reports, Implementation, Machine Safety Guarding, Maintenance, Maintaining. plant managers, safety leaders/managers, and engineering managers from across a range of industries including packaging, food, chemical, auto, aerospace and robotics, American Standards, United States, Robots, Risk assessment, Robotics, this includes medical devices, pharma, food bev production Machinery Safety aeSolutions is proud to offer Machinery Safety Services to reduce the risk of injury in the manufacturing industry. For our clients who operate and maintain machinery, safety is a top priority. We help manufacturing facilities achieve safe machine operation through risk assessment, application of the hierarchy of control, and sensible safeguard design. In addition, our program helps reduce exposure to liabilities that can lead to unmanageable costs. Our comprehensive, scalable program addresses client’s specific needs and the machinery lifecycle to provide tailored solutions aligned with international and United States standards. Guard Against Injuries. Decrease Risk. Service Description The following services are offered: Screening to prioritize corrective actions Risk A ssessment to discover hazards, classify risk, and identify safeguarding objectives - Specializing in Robots & Packaging machinery Evaluation of facility compliance and the State of Conformity to address areas of improvement for installed safeguards, including performance level verification Safeguard Specification and implementation to make certain risk reduction is achieved, including selection and design, functional safety analysis, safety function requirements, and implementation Training on hazard identification, risk assessment execution, and standard interpretation Contact One of Our Experts Top Mistake to Avoid in Machinery Functional Safety In the machinery industry, a safety function is a control function that reduces the risk of injury, exposure to hazards, or harm to the... Machinery Safety – Is it a Safety Function? Determining this is not always straightforward and requires a hazard assessment to identify safety functions (e.g., equipment, devices, ... Ten Fingers and Ten Toes: Applying Machinery Safety Principles in a Process Plant When performing risk assessments on process equipment, are you reviewing machinery as well? Machinery Safety Standards – The What and Why The machinery safety standards positively recompense designers, integrators and users along with providing a framework for achieving OSHA co Robotic Systems Risk Assessments An effective RA starts with including knowledgeable employees with expertise in the operations, specific robotic application, RA methodology Analysis Robot Integration Risk Assessments Safety Function Performance Level Verification & Validation Machine Guarding Assessments Machine Safety Risk Assessments Design/Specification Design/Specification Safe Machinery Design Robotic Safety Light Curtain Positioning Guarding Design Interlock Design Circuit Design Qualitative Training Procedures Reduce Injuries Mitigate Risk Safeguard Hazards Protect Employees

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

PSM stands for Process Safety Management, a process that helps prevent/reduce risk of hazardous chemical releases. Acronyms & Terms Glossary <- More Definitions What does PSM stand for in safety PSM stands for Process Safety Management, a process that helps prevent/reduce risk of hazardous chemical releases. 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 process control loop is a system of sensors, controllers, and actuators that work together to maintain a process variable, such as temperature or pressure, at a desired setpoint. Control loops are fundamental to automated process control in industrial settings. Acronyms & Terms Glossary <- More Definitions Process Control Loop A process control loop is a system of sensors, controllers, and actuators that work together to maintain a process variable, such as temperature or pressure, at a desired setpoint. Control loops are fundamental to automated process control in industrial settings. 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.

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.