Supplying World-Class Panels Hardware Design and Panel Fabrication Supplying World-Class Panels aeSolutions operates its own 10,000 square foot FM approved and UL 508a certified panel fabrication and testing facility. The aeSolutions team designs and builds sophisticated panels for a wide variety of projects, from small PLC cabinets, to large multi-bay safety and control systems designed to run large facilities. aeSolutions engineers specify and purchase hardware and software appropriate for client applications. Equipment is staged at our facility for integration and factory acceptance testing. • CAD drawings • Power supply, UPS, battery sizing • Heat load calculations • Panel Layout, wire ways, and interconnection wiring • Painting, labelling • Pressurization, purging • Master Fuel Trip relay and watchdog circuits • OEM racks, cards, relays, termination units, networks • Firmware, revisions, compatibilities • Bills of Material, purchasing, receiving, shipping Automation Services Previous Next

Burner management systems definition (BMS) is a system used for ensuring safe startup, control and monitoring of temperature, and shutdown of a heated vessel that can include interlocks, trips, flame monitoring, ignition systems, etc. aeSolutions' family of products includes industrial BMSs in several packages. The pre-engineered packages are configurable to meet the client's safety requirements and all prescriptive and performance standards for dependable protection of people and property, during startup, shutdown, and operation. The safety BMS is often supplied as an integrated Combustion Management System (CCS) package. Acronyms & Terms Glossary <- More Definitions Burner Management Systems Burner management systems definition (BMS) is a system used for ensuring safe startup, control and monitoring of temperature, and shutdown of a heated vessel that can include interlocks, trips, flame monitoring, ignition systems, etc. aeSolutions' family of products includes industrial BMSs in several packages. The pre-engineered packages are configurable to meet the client's safety requirements and all prescriptive and performance standards for dependable protection of people and property, during startup, shutdown, and operation. The safety BMS is often supplied as an integrated Combustion Management System (CCS) package. 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 relative importance assigned to each alarm indicating the urgency of response, typically using an allowable response time and consequence severity. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Acronyms & Terms Glossary <- More Definitions Alarm Priority A relative importance assigned to each alarm indicating the urgency of response, typically using an allowable response time and consequence severity. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

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

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: 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 protection layer is considered an independent protection layer (IPL) if it is effective independent of the occurrence or consequences of the initiating event, another IPL that is part of the scenario, and is unaffected by conditions that cause another IPL to fail. During hazard reviews protection layers implemented in both the BPCS (e.g., the DCS) and SIS are identified. Determining if different protection layers are truly independent so that they are credited properly in the risk analysis can be complex. Acronyms & Terms Glossary <- More Definitions IPL Independence A protection layer is considered an independent protection layer (IPL) if it is effective independent of the occurrence or consequences of the initiating event, another IPL that is part of the scenario, and is unaffected by conditions that cause another IPL to fail. During hazard reviews protection layers implemented in both the BPCS (e.g., the DCS) and SIS are identified. Determining if different protection layers are truly independent so that they are credited properly in the risk analysis can be complex. 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.

API 525 is a recommended practice developed by the American Petroleum Institute for conducting tests to determine performance characteristics of a given design of pressurerelieving device which is required to operate under variable superimposed back-pressure conditions with compressible fluids. Acronyms & Terms Glossary <- More Definitions API 525 API 525 is a recommended practice developed by the American Petroleum Institute for conducting tests to determine performance characteristics of a given design of pressurerelieving device which is required to operate under variable superimposed back-pressure conditions with compressible fluids. 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 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: 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 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 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.

API 535 is a recommended practice developed by the American Petroleum Institute for the selection and/or evaluation of burners installed in fired heaters in general refinery services. Acronyms & Terms Glossary <- More Definitions API 535 API 535 is a recommended practice developed by the American Petroleum Institute for the selection and/or evaluation of burners installed in fired heaters in general refinery services. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Barrier management involves implementing and maintaining physical or procedural barriers to prevent accidents or mitigate the effects of hazardous events. These barriers include safety devices, procedures, and policies designed to control risks and protect people, assets, and the environment. Acronyms & Terms Glossary <- More Definitions Barrier Management Barrier management involves implementing and maintaining physical or procedural barriers to prevent accidents or mitigate the effects of hazardous events. These barriers include safety devices, procedures, and policies designed to control risks and protect people, assets, and the environment. 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 project management process during early stages of a project designed to minimize risk for investors and other stakeholders by developing adequate project definition & scope. Key Deliverables of FEL: 1. Execution Strategy and Plan 2. Resource Plan 3. Risk Management Plan 4. Change Management Plan FEL can be multiple stages: FEL 1, FEL 2, and FEL 3. Some owners opt to only do a single FEL. However, the key is to consider all factors and engage in a level of FEL that is reasonable. Regardless of the number of FEL phases performed, all business needs should be evaluated, and a complete business case should be identified to minimize cost schedule budget (scope risk). Acronyms & Terms Glossary <- More Definitions Front End Loading (FEL) A project management process during early stages of a project designed to minimize risk for investors and other stakeholders by developing adequate project definition & scope. Key Deliverables of FEL: 1. Execution Strategy and Plan 2. Resource Plan 3. Risk Management Plan 4. Change Management Plan FEL can be multiple stages: FEL 1, FEL 2, and FEL 3. Some owners opt to only do a single FEL. However, the key is to consider all factors and engage in a level of FEL that is reasonable. Regardless of the number of FEL phases performed, all business needs should be evaluated, and a complete business case should be identified to minimize cost schedule budget (scope risk). 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.