Media Releases & Company News - aeSolutions is an Engineering Leader in Integrating Process Safety, Fired Equipment / Combustion and Automation Media Releases aeSolutions Announces Key Leadership Promotions to Support Continued Client Success aeSolutions announces leadership promotions to drive client success and strengthen resilient, safer operations across industries. aeSolutions Announces New Executive Leadership Appointments and Corporate Growth Structure C-Level Appointments and New Business Units Will Enhance Company Client Services; Set Stage for Projected Growth aeSolutions to Participate in AIChE 2024 Center for Hydrogen Safety Americas Conference Presented by the Center for Hydrogen Safety. aeSolutions to Serve as 2024 Conference Bronze Sponsor. aeSolutions to Bring New FM-Approved FGS Product, the FGS 5000, to Market in Summer of 2024 Built on Rockwell Automation’s ControlLogix platform - Release of the new product is planned for summer of 2024 awaiting FM approval. This aeSolutions to Present at AIChE 2024 Spring Meeting and 20th Global Congress on Process Safety Process Safety Group Manager Don Connolley to Serve as International Chair of the CCPS Conference at the 2024 GCPS Greenville, SC – March... Industrial Process Safety and Automation Company aeSolutions Positions Itself For Aggressive Growth Headed Into 2024 Company to Continue to Focus on Client Success and Employee Development and Recruitment in 2024 Greenville, SC – February 28, 2024 –... About aeSolutions Media Releases Greenville, South Carolina, USA – In business since 1998, aeSolutions is a consulting, engineering, and systems integration company that provides industrial process safety and automation products and services. They specialize in helping industrial clients achieve their risk management and operational excellence goals through expertise in process safety, combustion control and safeguarding, safety instrumented systems, control system design and integration, alarm management, and related operations and integrity management systems. All media inquires should be directed to info@aesolutions.com . The aeSolutions team often writes articles for industry publications. If you are interested in speaking to someone about that, Please Fill out a contact us form and someone will get back to you. A static high resolution image of the aeSolutions logo can be found at https://static.wixstatic.com/media/d7ed2a_d352b2e48f53412db23c9e8896ac7ca1~mv2.jpg/v1/fill/w_667,h_273,al_c,q_90,usm_0.66_1.00_0.01/d7ed2a_d352b2e48f53412db23c9e8896ac7ca1~mv2.webp aeSolutions offers performance-based process safety engineering, industrial , and automation solutions with proven processes that ensure consistent project execution, while helping customers optimize safety, quality and production. We are committed to providing engineering services that enable our clients to sustainably own, operate, and maintain their process facilities. Following its original vision of providing Value-Driven Engineering, aeSolutions continues to anticipate and exceed the expectations of their customers, employees, and the market.

There are many unique industry terms used with Process Safety, Automation, and Combustion. This ongoing glossary looks to define these in a quick and easy way. A B C D E F G H I J L M N O P Q R S T U V Z Industry Acronyms & Terms Glossary A Advanced Process Control (APC) Alarm Alarm Flood Alarm Management Alarm Philosophy Alarm Priority Alarm Rationalization Alarm Selection ANSI ISA-16511 (IEC 61511) ANSI ISA-18.2-2009 API 525 API 535 API 556 Arc Flash Hazard Area Classification As Low as Reasonably Practicable (ALARP) As-Built Automated Valve Automatic Shutdown System Availability (Reliability Engineering) B Balanced Design Barrier Management Basic Process Control Systems (BPCS) Blowdown Breakdown Maintenance Burn-In Burner Management System (BMS) C Calibration Curve Cause & Effect (C&E) Cause of Failure Center for Chemical Process Safety (CCPS) Central Utilities Plant (CUP) Certified Functional Safety Expert (CFSE) Code of Federal Regulation (CFR) Combustion Control System (CCS) Common Cause Failure Common Mode Failure Compliance Auditing Computational Fluid Dynamics (CFD) Conditional Modifier Consequence Modeling Control Hazard and Operability Study (CHAZOP) Control Panel Control Valve Covert Failure Critical Control Point (CCP) D De-energization (De)terminate Deflagration Detonation Deviation Dispersion Modeling Distributed Control System (DCS) Double Jeopardy Dust Hazard Analysis (DHA) Dynamic Simulation E Emergency Shutdown System (ESD) Emergency Response Planning Guideline (ERPG) Enabling Condition Environmental Protection Agency (EPA) Event Tree Analysis (ETA) F Facility Siting Study Factory Acceptance Testing (FAT) Fail Closed - Fail Open Failure Mode Failure Modes and Effects Analysis (FMEA) Fault Tolerance Fault Tree Diagram Fire and Gas Mapping Fire and Gas Philosophy Flash Fire Frequency Front En d Loading (FEL) Functional Safety Functional Safety Assessments (FSA) Functional Test G Gas Detection System Gas Reclamation H Hardware Fault Tolerance Hazard Hazard Identification (HAZID) HAZOP (Hazard and Operability) Analysis High Demand Mode Highly Hazardous Chemical (HHC) HIPPS System Hot Work Human Factors Human Machine Interface (HMI) Human Reliability Analysis (HRA) Hysteresis (dead band) I Immediately Dangerous to Life and Health (IDLH) Incident Independent Protection Layer (IPL) Industrial Automation Industrial Control Systems Inherently Safer Design (ISD) Initiating Event Interlock System Intrinsic Safety (IS) IPL Independence IPL Verification J Jet Fire L Latching Alarm Latent Failure Layers Of Protection Analysis (LOPA) Likelihood Low Demand Mode Lower Explosive Limit (LEL) Lower Flammability Limit (LFL) M Maintenance Override Switch (MOS) Management of Change (MOC) Maximum Credible Event (MCE) Mean Time Between Failures (MTBF) Mean Time to Repair (MTTR) Mitigation Measures N NFPA 85 NFPA 86 NFPA 87 Node Nuisance Alarm O Operational Readiness P Pigging Process Hazard Analysis (PHA) Probability Probability of Failure on Demand (PFD) Process Automation Process Control Loop Process Risk Management Programmable Logic Controller (PLC) Proof Test PSM (Process Safety Management) Covered Process Q Quantitative Risk Assessment (QRA) R Recognized and Generally Accepted Good Engineering Practice (RAGAGEP) Recommendation Redundancy Reliability Centered Maintenance (RCM) Risk Risk Reduction Factor (RRF) Root Cause S Safeguard Safety Controls, Alarms, and Interlocks (SCAI) Safety Critical Element (SCE) Safety Instrumented Function (SIF) Safety Instrumented System (SIS) Safety Integrity Level (SIL) Calculations Safety Integrity Level (SIL) Ratings Safety Lifecycle Safety Requirement Specification (SRS) Scenario Sequential Function Chart (SFC) Shutdown Shutdown Logic SIL Verification SIS Engineering Site Acceptance Testing (SAT) Software in Safety Instrumented Systems (SIS) Spurious Trips Start-Up Sequence Systematic Failure Systematic Failures Systems Integration Systems Theoretic Accident Model and Processes (STAMP) Systems Theoretic Process Analysis (STPA) T Trip Point Two-out-of-Three (2oo3) Voting U Upper Flammability Limit (UFL) V Valve Failure Mode Vapor Cloud Explosion (VCE) Variable Frequency Drives (VFD) Voting Logic Z Zero Energy State (ZES) A B C F H I L S P D E G J M N Q R O T U V Z

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

aeSolutions is the Go-To Partner for Our Clients' Tough Challenges - Innovative, Sustainable Sservices to Create Client Value - Professional Project Management to Drive Client Business Results - Consistent Performance and Delivery on Our Commitments from our service - line card of our serivces - Breakdown - clients Services We Offer Automation Conceptual & Preliminary Engineering (FEL/FEED) FD/P&ID Development Control System Platform Evaluation Continuous and Batch Design TIC Estimate Development Instrument and Electrical Design (l&E) Instrument Index, Specs & Installation Details Plan Drawings Controls Electrical - Field Wiring {Loop Sheets, Elementaries, etc.) MCC Specification & Design Cable Schedules Construction SOWs Systems Integration Control Hardware Design Control System Server Virtualization Network Architecture Layout/ Design PLC, DCS, SIS, SCADA Configuration Control Panel Fabrication & Testing Construction Oversight Commissioning/Startup Support Learn More SIS Engineering ISA 61511 Safety Lifecycle Planning Design and Verification Safety Requirement Specification (SRS) Protection Layer Requirements Specification Cause & Effect Diagrams Functional Test Plans Lifecycle Cost Analysis Safety Integrity Level (SIL) Calculations Functional Safety Assessment (FSA) Fault Tree Analysis Event Tree Analysis Reliability Data Analysis Learn More Alarm Management Alarm Philosophy Development Consulting and Facilitation for ISA 18.2: Philosophy Rationalization Operations (Training) Audits Learn More Machinery Safety Compliance with Safety Standards at Manufacturing Sites (OSHA, ANSI, ISO) Risk Assessment State of Conformity Safeguard Specifications Training Learn More Combustion Combustion Control Solutions (CCS) Fuel & Waste Optimization Combustion Optimization Availability/ Reliability Assessments Burner Management Systems (BMS) NFPA/API Code Compliance Screening Surveys Gap Assessments Gap Closur e Options/ Scoping PSM and SIL Rated BMS Risk-Based {PHA/LOPA) Assessments Code Equivalent Design Alternative Design of BMS/CCS AHJ Approval Consulting SIS Engineering Multidiscipline Project Execution Front End Loading "Outside the Box" System Design {l&E) Systems Integration {BMS, CCS) Fuel Trains Construction Scoping/ Management Commissioning/ Startup Support Annual Testing Learn More Process Safety Process Safety Management (PSM) Risk Management Program (RMP) PSM/RMP/RBPS Auditing PHA/HAZOP/LOPA/QRA/CHAZOP Procedural/Extreme Weather/ Abnormal Event PHAs Facility Siting PHAST/CFD Modeling Gas Dispersion Modeling Gas Sensor Mapping Human Reliability Analysis (HRA) Training Process Safety Overview PSM/RMP Auditor PHA/LOPA Facilitator Independent Protection Layer Verification Mechanical Integrity Programs Electrical Area Classification Combustible Dust Hazard Assessments Learn More Fire & Gas NFPA 72 and Life Safety Code Compliance Fire and Gas Panel Design FM Listed Systems FM Approved Large Battery Backup Systems FGS System Construction Package CFO, Dispersion, Gas & Flame Detector Coverage Modeling Gas Detection Philosophy Detector Placement Startup and Commissioning Fire Marshall Package Learn More Why aeSolutions? Trusted Go-To Partner for Our Cli ents' Tough Challenges Innovative, Sustainable Solutions to Create Client Value Professional Project Management to Drive Client Business Results Consistent Performance and Delivery on Our Commitments Recognized Extensively Credentialed Professionals (PE, CFSE, PMP) Active in Leadership of Professional Organizations (ISA, AIChE, CSIA) Involved in Development of International Standards & Industry Best Practices Deep Technical Acumen, Thought Leadership How can we help you?

Control rooms, ergonomic multi-window stations Field panels, touch screen HMI Situational awareness Contextual data and trends Intuitive navigation Meaningful dynamics Single HMI for multiple control platforms and migrations Project specific HMI style guide Rockwell, Siemens PC7, Safety systems and critical controls, Triconex Human Machine Interfaces - SCADA Interacting with Intuitive Information aeSolutions designs and configures human machine interfaces for control and safety systems. HMI varieties range from DCS vendors' hefty client-server systems to small touch screens engineered with special purpose panels. To avoid incidents, an operator needs to quickly comprehend and react appropriately to changing conditions in the plant. Flashy graphics of the 1990's had too many distractions and made it hard to comprehend abnormal situations. Standards working groups like ASM, and ISA101-HMI are driving toward industry consensus. Control rooms, ergonomic multi-window stations Field panels, touch screen HMI Situational awareness Contextual data and trends Intuitive navigation Meaningful dynamics Single HMI for multiple control platforms and migrations Project specific HMI style guide Automation Services

aeSolutions provides consultation on requirements to meet regulatory compliance required by OSHA, Life Safety 101, International Building Code, International Fire Code, and NFPA 72.  We can provide a turn-key fire protection solution that meets all of these regulatory requirements including detector placement to installation & start-up services. Industrial fire and gas , International building code fire and gas, FM CSA standards, NFPA 72 Combination Systems, FM Gas Detection Systems, mapping Fire Alarm & Suppression Expertise in regulatory compliance Next Steps Detailed Engineering Installation Support aeSolutions provides consultation on requirements to meet regulatory compliance required by OSHA, Life Safety 101, International Building Code, International Fire Code, and NFPA 72. We can provide a turn-key fire protection solution that meets all of these regulatory requirements including everything from detector placement to installation and start-up services. aeSolutions' Approach to Fire Alarm & Suppression Review/Develop Fire Detection Philosophy Fire detection philosophy is the design basis for an effective system. Identify Chemicals/Combustibles of Concern, Alarm Levels and Technologies Hazardous Chemicals and Combustibles must be detected at the correct levels. Collect Ambient Conditions Data Measure background heat and infrared sources both indoors and outdoors. Collect Process Safety Information Fire and Smoke migration is dependent on airflow and physical boundaries. Identify Hazard Scenarios High risk points of release related to flammable/ combustible materials needs to be identified. Collect Relevant Site Information Initial Detector Placement Detector placement can be made using experienced judgement. Assess Coverage Fire and smoke detector positions are reviewed against simulated fire scenarios of a certain size. Assess Safety Availability Performance Detection equipment is assessed for availability on demand performance. Planning & Verification Develop Front-End Specification Update Design to Achieve Performance Targets Fire detection system design is updated until all criteria are met. Issue Fire Detection Safety Requirement Specifications Specification gives information for detailed engineering to proceed. Detailed Engineering Fire & Gas Products NRTL Approved Fire Panels NRTL Approved Power Supplies NRTL Approved Proprietary Supervisor Stations Fire & Gas Lifecycle Services Ongoing Maintenance Training Contact Us

Our industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Process Control, Safety Instrumented Systems (SIS), Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas, systems integration, Rockwell, Triconex, Safety systems, critical controls DCS/PLC Migrations and Upgrades System Integration Solutions Upgrading a Distributed control system (DCS) is a complex task that requires careful planning, coordination, and testing to mitigate risks such as downtime and data loss. Site requirements, regulatory compliance, and minimizing disruptions must be considered to ensure a smooth cutover. However, the security and functionality benefits of newer technologies can outweigh the costs, making it a valuable process for industrial operations. aeSolutions can provide the methodology, technical services, resources, personnel, and field support to accomplish your goals and objectives working with you from project inception to final commissioning. Through a proven project delivery model, aeSolutions integrates diverse hardware, software, and services from multiple vendors and client stakeholders into a unified, integrated system. Our full range of services will lead you through the controls integration process to deliver a fully integrated, cohesive control system in a well-executed project. aeSolutions' Integration Services Conceptual & Preliminary Engineering - Front-End Loading (FEL) / Front-End Engineering Design (FEED) PFD/P&ID Development Control System Platform Evaluation Continuous and Batch Design TIC Estimate Development Instrument and Electrical Design (I&E) Instrument Index, Specs & Installation Details Plan Drawings Controls Electrical - Field Wiring MCC Specification & Design Cable Schedules Construction SOWs Systems Integration Control Hardware Design Control System Server Virtualization PLC, DCS, SIS, SCADA Configuration Network Architecture Layout/ Design Control Panel Fabrication & Testing Construction Oversight Commissioning/Startup Support Expanded "Design, Implement, & Commission" Our clients are increasingly challenged to produce more with less. The productivity of yesterday’s most efficiently operated facilities is not acceptable for even mid-pack performance today. We understand the economic pressures the industry faces —and our industrial automation services can help. Our teams are skilled in all aspects of process control engineering because 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. The overall result is a facility is both back online faster so you see the financial advantages of the new DCS faster. Automation Applications Our industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Safety Instrumented Systems (SIS), Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas Systems (FGS). The result is a totally integrated automation lifecycle, from project inception to operation. Process Automation Systems Modernizing for Productivity and Profit Factory Automation Systems Mechanizing in Real Time Safety Instrumented Systems Delivering Safety on Demand Fire and Gas Systems Furnishing the Last Line of Defense Advanced Regulatory Control (ARC) Enlisting More Variables Burner Management Systems (BMS) Mitigating Fired System Hazards Combustion Control Systems (CCS) Optimizing Fuel Air Operation Human Machine Interfaces (SCADA) Interacting with Intuitive Information Alarm Management Systems Alerting Appropriate Action Migration Solutions Moving up with Modernization Conceptual & Preliminary Engineering Project Management Shaping a Successful Result from the Start Project Assessment and Conceptual Design Articulating the Project Vision and Characterizing the Control System Preliminary Engineering Converting Concept to Design Basis Lifecycle and Upgrade Planning Looking Ahead Hardware Design Hardware Design Specifications Developing Hardware Details Electrical and Instrumentation Design Connecting to the Process Hardware Design and Panel Fabrication Supplying World-Class Panels Construction, Installation, Commissioning Realizing the Vision Systems Integration Software Design Specifications Developing Software Details Network Design Distributing Monitoring and Control Control System Configuration Creating Consistently Correct Control Simulation and Factory Acceptance Testing Approving the Configurations Site Acceptance Testing and Startup Testing and Turnover Maintenance and Support Supporting Client Successes Related Posts Control System Migrations | Procurement Specification & Vendor Selection Mitigating Project Risks through Front-End Loading for Control System Migrations Cost Justification for Control System Replacement Projects

aeSolutions is a total process automation provider with extensive experience in turnkey solutions. We've earned aeSolutions was the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification. ​aeSolutions' President, Ken O’Malley, holds a position on Siemens’ User Advisory Boar Siemens Solution Partner - aeSolutions aeSolutions is a process automation engineering company with extensive experience in delivering turnkey automation solutions and is a leading provider of critical systems such as Safety Instrumented Systems, Fire and Gas Systems, and Combustion Control and Safeguarding Systems in the country. The company maintains a team of experienced Professional Engineers and Certified Functional Safety Experts (CFSE). aeSolutions joined Siemens Solution Partner Program in 1999 and has earned the Solution Partner Specialist designation after achieving technical and commercial milestones associated with year-over-year quality performance delivering solutions in both brownfield migrations and greenfield expansions for over two decades. We're proud to have been the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification. Siemens.com Partner Detail Page aeSolutions' President, Ken O’Malley , holds a position on Siemens’ User Advisory Board as well as Siemens’ national Solution Partner Council. Service Portfolio: Consulting for process safety and automation conceptual design Automation of process manufacturing facilities Training on PSM and process automation and safety systems Integration, Engineering, and Commissioning of DCS, SIS, BMS and fire & gas systems FM and UL certified panel fabrication shop Migrations & upgrades of automation & safety systems aeSolutions: Certificates: Solution Partner Process Control System SIMATIC PCS 7 Advanced Factory Automation PCS 7 Safety Specialist Systems Intergration - Automation Services Combustion - Burner Management Systems aeSolutions & Siemens Media aeSolutions is the First in Americas to earn S iemens SIMATIC PCS 7 Safety Specialist Certifications “As customers require PCS 7 safety instrumented systems, we can recommend aeSolutions, our certified Process Safety Specialist Solution Partner, knowing that they have the engineering and quality practices to execute the project right the first time using best practices,” says Rich Chmielewski, Siemens USA PCS 7 Solution Partner Program Manager. Learn More Using the cloud to secure the cloud https://www.controlglobal.com Best practices for gas detection system design https://www.controlglobal.com aeSolutions is First in the Americas to Earn Siemens SIMATIC PCS 7 Safety Specialist Certification https://www.automationworld.com aeSolutions & Siemens Case Studies Ammonia isolation and mitigation safety system based on FGS 1400 MK II platform. Uses S7-400 safety controllers and S7-300 safety IO. Ammonia suppression safety system that is NRTL approved for toxic gas. FGS 1400 MK II product provides leak detection, occupant notification, equipment isolation, and hazard suppression capability for a pressurized ammonia storage facility. View Details aeSolutions applies our expertise to help you produce Hydrogen safely. Expertise is required to produce hydrogen safely especially indoors with electrolyzers. You are working with a dangerous chemical and with modeling of the gas, especially indoors, you can properly place the detectors. Fire and Gas, Safety Shutdown systems as well as overall process automation best practices, are critical to safely product hydrogen. View Details Optimizing Integration of Life-Saving Gas Detection Systems for the Pharmaceutical Industry Leverage the expertise of Solution Partner aeSolutions to provide plants with turnkey gas detection systems including all control system components, detectors and computational fluid dynamics modeling. Benefits can include: •Ensures OSHA compliance to reduce risk of overexposure, fire or explosion •Simplified integration of gas detection systems into plants •Minimized footprint due to modern I/O technology View Details Siemens PCS7 Implemented as SI-BMS for Utility Boilers at Chemical Plant Designed, fabricated, configured, tested and performed start-up services for seven burner management systems (BMS) on seven coal and gas fired process boilers for a chemical manufacturing plant. View Details Fire & Gas Safety System using SIMATIC S7-400F provides highly scalable flexibility for industrial Fire and Gas applications. FM approved Fire and Gas safety system based on S7-400 safety controllers and ET200MF safety IO. System provides detection, notification, suppression, and process ESD shutdowns. System also has FM approved power supply system capable of supplying OSHA and NFPA 72 power requirements. View Details Meeting Customer Demand by Doubling Production PCS 7 Simatic Batch and PCS 7 Failsafe were used to automate a new reactor and associated equipment to double production View Details Safety Shutdown and BMS needs met with Compliant System Refineries burner management and safety shutdown needs are met with rack-to-rack redundant PCS 7 Failsafe System and Safety Matrix. View Details Siemens PCS 7 TIA Success: Instrumentation and Motor Control Centers as a Modular and Scalable Solution The SEFA Group plant gives a local supply of a premium recycled product available for sustainable construction. Siemens PCS 7 was successfully integrated using TIA with all instrumentation and motor control centers to aid in elimination of up to 400,000 tons of fly ash per year transported to landfills. This also improved reliability with PCS7 tools View Details www.usa.siemens.com/process

aeSolutions has a unique process to design and implement ISA84/IEC 61511-compliant industrial safety instrumented systems. We integrate intimate knowledge and experience in PHA/LOPA along with control system hardware and field instrumentation to ensure that Safety Instrumented Functions (SIFs). Stage 4 FSA, Functional Safety Assesments, Field Investigation, 61511 gap assessments & audits , Field investigation, "control systems" IPL validation , SIF Definition , Management of Functional Safety Plant Protection Systems Combustibl e & Toxic Gas | Fired Equipment | Safety Instrumented Sy stems ↵ SIS Engineering Reducing systematic failures reduces risk Our full understanding of the lifecycle prevents rework, saves time, and produces a more effective safety system. Critical decisions made in the analysis phase reduce the risk of late discoveries on your capital projects. A successful Safety Instrumented System (SIS) project is one that meets its intended safety performance requirements while also achieving all other project objectives. aeSolutions will define, design, and document the safety functions to meet ANSI/ISA-61511 lifecycle requirements of a process safety project with expertise and attention to detail f rom study through start up. Clients trust aeSolutions to ensure that they get the best return on their capital expenditures. Safety Lifecycle Services During the hazard and risk analysis phase of the safety lifecycle Independent Protection Layers (IPLs) are identified. Claiming credit for one or more IPLs that do not provide the protection claimed will result in under-designed SIFs, increasing risk to the facility. Claiming less credit for IPLs than is actually provided will result in over-designed SIFs, increasing capital cost. aeSolutions has the expertise and experience to help you perform this critical task most effectively. BPCS/SIS Independence Assessment 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. With our experience in process automation and functional safety we can ensure this analysis is done correctly. Safety Requirements Specification (SRS) The SRS (clause 10 of ISA/IEC 61511) takes the results of the hazard and risk assessments and defines the requirements that the individual SIFs must meet. 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. The hazard and risk assessments identify the need for Independent Protection Layers (IPLs) to bring the risks associated with the various hazard scenarios in line with corporate risk tolerance guidelines. Where one or more IPLs are determined to be SIFs aeSolutions has the experience and expertise to: Confirm the SIL required for the SIF to avoid overdesign Create a preliminary design for the SIF that conforms to ISA/IEC 61511 Identify the failure rates and parameters needed to calculate the Probability of Failure on Demand (PFD) of the SIF We use the most appropriate tool for calculating PFDs (or use the tool the client requires); for complex SIFs we can use Fault Tree Analysis for the calculations Optimize the SIF to meet the desired proof test interval and spurious trip frequency Recommend specific field devices for the SIF Document the calculations including the data and parameters used C&E diagrams are frequently the input to developing the software to be implemented on a SIS logic solver (sometimes together with a narrative). As such they are of critical importance to successful implementation of the SIFs in any functional safety project. Our C&E templates have been developed from many years of experience to optimize ease-of-use for configuration, testing, operator training and turnover effectiveness. In cases where the functional complexity exceeds the capacity of C&Es, our staff is capable of selecting the most efficient alternate format. Quantitative Risk Assessment (QRA) is a risk assessment methodology that allows for numerical estimates of the level of risk associated with a certain activity or series of activities to be estimated and then assessed. Risk is a function of consequence and likelihood and aeSolutions has the experience and tools to evaluate both for a QRA. For example we can use the PHAST software to model chemical releases in evaluating consequences of an incident. QRA can be a valuable decision support tool when evaluating complex hazard scenarios. Logic narratives are sometimes required in addition to cause and effect diagrams to explain the functioning of a SIS, particularly when there are field devices shared among SIFs or there are other types of interdependencies. Sequential Function Charts (SFCs) are an example of logic diagrams that can be used to illustrate the functioning of a SIS. SFCs are frequently used to document the various operating modes of fired equipment. The aeSolutions staff is capable of selecting the best format, or combination of formats, to best meet the requirements of our clients. The Application Program Requirement Specification (APRS) is an extension of the SRS, and includes requirements for software applications used in a SIS. aeSolutions can assist you in developing an APRS so that the resulting application meets the requirements of ISA/IEC 61511 and correctly implements the different SIFs. The ISA/IEC 61511 standard (Clause 13) requires that the need for a FAT should be identified during safety planning for a project, and also provides guidance on how a FAT should be planned and conducted. Clause 15, SIS Safety Validation (also know as a SAT), provides similar guidance. aeSolutions SIS engineers have the experience to develop these plans, oversee their execution as an independent 3rd party, or execute these tests. The goal of a proof test of a SIF is to reveal previously undiagnosed dangerous hardware failures (those failures that would prevent the SIF from reacting to a hazard). Proof test coverage (the fraction of these failures a given proof can reveal) and the interval at which proof tests are conducted are important inputs into determining if a SIF meets its required SIL. Developing a proof test philosophy can provide for consistency in proof test procedures and how they are conducted. aeSolutions' experts have the field experience to discuss the testing requirements, site practices and available technologies to determine and document a comprehensive testing philosophy. We also have a library of proven proof test procedures to choose from when assembling a testing package, and we have the expertise to work with clients to implement effective testing, failure classification, and feedback mechanisms to validate reliability data claimed in Risk Analysis and SIL Verification. Corporate SIS Project Standards Development aeSolutions can help create or update the practices and procedures you need for compliance with the ISA/IEC 61511 standard. For example: Risk Assessment Standards SIL Selection Standards Functional Safety Assessment Templates SIS Design and Implementation Standards Functional Safety Management Planning (FSMP) The ISA/IEC 61511 standard identifies the management activities that are necessary to ensure that functional safety objectives are met: + Organization and resources + Risk evaluation and risk management + Safety Planning + Assessment, auditing and revisions + SIS configuration management aeSolutions can assist you in developing a management plan to accomplish what the standard requires but tailored to your specific circumstances and resources. Training The design and operation of Safety Instrumented Systems (SIS) requires an understanding of instrumentation failure characteristics, the Safety Lifecycle, probability mechanics, and the relevant international standards. We offer training in the following areas, and we also offer training customized to your specific needs: - Safety Requirements Specification (SRS) - Calculations of the Probability of Failure on Demand (PFD) - Fault Tree Analysis - Determination of Architectural Constraints - Identifying and Modeling for Common Causes of Failure - Degraded Voting - Failure Rate Estimation Management of Functional Safety, Lifecycle Planning Operations and Maintenance Services Stage 4 Functional Safety Assessment (FSA) Tracking Proof Tests and SIF Performance Modifications Stage 5 Functional Safety Assessment (FSA) Update SIS Related Documents After a Modification Management of Functional Safety, Lifecycle Planning Corporate SIS Project Standards Development Functional Safety Management Planning (FSMP) Functional Safety Assessments (FSAs) Lifecycle Cost Analysis Training Concept through Start Up Allocations of Safety Functions to Protection Layers Independent Protection Layer (IPL) Validation of Credits BPCS/SIS Independence Assessment Safety Requirement Specifications Safety Requirements Specification (SRS) Design and Engineering of Safety Instrumented Systems (SRS) Safety Instrumented Function (SIF) Design, Optimization, and Safety Integrity Level (SIL) Verification Cause & Effect Diagrams (C&Es) Quantitative Risk Assessment SIS/SIF Equipment Specifications Logic Narratives and Diagrams Application Program Requirement Specification Development Factory Acceptance Test (FAT) & Site Acceptance Test (SAT) Plan Development Installation, Commissioning, and Validation Proof Test Philosophy & Design aeShield Software Featured Stories PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations. FSA Stage 2: Evaluating the Safety Instrumented System (SIS) Readiness for Field Installation Learn how FSA Stage 2 ensures your Safety Instrumented System (SIS) is ready for field installation, preventing rework & project delays. Can Stage 3 FSA Confirm Your Safety Instrumented System Is Ready for Operational Use? Verify your Safety Instrumented System's readiness with a Stage 3 FSA, ensuring safe operation and compliance with design specifications. What is a Stage 1 FSA & How Can It Help Discover Critical SIS Flaws? Discover how a Stage 1 FSA can identify critical Safety Instrumented System (SIS) flaws early in the design process.

aeSolutions' has been a trusted provider of Process Hazard Analysis (PHA) Revalidation services for over 25 years. Let's Discuss your facility's PHA Reval today. Process Hazard Analysis (PHA) Revalidation Services In complex industrial environments, hazards evolve and your Process Hazard Analysis (PHA) should evolve with them. OSHA mandates that facilities conduct a PHA revalidation at least every five years to ensure safeguards and Independent Protection Layers (IPLs) are still appropriate and effective. Revalidations not only maintain compliance but help you adapt to changes in operations, technology, and risk. Missing this critical step can leave your facility exposed to preventable failures and regulatory consequences. Don’t let your next PHA revalidation become a missed opportunity — make it the foundation for safer, smarter decisions . Ready to Discuss Your Next PHA Reval? Why Partner With Us? At aeSolutions, we don’t just guide you through your PHA revalidation — we help you understand and prioritize your PHA recommendations, offering strategic solutions to close those gaps . Our credentialed engineers and facilitators bring decades of experience in process safety management, risk analysis, and standards compliance, including LOPA-trained facilitators to support higher-risk scenarios. We pair industry expertise with proven project delivery methods to make revalidations efficient, accurate, and actionable. From prioritizing risk to supporting the resolution of technical recommendations like SIS, BMS, alarm management, and fire & gas systems, aeSolutions can help you close the loop. Partnering with us means a PHA reval that goes beyond the worksheet. Our PHA revalidations go beyond "checking boxes" — we provide the solutions to prioritize & resolve your PHA recommendations. Trust Built On Experience Years of Combined PHA Experience PHA Revalidations Completed Years Serving the Industry Industries Served Chemical Manufacturing Metals & Mining Processing Renewable Fuels & Bioenergy Hydrogen Production & Processing Agrochemicals Petrochemical & Hydrocarbon Processing Specialty Chemicals & Advanced Materials Energy & Power Generation Oil & Gas Production & Processing Pharmaceuticals & Life Sciences Utilities & Critical Infrastructure Battery Materials & Mineral Processing About Process Hazard Analysis (PHA) Revalidations A Process Hazard Analysis (PHA) Revalidation is designed to systematically review and update your facility’s assessment of process risks, ensuring that evolving hazards are identified, existing safeguards and Independent Protection Layers (IPLs) are still effective, and new vulnerabilities are addressed. This process includes evaluating operational changes, modifications to equipment, and lessons learned from incidents to determine whether additional measures are needed to manage risk. Within the United States, PHA revalidation is required at least every five years under OSHA’s Process Safety Management Standard (29 CFR 1910.119(e)(6)) for sites that handle highly hazardous chemicals. aeSolutions’ PHA revalidation service stands above the rest by going beyond simply “checking the boxes”. We not only utilize risk assessment methodologies based on your process complexity and organizational preference — including HAZOP, LOPA, What-If and Checklist Analyses, HAZID, FMEA, and Bowtie Analysis methodologies — but we also provide strategically prioritized solutions and resources to help you resolve PHA recommendations efficiently. With a focus on actionable outcomes and ongoing support, we help ensure your facility achieves both compliance and continuous improvement. Ready to Discuss Your PHA Revalidation? Recent Posts PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations. Improve Your Process Safety Culture to Drive Improved Safety Performance In a process safety culture that is systematically improving, senior facility management demonstrates a strong commitment to process safety 5 Facets of an Efficient Process Hazard Analysis (PHA) Explore five key facets of an effective Process Hazard Analysis to boost safety and streamline risk management in your operations.

As a supplier of complete process safety systems and risk management solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety systems and backgrounds. Our specialists understand process safety. Planning "control systems" & "process controls", and process risk management. - Process Hazard Management HS4, HS5, HS- essential component of any facility. Learn about the importance of process safety management Process Safety Management As a supplier of complete process safety and risk management solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities. Ready to Discuss Your Project? Services: PSM/RMP Process Hazard Analysis Quantitative Risk Assessment Human Reliability Auditing Facility Siting & Modeling Machinery Safety PSM/RMP Program Development & Implementation Risk Management Plan/Hazard Assessment Management of Change (MOC) Program Development & Implementation Incident Investigation Mechanical Integrity Program Operating Procedures & Training Training (PS Leadership, Auditor, PHA/LOPA) Electrical Area Classification Learn More Process Safety Management/Risk Management Plan (PSM/RMP) Hazard and Operability (HAZOP) What if What-If/Checklist Analysis Process Hazard Analysis Revalidation Failure Modes and Effects Analysis (FMEA) Combustible Dust Hazard Assessment Control System Hazard and Operability (CHAZOP) Process Hazard Analysis (PHA) Learn More Risk Graphs Event Tree Analysis Bowtie Analysis Layers of Protection Analysis (LOPA) Independent Protection Layer (IPL) and Safety Integrity Level (SIL) Selection Learn More Implicit LOPA Safety Layer Matrix 3D Risk Matrix Quantitative/Semi-Quantitative Risk Assessment (QRA) Human Reliability Analysis (HRA) Human Error Analysis Human Reliability/Human Factors Learn More Compliance Auditing - PSM, RMP, and Risk Based Process Safety (RBPS) Independent Protection Layer (IPL) Verification Learn More Auditing Facility Siting Analysis Risk-based and Consequence-based Studies Gas Dispersion Modeling Failure Modes and Effects Analysis (FMEA) Gas Detector Placement Learn More Facility Siting & Dispersion Modeling Screening Robot Integration Risk Assessment Facility Compliance Evaluation State of Conformity Evaluation Safety Function Performance Level Verification & Validation Machine Guarding Assessment Machine Safety Risk Assessment Robotic Safety Light Curtain Positioning Interlock Design Circuit Design Safeguard Specification & Implementation Functional Safety Assessment Hazard Identification Training Learn More Machinery Safety PSM RMP PHA QRA LOPA Human Reliability Audit Siting & Modeling Machinery Safety Featured Stories PHA Revalidations | Beyond Checking Boxes Enhancing Process Safety: Five Tips to Build a Better System FSA Stage 2: Evaluating the Safety Instrumented System (SIS) Readiness for Field Installation — Let's Discuss Your Process Safety Management Project —

The latest online content put into a monthly email newsletter from aeSolutions, an integrated lifecycle partner in process safety, combustion / fired equipment and automation. aeSolutions' Email Newsletter The latest online content from aeSolutions, an integrated lifecycle partner in process safety, automation and fired equipment, emailed straight to you every other month. Past Month's Newsletters: aeSolutions May 2025: Upcoming EPC 2025 Conference & Expo | PHA Revalidations | Coverage in Processing Magazine aeSolutions February 2025: Control System Migrations Part 5 | Strategies for Boiler Fuel Conversion Projects | A Look Back at aeSolutions' 2024 Charitable Giving Initiative aeSolutions January 2025: Control System Migrations - Part 4 | Safety Culture: Examining Common Shortcomings | Unplanned Shutdowns as Proof Test Credits aeSolutions November 2024: Are You Ready for Your Next Facility Siting Study? | Control System Migrations - Part 3 | Integrating PHA LOPA Outputs into Effective SIS Engineering aeSolutions September 2024: Discover SIS Flaws With Stage 1 FSA | 2024 Mary Kay O'Connor Safety & Risk Conference | Success Story: Hydrogen Production Plant F&G System Design & Implementation R egister to Receive Monthly Emails Sign Up Now By providing this information, you agree to the processing of your personal data as described in our Privacy Policy. Sign Up Today! Keep up with aeSolutions Industry articles, upcoming events, and new ideas. Examples include topics such as Regulatory Compliance with Fire and Gas, Alarm Rationalization Whitepapers, Videos on Systematic Failures and what that really means, taking credit for protection layers, understanding protection layers and risk layering, and gas detection front end loading project management. What is LOPA and Lopa safety? Random failure of operator error due to human factors. Expert Engineers in Process Safety Management Services answers these with a PHA LOPA audit. We also often feature content on Burner Management systems. Our team understands the market and vendors.