Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility A multi-fuel boiler project for a chlor alkali production facility resulted in significant modernization and operational improvements. The client's legacy relay-based Burner Management System (BMS) was upgraded to a DeltaV CHARM Safety Logic Solver, providing enhanced visibility, safety, and operational flexibility. This project not only modernized the client's system but also ensured compliance with NFPA 85 codes and met all Safety Instrumented Systems (SIS) requirements. Challenge The client’s existing BMS was based on outdated relay logic technology, limiting visibility into critical boiler parameters. Operators struggled with frequent system trips but lacked the ability to identify the root causes. Their legacy system provided no direct diagnostics, forcing operators to visually inspect equipment and restart the system manually. Additionally, the client required operational flexibility to switch between multiple fuel types — natural gas, hydrogen, and oil — without system shutdowns. The client sought improved support and expertise with a configuration provider with SI-BMS experience. Their need for seamless integration, combined with complex fuel-switching requirements, posed significant technical challenges. Solution aeSolutions successfully delivered a comprehensive upgrade of the client’s BMS, integrating it into the existing DeltaV platform. Key elements of the solution included: • Integration with DeltaV: The new BMS was implemented using DeltaV’s CHARM Safety Logic Solver, ensuring compatibility with the client’s existing system and reducing the learning curve for operators. • Enhanced System Visibility: Operators gained real-time insight into key metrics such as pressure levels and temperature through custom Dynamos on the control room interface. First-out diagnostics were also added, enabling quicker root-cause analysis and reducing downtime. • NFPA 85 Code Compliance: The upgrade ensured the boiler system met the latest NFPA 85 safety codes, enhancing both safety and reliability. • Multi-Fuel Flexibility: The system was designed to allow seamless fuel switching between hydrogen, natural gas, and oil without requiring shutdowns. Custom Safety Instrumented Functions (SIFs) were implemented to manage the complexities of multiple fuel types safely. • Close Client Support: aeSolutions was able to provide prompt, on-site technical support as needed, ensuring smooth project delivery and ongoing assistance. Results The results of this project provided significant benefits to the client by improving both safety and operational efficiency. The upgraded BMS ensured compliance with NFPA 85 codes, enhancing safety and reducing the risk of boiler-related incidents. With the ability to switch seamlessly between hydrogen, natural gas, and oil, the system offered the client greater operational flexibility. The inclusion of real-time diagnostics and first-out alarms allowed for faster troubleshooting, reducing downtime, and improving system availability. Additionally, the operators benefited from a streamlined process, as they could now manage startups from the control room, minimizing manual interventions. To ensure a smooth transition, aeSolutions replicated the client's existing control graphics through custom Dynamos, maintaining familiarity for operators and preventing workflow disruptions. These enhancements collectively improved safety, reliability, and ease of operations for the client. Learn more about how aeSolutions could help you with a similar project Industry: Chlor Alkali Production Geography: Southeast Unit Operation: Burner Management System (BMS), DeltaV Previous Story Next Story

Mean Time Between Failures (MTBF) is a reliability metric that represents the average time between failures of a system or component. MTBF is used to predict the reliability and performance of equipment over time. Acronyms & Terms Glossary <- More Definitions Mean Time Between Failures (MTBF) Mean Time Between Failures (MTBF) is a reliability metric that represents the average time between failures of a system or component. MTBF is used to predict the reliability and performance of equipment over time. Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.

Moving up with Modernization Migration Solutions Moving up with Modernization Many clients are faced with moving their safety and control systems to a newer platform, sometimes to a different vendor. aeSolutions offers project services to assess system options and define an architecture that best serves the client's needs. Then the project stages described under "Automation Services" will shepherd the migration through definition, design, installation, and startup. Migrations offer opportunities to realize a maximally integrated safety and control system, with great benefits for functionality, operability, safety, maintenance, and engineering productivity. These migration projects, with careful planning can be done in phases, such as replacing operator consoles first. Finally, migrations usually involve moving from obsolete systems to newer generation platforms. aeSolutions' clients are encouraged to embrace the enhanced technology and take advantage of the opportunity to add improved process automation and modernized human interfaces. Automation Services Previous Next

A hypothetical explosion, fire, or toxic event that has the potential maximum consequence to the occupants of the building under consideration from among the major scenarios evaluated. The major scenarios are realistic and have a reasonable probability of occurrence considering the chemicals, inventories, equipment and piping design, operating conditions, fuel reactivity, process unit geometry, industry incident history, and other factors. Each building may have its own set of MCEs for potential explosion, fire, or toxic material release impacts. Maximum Credible Events (MCEs) are considered during facility siting studies conducted by aeSolutions' experienced modelers. to help companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Acronyms & Terms Glossary <- More Definitions Maximum Credible Event (MCE) A hypothetical explosion, fire, or toxic event that has the potential maximum consequence to the occupants of the building under consideration from among the major scenarios evaluated. The major scenarios are realistic and have a reasonable probability of occurrence considering the chemicals, inventories, equipment and piping design, operating conditions, fuel reactivity, process unit geometry, industry incident history, and other factors. Each building may have its own set of MCEs for potential explosion, fire, or toxic material release impacts. Maximum Credible Events (MCEs) are considered during facility siting studies conducted by aeSolutions' experienced modelers. to help companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.

An Alarm Philosophy establishes how a company addresses alarm management through all phases of its lifecycle. An effective alarm philosophy document defines the alarm system’s design philosophy as well as how it should be managed and maintained with information such as alarm criteria, specifications, and responsibilities. This document is typically the starting point of any alarm management project. Learn more at https://www.aesolutions.com/alarm-management Acronyms & Terms Glossary <- More Definitions Alarm Philosophy An Alarm Philosophy establishes how a company addresses alarm management through all phases of its lifecycle. An effective alarm philosophy document defines the alarm system’s design philosophy as well as how it should be managed and maintained with information such as alarm criteria, specifications, and responsibilities. This document is typically the starting point of any alarm management project. Learn more at https://www.aesolutions.com/alarm-management Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.

A document establishing the expected conduct for areas of concern by the federal government. aeSolutions has the knowledge and experience to assist with PSM/RMP development and implementation required by the Code of Federal Regulations (CFRs) -- including OSHA PSM Standard, 29 CFR 1910.119 and EPA RMP Standard, 40 CFR 68 -- from high level gap and applicability assessments to complete RMP site program development, including drafting procedures and creating mechanical integrity programs. Acronyms & Terms Glossary <- More Definitions Code of Federal Regulation (CFR) A document establishing the expected conduct for areas of concern by the federal government. aeSolutions has the knowledge and experience to assist with PSM/RMP development and implementation required by the Code of Federal Regulations (CFRs) -- including OSHA PSM Standard, 29 CFR 1910.119 and EPA RMP Standard, 40 CFR 68 -- from high level gap and applicability assessments to complete RMP site program development, including drafting procedures and creating mechanical integrity programs. Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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 cause of failure is the specific reason or condition that leads to the malfunction or breakdown of a system, component, or process. Identifying the cause of failure is essential for implementing corrective actions and improving reliability. Acronyms & Terms Glossary <- More Definitions Cause of Failure The cause of failure is the specific reason or condition that leads to the malfunction or breakdown of a system, component, or process. Identifying the cause of failure is essential for implementing corrective actions and improving reliability. Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.

A measure of the expected probability or frequency of occurrence of an event. This may be expressed as an event frequency (e.g., event per year), a probability of occurrence during a time interval (e.g., annual probability), or a conditional probability (e.g., probability of occurrence, given that a precursor event has occurred). Acronyms & Terms Glossary <- More Definitions Likelihood A measure of the expected probability or frequency of occurrence of an event. This may be expressed as an event frequency (e.g., event per year), a probability of occurrence during a time interval (e.g., annual probability), or a conditional probability (e.g., probability of occurrence, given that a precursor event has occurred). Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.

Developing Hardware Details Hardware Design Specifications Developing Hardware Details aeSolutions works with clients to establish specific project standards for the detailed hardware design of the system and field I/O. • Input / Output database and signal types • Control system cabinet layout practices • Controller, I/O, and interface modules • HMI operator interface equipment • Control networks, switches, fiber optics, and cabling • Marshalling cabinets and interposing relays • Servers and clients • Engineering workstations • Purging, temperature, smoke and fire detection Automation Services Previous Next

Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities A globally recognized chemical producer that had recently acquired a legacy plant used to produce highly hazardous agricultural chemicals turned to aeSolutions’ multi-disciplinary capabilities for a comprehensive solution to bring their legacy plant into compliance. The client was faced with a tight schedule to meet their corporate process safety standards through a functional safety upgrade, with the goal of bringing the facility into PSM OSHA 1910.119 compliance. Once awarded the project, aeSolutions successfully delivered the client’s FEL3 and Detail Design goals. As part of the FEL3 project, aeSolutions collaborated with the client to establish an estimate basis. This helped ensure the accuracy of the total installed cost estimate, with the project coming in slightly under the estimated value. The success and quality of this project’s outcome serves as an example of aeSolutions’ unrivaled capabilities as a comprehensive lifecycle solutions provider within the industry. Challenge This complex project posed numerous challenges during the Front-End Loading (FEL) phase for the client’s newly acquired agricultural chemical production facility. The legacy facility did not meet the client’s corporate process safety standards, nor was it PSM OSHA 1910.119 compliant. aeSolutions was tasked with providing Front End Loading (FEL) level III engineering design services for the Process Control Technology (PCT) discipline. Basic design for Phase 1 at the legacy facility was to cover a kiln, a hydro clarifier, a waste heat boiler, and multiple coal mills. The final challenge was developing an accurate total installed cost estimate that the client then used to secure funding. Solution • By implementing processes and project sponsorship to promote efficient communication between the client’s remote stakeholders and the management team of the legacy facility, aeSolutions was able to foster an environment that proved to be essential in meeting the client’s goals of achieving PSM OSHA 1910.119 compliance within their schedule. • aeSolutions successfully provided cross-discipline deliverables within the client’s timeline, while accommodating several scope revisions from the client. • aeSolutions’ recognition of the importance of not only being aware of a project’s information but having the experience to also know where the information needs to flow helped facilitate the overall success of the project. • By utilizing aeSolutions’ team of experienced subject matter experts across multiple disciplines, we were able to provide the level of knowledge, understanding, competency, and dedication required to meet the client’s strict requirements. • By educating the client’s operations team about the rationale of actions throughout the project, aeSolutions helped to facilitate better alignment between the client’s corporate/capital project team and the facility operations team. • Through the meticulous attention to detail and quality of services provided, aeSolutions’ was able to bring a highly hazardous chemical production facility into PSM OSHA 1910.119 compliance. - aeSolutions worked closely with the client to establish a comprehensive and accurate total installed cost estimate for the project. • The accuracy of aeSolutions’ estimate meant that the client did not have to request supplemental funding, that no change orders were required, and that the project was ultimately completed slightly under the total installed cost budget. • Adherence to the client’s aggressive timeline relied on the versatility of aeSolutions to integrate with the client’s newly implemented document control system. This adaptability proved to be an integral part of aeSolutions’ ability to complete the project roughly two months ahead of schedule — relative to other groups that were working in parallel. • In the face of the complexities and evolving requirements of this project, aeSolutions was able to deliver FEL3 and the Detailed Design results that the client was thrilled with. • aeSolutions’ assignment of appropriate resources based on alignment with the requirements of the project’s complexity and risks — contributed to the high productivity rate realized during this project. Results This project’s successful execution serves as a textbook example of the results clients hope for. From the initial development of front-end loading (FEL3), a highly accurate total installed cost estimate, and Detail Design deliverables, every aspect of our contribution to this project helped bring the client’s legacy facility into compliance with PSM OSHA 1910.119 regulations as well as the client’s own corporate safety standards. The aeSolutions multi-disciplinary team and their ability to adapt to the client’s evolving needs played a pivotal role in achieving the project’s success. By integrating seamlessly with the client’s document control system and maintaining strict adherence to safety and regulatory requirements, aeSolutions delivered results that represented an — according to the client — excellent quality of deliverables. Industry: Hazardous Agricultural Chemical Production Geography: West Unit Operation: Front End Loading Level III (FEL3), Detail Design Previous Story Next Story

PSM is an acronym for Process Safety Management (PSM), a system that helps prevent/reduce risk of hazardous chemical releases Acronyms & Terms Glossary <- More Definitions What is PSM PSM is an acronym for Process Safety Management (PSM), a system that helps prevent/reduce risk of hazardous chemical releases Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.

A structured approach used to identify potential human failure events and to systematically estimate the probability of those events using data, models, or expert judgment. Human Factor Analyses provide qualitative insight to the human factors issues related to the error, and also provide a more accurate quantitative assessment than is found in standard LOPA tables for human performance credits. The ability to model conditional dependence among operator tasks, as well as model potential human recovery factors from errors, makes the HRA a valuable tool. For a typical HRA, a standard operating procedure (SOP) is broken down into discrete tasks. Interviews with Operations are conducted, known as a ""talk-through,"" as well as a plant ""walk-through"" which covers the equipment of concern from the SOP. PSFs (Performance Shaping Factors) related to each task are discovered. Dependencies among tasks are estimated. Each of these will influence the HEP (Human Error Probability) for each task. Each task is to be modelled as a success or failure. An HRA Event Tree is constructed, each identified task being a branch in the tree, and then solved; the output of which is typically an input to a QRA. aeSolutions has the Human Factors Reliability Experts to handle this task. Acronyms & Terms Glossary <- More Definitions Human Reliability Analysis (HRA) A structured approach used to identify potential human failure events and to systematically estimate the probability of those events using data, models, or expert judgment. Human Factor Analyses provide qualitative insight to the human factors issues related to the error, and also provide a more accurate quantitative assessment than is found in standard LOPA tables for human performance credits. The ability to model conditional dependence among operator tasks, as well as model potential human recovery factors from errors, makes the HRA a valuable tool. For a typical HRA, a standard operating procedure (SOP) is broken down into discrete tasks. Interviews with Operations are conducted, known as a ""talk-through,"" as well as a plant ""walk-through"" which covers the equipment of concern from the SOP. PSFs (Performance Shaping Factors) related to each task are discovered. Dependencies among tasks are estimated. Each of these will influence the HEP (Human Error Probability) for each task. Each task is to be modelled as a success or failure. An HRA Event Tree is constructed, each identified task being a branch in the tree, and then solved; the output of which is typically an input to a QRA. aeSolutions has the Human Factors Reliability Experts to handle this task. Our Services Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals As the process industries experience the “great shift change,” developing the next generation of leaders requires more than technical competence. It demands ethical courage and the ability to influence others to uphold process safety under pressure. This paper explores how ethical decision-making and leadership behaviors can be intentionally developed through structured case-based learning derived from real engineering failures. aeSolutions Recognized with 2026 CSIA Social Responsibility Award aeSolutions is proud to share that we were recognized with the 2026 Social Responsibility Award at the 2026 CSIA Awards, held during the Control System Integrators Association Conference in Baltimore, Maryland. 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.