A control valve is a device used to regulate the flow, pressure, or temperature of a fluid within a system by varying the size of the flow passage. Control valves are key components in process control systems, enabling precise control over process variables. Acronyms & Terms Glossary <- More Definitions Control Valve A control valve is a device used to regulate the flow, pressure, or temperature of a fluid within a system by varying the size of the flow passage. Control valves are key components in process control systems, enabling precise control over process variables. 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.

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.

Mean Time To Repair (MTTR) is the average time required to repair a failed system or component and restore it to operational status. MTTR is a key metric in maintenance management, reflecting the efficiency of repair processes. Acronyms & Terms Glossary <- More Definitions Mean Time To Repair (MTTR) Mean Time To Repair (MTTR) is the average time required to repair a failed system or component and restore it to operational status. MTTR is a key metric in maintenance management, reflecting the efficiency of repair processes. 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.

Our professional staff ranges from recent college graduates to professional engineers with our more experienced professionals mentoring our newer staff. Many members of our team are industry leaders, serving in leadership positions on key industry committees. Our principals and employees have active The Leadership Team Ken O'Malley Founder & Chief Executive Officer (CEO) Joel Read Chief Financial Officer (CFO) Chris Neff Chief Operating Officer (COO) Ben Krisher Human Resources Director Roland Stock Vice President of Projects Chris Powell Director of Engineering Sarah Manelick Director of Sales & Marketing Our professional staff ranges from recent college graduates to professional engineers with our more experienced professionals mentoring our newer staff. Many members of our team are industry leaders, serving in leadership positions on key industry committees. Our employees actively participate in the development of industry codes and standard practices for engineering and implementation of control and safety-related system solutions. Our clients trust the aeSolutions team to deliver consulting and engineering expertise for smarter, more resilient industrial operations and safer communities.

Learn how aeSolutions was able to help our clients overcome their unique and challenging difficulties. Also see the Industry, Geography, Unit Operation, Governing Autority of the site Project Success Stories Learn how aeSolutions was able to help our clients overcome their challenges. Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility A critical pipeline transportation facility required a custom Safety Instrumented Burner Management System (SI-BMS) upgrade for their incinerator operations. The project involved implementing a SI-BMS compliant with NFPA 86, integrating alarm and first-out features, and establishing seamless communication with their existing Distributed Control System (DCS)... Read More Achieving a High-Risk Systems Overhaul on an Accelerated Schedule When TGES America, Ltd. needed a critical overhaul of the complex control system and instrumentation for the central utilities plant (CUP) of a specialty materials manufacturing plant, they turned to aeSolutions, a Siemens Solution Partner. Subsequently, due to the need to complete the project four months early, the planned cold cutover to the new systems had to be done as a hot cutover without disrupting production. TGES America, aeSolutions, and Siemens made it happen, much to the delight of the customer. Read More 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. Read More Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities aeSolutions was tasked to provide Front-End Loading (FEL) and Detail Design for a newly acquired legacy agricultural chemical facility in order to meet full compliance with PSM OSHA 1910.119 standards and the client’s corporate safety requirements. Read More Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant aeSolutions was challenged to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Read More A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Implementing Safety Instrumented Systems (SIS) and Burner Management Systems (BMS) within tight deadlines and supply chain disruptions is challenging. A recent project converting boiler fuel from coal to natural gas with a Safety Instrumented BMS met strict safety standards despite these hurdles. Read More Alarm Management for a Greenfield LNG Facility A Liquefied Natural Gas (LNG) facility was being newly constructed (i.e., Greenfield) and the company wanted to conduct an alarm rationalization on the process prior to initial startup. Existing facilities (i.e., Brownfield) have the benefit of historical operating trends and data during a rationalization session to recognize whether setpoints are effective and which alarms might give troubles. Read More Pharma Company Detecting Natural Gas Leaks in Boiler House A pharmaceutical client determined they needed a natural gas leak detection and isolation system for a utility building based on a PHA recommendation. aeSolutions installed a combustible gas leak detection system to shut off the gas supply to the boiler, bringing the facility into compliance with the safety program requirements. Read More Large Specialty Chemical Company Reduces Alarm Floods A large specialty chemical company was facing alarm floods in their utility unit. With aeSolutions guidance, the site was able to effectively prioritize and reduce alarms through the rationalization process, which includes reviewing, validating, and justifying alarms needed for avoiding potential process upsets or abnormal deviations from normal operation. Read More Simplified, Cost-Effective, and Consistent Acidic Compound Detection New acid detector placement philosophy led to reduced maintenance , lowered costs, a reduced the likelihood of confusion during leaks, and helped create a uniform response strategy. Read More Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million A client was facing a lengthy compliance process to upgrade a fleet of fired heaters. With aeSolutions guidance, the client reduced their compliance scope by 50%. Focusing on the NFPA 86 prescriptive design applicable to waste gas thermal oxidizers and applying our experience in Process Safety Management (PSM)... Read More Water Cannons Protect Community from Anhydrous Ammonia Leaks Client needed to reduce liability and risk associated with anhydrous ammonia storage tanks. aeSolutions provided a leak detection and suppression system that alerts personnel and provides the means to contain the resulting vapor cloud to the storage tank area using high-pressure, high-volume water cannons integrated with the control system. Read More Pharmaceutical Company Required Toxic & Combustible Gas Detection System A large-scale pharmaceutical manufacturing facility needed to develop and implement a gas detection system at their site to mitigate risk to personnel and equipment from a potential combustible or toxic gas leak. The project progressed from the assessment stages of developing a gas detection philosophy to ultimately integrating an industrially designed GDS 1400 MK II panel for the gas detection control and alarm system. Read More Complex Hot Cutover of Large Natural Gas Processing Facilities Due to facility siting factors, control rooms of one of the world’s largest natural gas (NG) processing and compression facilities were relocated from a possible blast zone to a Blast Resistant Modules (BRMs). This complex cutover for personnel relocation needed to be accomplished without a shutdown (S/D) of either interdependent ... Read More Specialty Chemical Site’s Increasingly Complicated Cutover When a project that began with standard safety system upgrades quickly expanded to a much broader scope of engineering with tight deadlines, aeSolutions responded with an experienced engineering workforce to deliver above-quality expectations while meeting key deadlines. Read More “Fit for Purpose” Solution Reduces Planned Downtime by 66% aeSolutions’ hybrid safety system design enabled the client to maintain safe continuity of their fired equipment, meet NFPA compliance, and significantly lower planned downtime. Read More Protecting Personnel with Practical Gas Detector Placement A pharmaceutical company needed to implement gas detectors at their facility to protect personnel from potential leaks of toxic and combustible gases. aeSolutions evaluated the gas detector placement and number of detectors that would provide the earliest warning to personnel based on the expected dispersion and behavior of specific gas release scenarios. Read More Alarm System Rationalization and Safe Operating Limit for Energy Production A current client was adding a new energy production unit with an innovative process to an existing site and wanted to ensure the new design incorporated the site’s existing alarm management practices that were previously set up by the aeSolutions alarm management team. Read More