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

A 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: 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.

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. Challenge A global manufacturer of agricultural chemicals stores 30,000 tons of anhydrous ammonia on-site in two large storage tanks. A large leak from one of these tanks would be hazardous and potentially fatal to on-site personnel and to the public in the surrounding areas. The client needed the ability to detect and alert personnel of leaks and allow operators to contain the resulting vapor cloud from a safe remote location. Solution After a thorough corporate safety review of the pressurized ammonia storage facility, aeSolutions provided an innovative safety shutdown and suppression system utilizing water cannons capable of manual or automatic operation from the safety system. Fourteen 2000 GPM water cannons capable of knocking the ammonia cloud to the ground and neutralizing its caustic characteristics were integrated, giving control room operators control over each cannon: • 340 Degree rotational movement • Vertical movement • Nozzle pattern control from fog to stream • Water flow control Results The client now has an effective means of monitoring and controlling an accidental release of ammonia and minimizing the impact to personnel, the public, and to the environment. aeSolutions increased the safety by providing leak detection and notification, equipment isolation, and large-scale leak dispersion containment through perimeter water cannons. Learn more about how aeSolutions could help you with a similar gas detection project. Industry: Agricultural Chemicals Geography: Southeast US Unit Operation: Beam type gas detectors, point type gas detectors, product isolation valves, and electronically operated water cannons Governing: FM Approvals Previous Story Next Story

Connecting to the Process Electrical and Instrumentation Design Connecting to the Process aeSolutions provides CAD and engineering services for instrumentation, field devices, and electrical equipment including layout, installation, wiring, junction boxes, and cable runs. • Instrument data sheets • Installation details and connection diagrams • Junction box layout and interconnections • Location and arrangement drawings • Loop sheets and field wiring • Intrinsic safety analysis and barriers • Field bus and device wiring • Cabling, conduit, tray routing and fill • Grounding and shielding • Conductor sizing, voltage drop calculations • Lighting, power plans, panel schedules • Single-line diagrams, motor elementaries, MCC views • Demolition drawings Automation Services Previous Next

A Quantitative Risk Assessment is a systematic approach to determining the likelihood and consequences of hazardous events and expressing the results quantitatively as risk to personnel, the site being studied, the overall environment, and/or a company. Risk is a function of consequence and likelihood and aeSolutions has the experience and tools to evaluate both for a QRA. A QRA is a specialized approach to assess high consequence LOPA scenarios with large risk gaps to close. Further "pencil-sharpening" in the QRA will verify the severity of the scenario through consequence modeling, as well as the frequency of the scenario through fault tree modelling. Often conservative assumptions made in LOPA are revealed in QRA, which makes the solution to gap closure more practical. QRA will handle conditional dependence among IPL(s) and the initiating cause(s). aeSolutions utilizes commercially available software tools, along with in-house expertise, to facilitate QRAs. For example we can use the PHAST and SAFETI software to model chemical releases in evaluating consequences of an incident. QRA can be a valuable decision support tool when evaluating complex hazard scenarios. Acronyms & Terms Glossary <- More Definitions Quantitative Risk Assessment (QRA) A Quantitative Risk Assessment is a systematic approach to determining the likelihood and consequences of hazardous events and expressing the results quantitatively as risk to personnel, the site being studied, the overall environment, and/or a company. Risk is a function of consequence and likelihood and aeSolutions has the experience and tools to evaluate both for a QRA. A QRA is a specialized approach to assess high consequence LOPA scenarios with large risk gaps to close. Further "pencil-sharpening" in the QRA will verify the severity of the scenario through consequence modeling, as well as the frequency of the scenario through fault tree modelling. Often conservative assumptions made in LOPA are revealed in QRA, which makes the solution to gap closure more practical. QRA will handle conditional dependence among IPL(s) and the initiating cause(s). aeSolutions utilizes commercially available software tools, along with in-house expertise, to facilitate QRAs. For example we can use the PHAST and SAFETI software to model chemical releases in evaluating consequences of an incident. QRA can be a valuable decision support tool when evaluating complex hazard scenarios. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

API 556 is a recommended practice developed by the American Petroleum Institute for use of instrument, control and protective system installations for gas fired heaters in petroleum production, refineries, petrochemical and chemical plants. It offers information and descriptions of burner types available to the designer/user for purposes of selecting the appropriate burner for a given application. Acronyms & Terms Glossary <- More Definitions API 556 API 556 is a recommended practice developed by the American Petroleum Institute for use of instrument, control and protective system installations for gas fired heaters in petroleum production, refineries, petrochemical and chemical plants. It offers information and descriptions of burner types available to the designer/user for purposes of selecting the appropriate burner for a given application. 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.

Enlisting More Variables Advanced Regulatory Control - ARC Enlisting More Variables aeSolutions process control specialists solve problems with Advanced Regulatory Control (ARC) when single variable PID control is not adequate. Cascade, feed forward, ratio, Smith predictor, and override controls are standard methods to include an additional process variable in PID loops to compensate for process dead time, or non-linearity. Multivariable and model-based controls are employed for more complex process automation challenges encountered in chemical plants and refineries. aeSolutions helps the client's process engineers take advantage of the multivariable control capabilities found in the latest generation of DCS systems. These offer real time performance with multivariable models available at the controller's function library level. Automation Services Previous Next

Control system that monitors the concentration of combustible gases and initiates alarm and shutdown functions at predetermined concentrations. aeSolutions' Fire and Gas team can support gas detection systems from conceptual design through field installation. This includes developing a Fire and Gas philosophy, technology selection, ensuring an appropriately sized system, and fire and gas mapping using the Geographic coverage approach and/or Computational Fluid Dynamics (CFD) scenario-based modeling to determine gas detector placement. Acronyms & Terms Glossary <- More Definitions Gas Detection System Control system that monitors the concentration of combustible gases and initiates alarm and shutdown functions at predetermined concentrations. aeSolutions' Fire and Gas team can support gas detection systems from conceptual design through field installation. This includes developing a Fire and Gas philosophy, technology selection, ensuring an appropriately sized system, and fire and gas mapping using the Geographic coverage approach and/or Computational Fluid Dynamics (CFD) scenario-based modeling to determine gas detector placement. 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.

AAn organization established by AIChE in 1985 to serve as a focus for a continuing program for process safety. CCPS has published many guidelines that have a practical application within industry to improve industrial process safety. Topics range from human factor issues to qualitative and quantitative risk analysis to security vulnerability to interently safe design. Acronyms & Terms Glossary <- More Definitions Center for Chemical Process Safety (CCPS) AAn organization established by AIChE in 1985 to serve as a focus for a continuing program for process safety. CCPS has published many guidelines that have a practical application within industry to improve industrial process safety. Topics range from human factor issues to qualitative and quantitative risk analysis to security vulnerability to interently safe design. 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.

Process Hazard Analysis (PHA) is a process for analyzing hazards with hazardous chemicals. The goal is to recognize potential causes and evaluate the consequences of hazardous chemical releases. PHA studies are the core of process safety and risk management programs. They help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. PHA also is required by OSHA's PSM (29 CFR 1910.119) and EPA's RMP (40 CFR 68) regulations in the US and process safety and risk management regulations around the world. Types of PHAs include: - Hazard and Operability (HAZOP) - What if - What-If/Checklist Analysis - Failure Modes and Effects Analysis (FMEA) - Dust Hazard Assessment - Control System Hazard and Operability (CHAZOP) Acronyms & Terms Glossary <- More Definitions PHA Process Hazard Analysis (PHA) is a process for analyzing hazards with hazardous chemicals. The goal is to recognize potential causes and evaluate the consequences of hazardous chemical releases. PHA studies are the core of process safety and risk management programs. They help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. PHA also is required by OSHA's PSM (29 CFR 1910.119) and EPA's RMP (40 CFR 68) regulations in the US and process safety and risk management regulations around the world. Types of PHAs include: - Hazard and Operability (HAZOP) - What if - What-If/Checklist Analysis - Failure Modes and Effects Analysis (FMEA) - Dust Hazard Assessment - Control System Hazard and Operability (CHAZOP) 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.

Simultaneous occurrence of two or more independent, revealed (overt) failures in a system. Double jeopardy is considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Acronyms & Terms Glossary <- More Definitions Double Jeopardy Simultaneous occurrence of two or more independent, revealed (overt) failures in a system. Double jeopardy is considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

A system that responds to input signals from the equipment under control and/or from an operator and generates output signals that cause the equipment under control to operate in the desired manner. It gathers process data, generates alarms, and provides a structured view of a facility system with the capability to control the operation. aeSolutions helps the client's process engineers take advantage of the multivariable control capabilities found in the latest generation of DCS systems. These offer real time performance with multivariable models available at the controller's function library level. Acronyms & Terms Glossary <- More Definitions Distributed Control System (DCS) A system that responds to input signals from the equipment under control and/or from an operator and generates output signals that cause the equipment under control to operate in the desired manner. It gathers process data, generates alarms, and provides a structured view of a facility system with the capability to control the operation. aeSolutions helps the client's process engineers take advantage of the multivariable control capabilities found in the latest generation of DCS systems. These offer real time performance with multivariable models available at the controller's function library level. 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.