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

Systematic failures are repeatable, deterministic, non-random failures and can be caused by failure in following standards and best practices. They are typically removed by fixing the design/process, Acronyms & Terms Glossary <- More Definitions Systematic Failures Systematic failures are repeatable, deterministic, non-random failures and can be caused by failure in following standards and best practices. They are typically removed by fixing the design/process, Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

A systematic assessment to identify hazards associated with the plant, system, operation, design, and maintenance. Acronyms & Terms Glossary <- More Definitions Hazard Identification (HAZID) A systematic assessment to identify hazards associated with the plant, system, operation, design, and maintenance. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

Software and hardware that allows human operators to monitor the state of a process under control, modify control settings to change the control objective, and manually override automatic control operations in the event of an emergency. The HMI also allows a control engineer or operator to configure set points or control algorithms and parameters in the controller. The HMI also displays process status information, historical information, reports, and other information to operators, administrators, managers, business partners, and other authorized users. Operators and engineers use HMIs to monitor and configure set points, control algorithms, send commands, and adjust and establish parameters in the controller. 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. aeSolutions also develops alarm management philosophies which include HMI design guidance; a facility's various alarms and alert states are properly managed and prioritized to help operators maintain situational awareness. Acronyms & Terms Glossary <- More Definitions Human Machine Interface (HMI) Software and hardware that allows human operators to monitor the state of a process under control, modify control settings to change the control objective, and manually override automatic control operations in the event of an emergency. The HMI also allows a control engineer or operator to configure set points or control algorithms and parameters in the controller. The HMI also displays process status information, historical information, reports, and other information to operators, administrators, managers, business partners, and other authorized users. Operators and engineers use HMIs to monitor and configure set points, control algorithms, send commands, and adjust and establish parameters in the controller. 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. aeSolutions also develops alarm management philosophies which include HMI design guidance; a facility's various alarms and alert states are properly managed and prioritized to help operators maintain situational awareness. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

Intrinsic Safety is an equipment design approach that reduces the available energy to a level where it is too low to cause ignition. This is done for equipment that will be placed in particularly hazardous areas for the purpose to keep all temperatures low and to prevent sparks that could cause fires or explosions. Acronyms & Terms Glossary <- More Definitions Intrinsic Safety (IS) Intrinsic Safety is an equipment design approach that reduces the available energy to a level where it is too low to cause ignition. This is done for equipment that will be placed in particularly hazardous areas for the purpose to keep all temperatures low and to prevent sparks that could cause fires or explosions. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

A suggested course of action intended to prevent the occurrence (or recurrence) of an acident event sequence, or to mitigate its consequences. Acronyms & Terms Glossary <- More Definitions Recommendation A suggested course of action intended to prevent the occurrence (or recurrence) of an acident event sequence, or to mitigate its consequences. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

A calibration curve is a graph of the relationship between instrument readings and true values, used to adjust instruments such that the readings are closer to the true values. Acronyms & Terms Glossary <- More Definitions Calibration Curve A calibration curve is a graph of the relationship between instrument readings and true values, used to adjust instruments such that the readings are closer to the true values. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

An Emergency Shutdown System (ESD) is a safety system designed to rapidly shut down processes or equipment in response to unsafe conditions, such as a gas leak or fire. ESD systems are crucial for preventing accidents, limiting damage, and protecting personnel. Acronyms & Terms Glossary <- More Definitions Emergency Shutdown System (ESD) An Emergency Shutdown System (ESD) is a safety system designed to rapidly shut down processes or equipment in response to unsafe conditions, such as a gas leak or fire. ESD systems are crucial for preventing accidents, limiting damage, and protecting personnel. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

Process safety safeguards implemented with instrumentation and controls, used to achieve or maintain a safe state for a process, and required to provide risk reduction with respect to a specific hazardous event. These are sometimes called safety critical devices or critical safety devices. Acronyms & Terms Glossary <- More Definitions Safety Controls, Alarms, and Interlocks (SCAI) Process safety safeguards implemented with instrumentation and controls, used to achieve or maintain a safe state for a process, and required to provide risk reduction with respect to a specific hazardous event. These are sometimes called safety critical devices or critical safety devices. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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

Converting Concept to Design Basis Preliminary Engineering Converting Concept to Design Basis aeSolutions works with clients to form preliminary engineering documentation based on the conceptual design and assists clients in choosing an appropriate control system vendor. Client review and approval cycles assure the quality of the functional requirements specification. • Instrument data sheets • Functional requirements specification • Instrument list and I/O count • Operating ranges, alarm and trip setpoints • Plant drawings (P&I, I&E, Loop, LAN, Arrangement) • Preliminary project architecture and migration drawings • Vendor platform evaluations • Bills of Material - hardware and software • Project cost and schedule estimates +/- 10% Automation Services Previous Next

Alerting Appropriate Action With aeSolutions' Alarm Management Systems Alarm Management Systems - Automation Application Alerting Appropriate Action With aeSolutions' Alarm Management Systems aeSolutions provides services and systems to bring the client's alarm management practices into compliance with the standards that are now required for hazardous processes. Poor alarm management has been a critical factor in major process safety incidents. The new requirements address the effectiveness of alarms and the ability of operating personnel to respond promptly and correctly. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. • IEC 62682, ISA 18.2, EEMUA 191 • Alarm management training seminars • Alarm philosophy document • Alarm Master Data Base • Alarm rationalization, classification, prioritization • Alarm suppression and shelving logic • Alarm summaries, journals, hit lists • Alarm audible / visual annunciation Automation Services Previous Next

API 535 is a recommended practice developed by the American Petroleum Institute for the selection and/or evaluation of burners installed in fired heaters in general refinery services. Acronyms & Terms Glossary <- More Definitions API 535 API 535 is a recommended practice developed by the American Petroleum Institute for the selection and/or evaluation of burners installed in fired heaters in general refinery services. Our Services The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Scheduling and operational disruptions are among the most common barriers to closing PHA recommendations. When safety improvements require outages or process changes, timing becomes the challenge. This article explores how facilities can plan ahead, manage risk, and turn scheduling constraints into long-term operational resilience. Understanding UL 508A Certified Control Panels | Enabling Safer, More Resilient Industrial Facilities UL 508A certified control panels give industrial facilities a clear path to safer, code-compliant operation. This article explains what the standard covers, how SCCR is established, what changed in 2025, and why working with a certified panel shop helps reduce risk, streamline inspections, and support long-term maintainability. 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