series , FSA Stage 2 is a critical checkpoint after design and engineering of the Safety Instrumented System This involves evaluating the SIS logic solver(s), input/output (I/O) modules, communication system(s) , control panel(s), and other critical components, including field instrumentation, to ensure they meet Factory Acceptance Testing (FAT) , where the SIS logic solver(s) hardware and software are tested in a controlled In reality, they are complementary processes that work together to ensure system reliability.

September 2024 — The primary goal of an FSA Stage 3 is to verify that the installed safety instrumented system Stages 1 through 3 of an FSA cover the Safety Instrumented System  (SIS) from its inception through design These stages are essential for the implementation of a new or modified safety system. and understand its impact on process control. ●      Procedure Verification : Ensure that operating For instance, sensors must accurately detect process parameters, and actuators and final control elements

by Brittany Lampson, PhD & aeSolutions Technical Team Implementing a Safety Instrumented Burner Management (SI‐BMS) can be challenging, costly, and time consuming. Simply identifying design shortfalls/gaps can be costly, and this does not include costs associated with the capital project to target the gap closure effort itself. Additionally, when one multiplies the costs by the total number of heaters at different sites, these total costs can escalate quickly. However, a “template” approach to implementing SI‐BMS in a brownfield environment can offer a very cost effective solution for end users. Creating standard “templates” for all deliverables associated with a SI‐BMS will allow each subsequent SI‐BMS to be implemented at a fraction of the cost of the first. This is because a template approach minimizes rework associated with creating a new SIBMS package. The ultimate goal is to standardize implementation of SI‐BMS in order to reduce engineering effort, create standard products, and ultimately reduce cost of ownership. Click here to view the complete whitepaper What is a BMS? What is Safety Instrumented Function (SIF) What is Function Safety?

initially apply the concepts of the Safety Lifecycle per ANSI / ISA S84.01 to the design of a Life Safety System In addition, industry specific issues associated with the design of Life Safety Systems and the use of Topics include: ANSI / ISA S84.01, Safety Instrumented Systems, Safety Instrumented Functions, Safety Integrity Levels, Life Safety Systems IDENTIFYING REQUIRED SAFETY INSTRUMENTED FUNCTIONS FOR LIFE SAFETY SYSTEMS IN THE HIGH-TECH AND SEMICONDUCTOR MANUFACTURING INDUSTRIES Click here to view the complete

by Melissa Langsdon Senior Principal Specialist In the Clean Air Act Amendments of 1990, Congress required the Occupational, Safety and Health Administration (OSHA) to adopt the Process Safety Management (PSM) standard to protect workers and required the Environmental Protection Agency (EPA) to protect the community and environment by issuing the Risk Management Plan Rule (RMP). PSM and RMP were written to complement each other in accomplishing these Congressional goals. Both the PSM regulation in 29 CFR 1910.119 and the RMP Rule codified in 40 CFR Part 68 are critical aspects of industrial operations, aimed at protecting employees, facilities and communities from potential hazards associated with highly hazardous chemicals and regulated substances, respectively. To ensure adherence to regulatory standards, companies often seek the expertise of PSM/RMP consultants. In this blog post, we will delve into the role of process safety consultants and explore how they assist clients in understanding their compliance gaps, implementing effective safety programs, and continuously reducing risks. Understanding the Need for PSM Consultants PSM/RMP Program Development and Implementation can be overwhelming. In addition, many organizations require additional resources to support existing process safety programs due to a lack of dedicated resources or spending cutbacks. This is where PSM/RMP consultants come in. Their primary goal is to help clients bridge the gap between their existing safety programs and the requirements mandated by regulatory bodies such as OSHA and EPA with regard to process safety. Compliance and Beyond PSM/RMP consultants cater to a wide range of clients with varying objectives. Some clients approach consultants solely to ensure regulatory compliance by meeting the minimum requirements of regulations. Others seek to exceed regulatory requirements and proactively enhance their safety programs. Additionally, there are companies that are entirely new to the regulatory landscape, requiring guidance on implementing PSM/RMP programs for the first time. In some cases, regulatory requirements may even mandate the involvement of third-party auditors. It is worth noting that future changes in regulations may further emphasize the use of third-party auditors. The Dual Perspective of OSHA and EPA OSHA and EPA approach process safety from different angles. OSHA focuses on mitigating workplace-related risks and injuries from highly hazardous chemicals. On the other hand, EPA addresses regulated substances and emphasizes community safety and the prevention of offsite impacts. Process safety consultants possess expertise in both perspectives, ensuring comprehensive safety measures that protect both employees and the community. The Importance of Fresh Perspectives Having an external consultant with a fresh set of eyes is invaluable in identifying potential non-compliance issues and process gaps. Long-standing internal employees may inadvertently overlook certain aspects of the site’s safety program, leading to compliance risks. By bringing in a different viewpoint, process safety consultants can help identify and rectify such issues, ensuring a more robust and effective safety program. Real-Life Implications Real-world incidents, such as the West Texas Fertilizer incident in 2013, have highlighted the need for continuous improvement in process safety. OSHA and EPA have pushed for regulatory changes as a result of these incidents. PSM/RMP consultants play a crucial role in helping facilities reduce their risk of chemical releases, thereby improving workplace and community safety, environmental contamination, and other onsite and offsite impacts. The Capabilities of PSM/RMP Consultants PSM/RMP consultants offer a range of services to assist organizations in enhancing their process safety programs. These include: Process Hazard Analysis (PHA) Facilitation: PSM/RMP consultants facilitate PHA sessions, which are used to identify potential hazards and develop risk reduction strategies. Overall Process Safety Program Development: PSM/RMP consultants assist in the development of comprehensive process safety programs, including management procedures, operating procedure development, and mechanical integrity procedure development. PSM/RMP Compliance Audits: PSM/RMP consultants conduct regulatory required 3-year audits to assess the compliance and effectiveness of PSM and RMP programs, identifying areas for improvement. Training: PSM/RMP consultants provide management-level training and internal training to equip employees with the necessary skills to facilitate PHA sessions and conduct internal audits. Risk Assessment: PSM/RMP consultants perform different types of Risk Assessments including Quantitative Risk Assessments (QRA), Safety Case Development, Layer of Protection Analysis (LOPA), and Alarm Rationalization. EPA Risk Management Plans: PSM/RMP consultants prepare initial and 5-year resubmission of EPA required Risk Management Plans, along with the Hazard Assessment for the development of Worst Case Release and Alternative Case Release Scenarios (WCRS and ACRS). As a supplier of complete process safety and risk management solution consultants, aeSolutions is proud to provide engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities. Their knowledge supports a practical approach to risk reduction solutions for PSM and RMP compliance.

“The FGS 5000 can be used as a standalone system or as an upgrade to legacy fire and gas systems. By using the same hardware/software platform as Rockwell Automation’s Basic Process Control System (BPCS ), the FGS 5000 can be integrated seamlessly into a facility’s existing control architecture with common 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

is excited to announce the release of aeAlarm, a proprietary alarm rationalization tool. aeAlarm is control system platform-agnostic and is adaptable across all industrial sectors. 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.

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Update Provides a Migration Path for Existing FGS 1400 Installations Greenville, SC – October 10th, 2022 As the update is rolled out, aeSolutions can supply migration fabrication kits that will enable end users to easily migrate to the ET 200SP HA I/O cards. “When spare parts are no longer available, this important update to the FGS 1400 MK II provides a migration and safeguarding, safety instrumented systems, control system design and integration, alarm management

OSHA contended that the boiler was interconnected to a covered process throug h the refinery fuel gas system Often the default for the Burner Management System (BMS) is the application of NFPA. incorporates the appropriate application-based safety integrity level (SIL) for safety instrumented systems conclusion: PSM covered facilities should evaluate the applicability of their PSM and NFPA management systems , Fired Equipment, Safety Instrumented Systems, ISA/IEC 61511 , NPFA 85, NFPA 86, NFPA 87, ISA 84,

The analysis of existing gas detection systems has shown that the primary limiting factor in the effectiveness of a system is incorrect detector placement. This factor alone outweighs the probability of failure on demand of the individual system components Incorrect detector placement can be so detrimental that the system cannot even be credited as an effective What is the effectiveness of the mitigation system?

The system supports both local and remote I/O. horns, lights, text displays), fire safety functions (designed to increase the level of life safety or control A proprietary fire command / supervisory station allows an operator to view and control multiple systems System configuration is limited to authorized users with password access. The system incorporates many cybersecurity features.