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NFPA 86 is the standard from the National Fire Protection Association that provides guidance for the minimization of fire and explosion hazards in ovens and furnaces used for the commercial and industrial processing of materials. This code provides structural, service, heating, and cooling design guidelines for these ovens and furnaces. Acronyms & Terms Glossary <- More Definitions NFPA 86 NFPA 86 is the standard from the National Fire Protection Association that provides guidance for the minimization of fire and explosion hazards in ovens and furnaces used for the commercial and industrial processing of materials. This code provides structural, service, heating, and cooling design guidelines for these ovens and furnaces. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant In the rapidly expanding field of hydrogen production and storage, safety is paramount. aeSolutions was presented with the complex challenge of designing and installing a fire & gas (F&G) detection system for a greenfield hydrogen production plant. This case study explores how aeSolutions overcame the unique hazards associated with hydrogen to create a robust and efficient detection system, ensuring the protection of both personnel and assets. Through a combination of advanced modeling techniques and strategic detector placements, aeSolutions delivered a solution that not only met safety requirements but also optimized system performance and cost-efficiency. Challenge aeSolutions was tasked with designing and installing a Fire & Gas (F&G) detection system for a new hydrogen production plant, which presented unique challenges due to the flammable nature of hydrogen. The plant included both indoor and outdoor processes, with hydrogen production occurring inside a ventilated building and other processes like filtration, compression, and storage taking place outdoors. The key challenge was to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Solution aeSolutions implemented a multi-step approach to optimize the gas detection system layout. The process began with preliminary geographic placements based on recognized standards and was followed by scenario-based placements using consequence modeling software. When initial models indicated uncertainties regarding potential explosion severity, aeSolutions employed Computational Fluid Dynamics (CFD) modeling to refine detector placements, reducing the number of detectors required while ensuring comprehensive coverage. Additionally, the design included strategic placements of both catalytic bead and ultrasonic gas detectors indoors and outdoors to efficiently detect leaks and mitigate potential hazards. Results The final design resulted in a robust detection system that optimized the placement and number of detectors, ensuring reliable detection of hydrogen leaks with minimal risk of undetected releases. The CFD modeling confirmed that with proper mitigation measures, hydrogen leaks could be controlled, preventing catastrophic explosions. The project concluded with the successful installation of 18 lower explosive limit (LEL) indoor detectors and 7 outdoor detectors, along with additional safety features like ultrasonic detectors and flame detectors. This approach not only enhanced safety but also minimized system costs and maintenance needs, providing a scalable solution for this hydrogen production facility. Learn more about how aeSolutions could help you with a similar project Industry: Hydrogen Geography: Southeast Unit Operation: Hydrogen production including the use of electrolyzers Previous Story Next Story

To use an instrument or component that has not been designed in accordance with IEC 61508, the "proven in use" concept can be applied given that a system for gathering reliability data and ways to assess the recorded data to determine the safety integrity of the system, as well as recorded historical evidence of device hours in use are present. Acronyms & Terms Glossary <- More Definitions Proven in Use To use an instrument or component that has not been designed in accordance with IEC 61508, the "proven in use" concept can be applied given that a system for gathering reliability data and ways to assess the recorded data to determine the safety integrity of the system, as well as recorded historical evidence of device hours in use are present. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

aeSolutions is the Go-To Partner for Our Clients' Tough Challenges - Innovative, Sustainable Sservices to Create Client Value - Professional Project Management to Drive Client Business Results - Consistent Performance and Delivery on Our Commitments from our service - line card of our serivces - Breakdown - clients Services We Offer Automation Conceptual & Preliminary Engineering (FEL/FEED) FD/P&ID Development Control System Platform Evaluation Continuous and Batch Design TIC Estimate Development Instrument and Electrical Design (l&E) Instrument Index, Specs & Installation Details Plan Drawings Controls Electrical - Field Wiring {Loop Sheets, Elementaries, etc.) MCC Specification & Design Cable Schedules Construction SOWs Systems Integration Control Hardware Design Control System Server Virtualization Network Architecture Layout/ Design PLC, DCS, SIS, SCADA Configuration Control Panel Fabrication & Testing Construction Oversight Commissioning/Startup Support Learn More SIS Engineering ISA 61511 Safety Lifecycle Planning Design and Verification Safety Requirement Specification (SRS) Protection Layer Requirements Specification Cause & Effect Diagrams Functional Test Plans Lifecycle Cost Analysis Safety Integrity Level (SIL) Calculations Functional Safety Assessment (FSA) Fault Tree Analysis Event Tree Analysis Reliability Data Analysis Learn More Alarm Management Alarm Philosophy Development Consulting and Facilitation for ISA 18.2: Philosophy Rationalization Operations (Training) Audits Learn More Machinery Safety Compliance with Safety Standards at Manufacturing Sites (OSHA, ANSI, ISO) Risk Assessment State of Conformity Safeguard Specifications Training Learn More Combustion Combustion Control Solutions (CCS) Fuel & Waste Optimization Combustion Optimization Availability/ Reliability Assessments Burner Management Systems (BMS) NFPA/API Code Compliance Screening Surveys Gap Assessments Gap Closur e Options/ Scoping PSM and SIL Rated BMS Risk-Based {PHA/LOPA) Assessments Code Equivalent Design Alternative Design of BMS/CCS AHJ Approval Consulting SIS Engineering Multidiscipline Project Execution Front End Loading "Outside the Box" System Design {l&E) Systems Integration {BMS, CCS) Fuel Trains Construction Scoping/ Management Commissioning/ Startup Support Annual Testing Learn More Process Safety Process Safety Management (PSM) Risk Management Program (RMP) PSM/RMP/RBPS Auditing PHA/HAZOP/LOPA/QRA/CHAZOP Procedural/Extreme Weather/ Abnormal Event PHAs Facility Siting PHAST/CFD Modeling Gas Dispersion Modeling Gas Sensor Mapping Human Reliability Analysis (HRA) Training Process Safety Overview PSM/RMP Auditor PHA/LOPA Facilitator Independent Protection Layer Verification Mechanical Integrity Programs Electrical Area Classification Combustible Dust Hazard Assessments Learn More Fire & Gas NFPA 72 and Life Safety Code Compliance Fire and Gas Panel Design FM Listed Systems FM Approved Large Battery Backup Systems FGS System Construction Package CFO, Dispersion, Gas & Flame Detector Coverage Modeling Gas Detection Philosophy Detector Placement Startup and Commissioning Fire Marshall Package Learn More Why aeSolutions? Trusted Go-To Partner for Our Cli ents' Tough Challenges Innovative, Sustainable Solutions to Create Client Value Professional Project Management to Drive Client Business Results Consistent Performance and Delivery on Our Commitments Recognized Extensively Credentialed Professionals (PE, CFSE, PMP) Active in Leadership of Professional Organizations (ISA, AIChE, CSIA) Involved in Development of International Standards & Industry Best Practices Deep Technical Acumen, Thought Leadership

SIL Verification is the process of confirming that a Safety Instrumented Function (SIF) meets its required Safety Integrity Level (SIL). This involves testing and analysis to ensure that the SIF will perform reliably under specified conditions. Acronyms & Terms Glossary <- More Definitions SIL Verification SIL Verification is the process of confirming that a Safety Instrumented Function (SIF) meets its required Safety Integrity Level (SIL). This involves testing and analysis to ensure that the SIF will perform reliably under specified conditions. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

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). aeSolutions provided an Allen-Bradley control system featuring a GuardLogix controller with POINT Guard Safe I/O, a new Human-Machine Interface (HMI), and extensive on-site support, significantly improving the reliability and safety of the client’s operations. Challenge The client faced numerous challenges with their existing incinerator burner management system. The previous system lacked first-out indications and alarm features, making troubleshooting operational shutdowns time-consuming and inefficient. Additionally, there were challenges in implementing a new BMS. Handling multiple burners and switching fuel sources between fuel oil and waste gas added further complexity to operations. Moreover, integration between the new BMS and existing DCS required extensive on-site testing and validation. The remote geographic location compounded these challenges, requiring extended on-site support due to logistical constraints related to weather and travel. Solution Leveraging dual expertise in safety engineering and control systems integration, aeSolutions implemented a tailored SI-BMS that significantly enhanced operational transparency and control. The new SI-BMS solution provided clear first-out alarms, pinpointing exact causes for shutdowns and drastically reducing troubleshooting time. aeSolutions ensured NFPA 86 compliance and delivered a robust solution capable of managing the complex operational scenarios involving four burners with interchangeable fuel sources. One of the key factors in the success of this project was aeSolutions’ project delivery team, which brought together our risk-focused industry experts and hands-on technical specialists. This enabled real-time responsiveness to client needs during commissioning. Changes to the Safety Requirements Specification (SRS) and system configuration were executed seamlessly, including on-site, in direct response to client feedback and operating conditions. The team’s ability to evaluate safety impacts and implement adjustments quickly, without compromising compliance, demonstrated the strength of integrating safety and controls expertise within one provider. aeSolutions worked closely with the client’s DCS programmer to resolve integration challenges, coordinating communication protocols and aligning system behaviors across platforms. This flexibility not only helped overcome technical hurdles but also ensured that the final system supported the client’s preferred operational practices. Results The client’s operational efficiency, reliability, and resilience substantially improved upon commissioning of the new BMS solution. Operators gained immediate clarity from the introduction of first-out alarms, resulting in quicker resolutions and significantly reduced downtime. The upgraded system consistently achieved reliable startups, eliminating previous issues related to intermittent operational failures. Furthermore, aeSolutions’ flexible and collaborative approach in adjusting and refining system configurations during commissioning directly supported the client’s unique operational needs. This approach not only ensured safety and compliance but also provided tangible time savings, thereby delivering immediate and ongoing value. Following this project’s success, the client has continued to engage aeSolutions for additional critical infrastructure projects, highlighting the sustained value and effectiveness of our tailored solutions. Industry: Oil & Gas Geography: Pacific Northwest Unit Operation: Customized Safety Instrumented Burner Management System (SI-BMS), POINT Guard Safe I/O, Human-Machine Interface (HMI) Previous Story Next Story

Safety cycle is the overall process of maintaining the integrity of a safety system starting with initial analysis and design, continuing through operation and rigorous testing, until final decommission of safety system Acronyms & Terms Glossary <- More Definitions Safety Lifecycle Safety cycle is the overall process of maintaining the integrity of a safety system starting with initial analysis and design, continuing through operation and rigorous testing, until final decommission of safety system Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

Site Acceptance Testing occurs at a client’s site after equipment delivery to verify whether equipment meets the functionality and performance requirements specified by the client. This testing occurs after all equipment commissioning tasks but before installation. This differs from a Factory Acceptance Test (FAT) since it occurs after delivery. AKA: What is a site acceptance test? or What is a sat acceptance test? Acronyms & Terms Glossary <- More Definitions Site Acceptance Testing (SAT) Site Acceptance Testing occurs at a client’s site after equipment delivery to verify whether equipment meets the functionality and performance requirements specified by the client. This testing occurs after all equipment commissioning tasks but before installation. This differs from a Factory Acceptance Test (FAT) since it occurs after delivery. AKA: What is a site acceptance test? or What is a sat acceptance test? Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

The architecture or voting arrangment used in the field instrument or final control element of a safety instrumented system (SIS) to reach a certain safety integrity level (SIL). Voting logics include one-out-of-one (1oo1), 1oo2, 2oo2, 2oo3, etc. For example, a 2oo2 voting logic indicates there are two protective devices/instruments in a system and both devices (two-out-of-two) are needed to properly shut down the system or mitigate the hazard. 1oo2 indicates that only one of the devices would be required to properly prevent the situation from occurring. Acronyms & Terms Glossary <- More Definitions Voting Logic The architecture or voting arrangment used in the field instrument or final control element of a safety instrumented system (SIS) to reach a certain safety integrity level (SIL). Voting logics include one-out-of-one (1oo1), 1oo2, 2oo2, 2oo3, etc. For example, a 2oo2 voting logic indicates there are two protective devices/instruments in a system and both devices (two-out-of-two) are needed to properly shut down the system or mitigate the hazard. 1oo2 indicates that only one of the devices would be required to properly prevent the situation from occurring. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

QRA stands for quantitative risk analysis, a technique for assessing the risk of prospective asset risks. Acronyms & Terms Glossary <- More Definitions What is QRA in safety QRA stands for quantitative risk analysis, a technique for assessing the risk of prospective asset risks. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.

Modernizing for Productivity and Profit Process Automation Systems Modernizing for Productivity and Profit Modernizing for Productivity and Profit aeSolutions has years of experience automating industrial processes using state of the art Distributed Control System (DCS) technologies. From the proprietary control system processors of the 1990's, to the powerful open-systems DCS platforms of today, aeSolutions engineers have provided process automation solutions to clients in every type of industry: chemical, polymer, textile, pharmaceutical, food and beverage, automotive, mining, oil and gas, refining, combustion, power, utilities, water treatment, and more. Using comprehensive standards for project definition and execution, aeSolutions promises a Successful Result from the Start™. • DCS - 300 tags to 30,000 tags • Batch, continuous, and sequential controls • Advanced and model-based controls • Communications, networks, security • Human Machine Interface (HMI) solutions • Safety and control systems integration • Batch Control • Automating Batch Procedures --------------------------------- aeSolutions designs and implements discrete and continuous batch systems for DCS supervision and control as well. Some clients who chose to avoid batch in previous generations of DCS now find it advantageous to implement batch with their process automation migrations. • ANSI/ISA-88 standards • Batch management • Batch historian • Batch reports • Golden batches • Recipes • Routing • Process units, equipment and control modules • Unit procedures, operations, phase logic • Sequential function control Automation Services Previous Next

A Certified Functional Safety Expert (CFSE) is a professional certification for individuals with advanced knowledge and experience in functional safety, particularly in designing and assessing safety instrumented systems (SIS). CFSEs are recognized for their expertise in ensuring the safety and reliability of critical systems. Acronyms & Terms Glossary <- More Definitions Certified Functional Safety Expert (CFSE) A Certified Functional Safety Expert (CFSE) is a professional certification for individuals with advanced knowledge and experience in functional safety, particularly in designing and assessing safety instrumented systems (SIS). CFSEs are recognized for their expertise in ensuring the safety and reliability of critical systems. Our Services What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Leaders face constant pressure to move fast and hit targets. The risk isn't a single bad decision, it's the small compromises that start to look reasonable. What are tomorrow's leaders learning from watching how we handle that pressure today? 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.