aeSolutions offers expert functional safety engineering across the full safety lifecycle, supporting risk reduction, regulatory compliance, and long-term system resilience. Transforming Your Functional Safety From ISA 61511 Requirements Unclear Functional Safety Ownership Unverified Safety Functions Does this sound familiar? Ready for Relief? Let's Chat Legacy SIS Platforms — Our Functional Safety Capabilities — Functional safety is essential for building operational resilience in complex, automated industrial environments. Gaps in functional safety, whether due to incomplete safety requirements, outdated documentation, fragmented lifecycle execution, or unclear ownership between engineering and operations, can elevate risk and create costly disruptions. Without a clear strategy and structured approach to managing safety functions throughout their entire lifecycle, facilities face growing compliance burdens, reduced confidence in safety system performance, and internal strain that hinders team effectiveness. An effective functional safety program that meets ANSI/ISA 61511 requirements is more than a technical obligation — it is a framework for predictability, accountability, and smarter decision-making that strengthens safety and reliability across the organization. Learn more about how our team of CFSEs and industry experts can help close functional safety gaps and improve your facility's resilience. SIL Verification Functional Safety Assessment Functional Safety Management Proof Test Procedures & Verification Safety Requirements Specifications Click Here to Speak with a Functional Safety Expert About Your Facility's Resilience — The aeSolutions ResiliencePath™ Method — We’re an integrative specialist with a proven methodology that we call ResiliencePath ™ that embeds safety into every stage of the project lifecycle — from concept to closure — for compliance today and resilience tomorrow. Empowering — Not Enforcing Rather than checking boxes, we help you identify the right questions early to prevent costly late-stage corrections and avoid years of OpEx fixes. Each ResiliencePath™ step is driven by one goal: empowering resilient, value-aligned decisions that stand the test of time. EPC & Subcontractor Integration ResiliencePath™ is adaptable to collaborate seamlessly with EPCs and subcontractors, integrated into a structured workflow designed to adapt to real-world project dynamics without compromising on results. Your Process, Our Expertise At aeSolutions, we help clients reduce complexity and strengthen operational performance by aligning the functional safety lifecycle with real-world project execution. Our integrated services span functional safety assessments, Safety Integrity Level determination and verification, Safety Requirements Specification development, safety system design, and lifecycle support, all grounded in domain expertise and a focus on practical implementation. We work closely with your team to close gaps, clarify ownership across engineering and operations, and transform fragmented safety practices into a cohesive, defensible functional safety program that protects people, assets, and uptime. Whether you are addressing legacy safety systems or building a long-term functional safety strategy, aeSolutions helps you move from risk to resilience with clarity and confidence. Learn More About the aeSolutions ResiliencePath ™ Methodology — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production View More Case Studies Here — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Click Here to Chat With Our Industry Experts — Our Functional Safety Whitepapers — Whitepaper - Decoding SIS: Are You Doing What's Necessary to Prevent Disasters Whitepaper - Improving the Safety Instrumented System Design Process with Graphic Diagrams Whitepaper - Lessons Learned on SIL Verification and SIS Conceptual Design View More Whitepapers Here — Let's Discuss Your Functional Safety Needs —

aeSolutions systems integration services support moving industrial manufacturing facilities from Risk to Resilience by integrating control systems and ensuring reliable performance. Systems Integration Services Click Here to Chat With Our Systems Integration Experts Connecting Control Systems for Reliable, Consistent, and Scalable Operations Outdated systems, inconsistent configurations, or poorly integrated components introduce risk, reduce visibility, and create challenges for operations and maintenance teams. aeSolutions works with clients to integrate control systems in a way that supports consistency, reliability, and long-term maintainability. aeSolutions provides Systems Integration services to help industrial manufacturing facilities connect and align control systems, platforms, and field devices into a cohesive, functional environment. Effective integration is essential to ensuring that automation systems operate reliably, data flows accurately, and system performance meets operational expectations. Our Systems Integration services include: Integration of control systems, including DCS, PLC, and HMI platforms Configuration and alignment of system communications and data exchange Integration of field instrumentation and control devices into automation systems Support for system interoperability across new and existing platforms Coordination of system interfaces and data flow between components Verification of system functionality and alignment with project requirements Documentation of integrated system architecture and configurations Development of I/O lists, control narratives, and logic documentation Design of HMI interfaces and operator displays aeSolutions works closely with your engineering, operations, and project teams to deliver integrated control systems that function as intended in real-world environments. Whether supporting new system deployments or upgrades to existing infrastructure, our systems integration expertise helps ensure reliable performance, improved visibility, and a more connected operational environment. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Learn More About aeSolutions — Let's Discuss Your Systems Integration Needs —

Identify and mitigate process risks with aeSolutions’ HAZOP study services. Our expert-led analyses help facilities improve safety, ensure compliance, and reduce operational risk. HAZOP Study Services Click Here to Chat With Our HAZOP Study Experts Structured Hazard Identification for Safer and More Resilient Process Operations aeSolutions provides expert Hazard and Operability (HAZOP) study facilitation to help industrial manufacturing facilities systematically identify and evaluate process hazards and operability issues. Our experienced facilitators guide your team through a structured analysis that helps uncover potential deviations, evaluate safeguards, and reduce process safety risks. HAZOP studies are a critical component of effective Process Safety Management (PSM) programs. aeSolutions supports facilities throughout the HAZOP lifecycle, from preparation and study execution to documentation and action item tracking, ensuring studies deliver practical insights that strengthen operational safety and reliability. Our HAZOP study capabilities include: HAZOP study facilitation by experienced process safety professionals Node definition and deviation analysis using standard guide words Identification of credible hazard and operability scenarios Safeguard evaluation and risk ranking Documentation of study findings and recommendations Support for capital projects, facility modifications, and management of change (MOC) Integration with broader PHA and process safety programs Revalidation support for existing HAZOP studies With aeSolutions’ HAZOP expertise, organizations can improve hazard visibility, strengthen process safety programs, and ensure operational risks are identified and addressed through a structured and defensible methodology. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Learn More About aeSolutions — Let's Discuss Your HAZOP Study Needs —

Our industrial automation services supply complete, fabricated, configured, and tested safety and control systems, including Basic Process Control Systems (BPCS), Process Control, Safety Instrumented Systems (SIS), Burner Management Systems (BMS), High Integrity Pressure Protection Systems (HIPPS), and Fire and Gas, systems integration, Rockwell, Triconex, Safety systems, critical controls Transforming Through Integrated Control & Safety Systems Network & Architecture Gaps Persistent Downtime Complex I/O Cutovers Does this sound familiar? Ready for Relief? Let's Chat Unsupported Hardware & Software — Our Control System Capabilities — Integrated systems are essential for building operational resilience in complex industrial facilities. With a structured strategy and disciplined approach to migrations, upgrades, and system integration, facilities avoid costly outages, fragmented documentation, unclear cutover planning, and internal strain on operations and engineering teams. Effective control system modernization isn’t just a one-off technology project, it’s a risk-aware, outcome-driven program that strengthens reliability, enhances visibility, and supports smarter, more predictable decision-making across your operation. Conceptual & Preliminary Engineering Systems Integration Detail Design UL Certified Fabrication Installation & Ongoing Support Click Here to Speak with an Control System Expert About Your Facility's Resilience — The aeSolutions ResiliencePath™ Method — We’re an integrative specialist with a proven methodology that we call ResiliencePath ™ that embeds safety into every stage of the project lifecycle — from concept to closure — for compliance today and resilience tomorrow. Empowering — Not Enforcing Rather than checking boxes, we help you identify the right questions early to prevent costly late-stage corrections and avoid years of OpEx fixes. Each ResiliencePath™ step is driven by one goal: empowering resilient, value-aligned decisions that stand the test of time. EPC & Subcontractor Integration ResiliencePath™ is adaptable to collaborate seamlessly with EPCs and subcontractors, integrated into a structured workflow designed to adapt to real-world project dynamics without compromising on results. Your Process, Our Expertise At aeSolutions, we help clients reduce project risk and strengthen operational performance by integrating the control system lifecycle with the project lifecycle. Our capabilities span front-end engineering and conceptual design, functional requirements development, architecture and network design, I/O cutover planning, system configuration, panel fabrication, and commissioning support, all delivered with expertise and a focus on disciplined execution. We work alongside your operations, maintenance, and engineering teams to preserve process knowledge, minimize downtime, and transform fragmented legacy systems into a modern, resilient automation environment. Whether you're planning a phased migration or a full platform replacement, aeSolutions helps you move from risk to resilience with clarity and confidence. Learn More About the aeSolutions ResiliencePath ™ Methodology — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Alarm Management for a Greenfield LNG Facility Pharma Company Detecting Natural Gas Leaks in Boiler House Large Specialty Chemical Company Reduces Alarm Floods Simplified, Cost-Effective, and Consistent Acidic Compound Detection Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million Water Cannons Protect Community from Anhydrous Ammonia Leaks Pharmaceutical Company Required Toxic & Combustible Gas Detection System Complex Hot Cutover of Large Natural Gas Processing Facilities Specialty Chemical Site’s Increasingly Complicated Cutover “Fit for Purpose” Solution Reduces Planned Downtime by 66% Protecting Personnel with Practical Gas Detector Placement Alarm System Rationalization and Safe Operating Limit for Energy Production View More Case Studies Here — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Click Here to Chat With Our Industry Experts — Our Control Systems Whitepapers — Whitepaper - Lessons Learned on SIL Verification and SIS Conceptual Design Control System Migrations | Best Practices for Installation, Testing, & Commissioning Control System Migrations | Developing Scope, Schedule, & Budget View More Whitepapers Here — Let's Discuss Your Control System Needs —

aeSolutions facilitates alarm rationalization to reduce alarm flood, improve operator response, and align with ISA 18.2 and IEC 62682 standards. Alarm Rationalization Facilitation Service Click Here to Chat With Our Alarm Rationalization Facilitation Experts Defining Meaningful, Actionable Alarms Through Structured Rationalization aeSolutions provides Alarm Rationalization Facilitation services to help organizations systematically evaluate and define their alarm set to ensure each alarm is necessary, prioritized correctly, and actionable by operators. Our structured approach aligns key stakeholders on alarm intent, response, and performance expectations using consistent, standards-based methodologies. Rationalization is where alarm management gets real, and where most programs stall. Reviewing thousands of alarms with cross-functional teams is time-intensive, politically complex, and technically demanding. Without experienced facilitation, workshops lose momentum, criteria drift between sessions, records become inconsistent, and the resulting alarm set doesn’t hold up during implementation or audits. aeSolutions facilitates rationalization workshops that keep teams productive, criteria consistent, and records audit-ready. We guide your operations, engineering, and process safety stakeholders through structured, standards-based review of every alarm’s necessity, priority, setpoints, deadbands, cause, consequence, and required operator response, aligned with ANSI/ISA-18.2, EEMUA 191, or IEC 62682. Proven Results from Large-Scale Alarm Rationalization Our rationalization methodology and aeAlarm platform were central to the results documented in our award-winning research presented at the 2025 Mary Kay O’Connor Process Safety Conference. Working with cross-functional teams at a midstream LNG facility, we rationalized over 55,000 alarm points across two process units on Honeywell Experion, achieving 84–92% reductions in urgent alarm activations. Unit A reduced urgent alarms from 45% of total alarm load to just 7%. Unit B reduced urgent alarms from 62% to 5%. Over 7,800 nuisance urgent alarms were eliminated, and 100% of remaining alarms now have documented operator response procedures. These results demonstrate what structured rationalization looks like when methodology, tooling, and facilitation expertise come together. Read the full paper here . What to Expect from a Typical Alarm Rationalization Engagement A typical rationalization engagement for a medium-sized process unit involves 2–4 weeks of facilitated workshop sessions, with preparation, data collection, and documentation extending the overall timeline to 8–12 weeks. We work with your team to define scope, establish session schedules that minimize production impact, and deliver implementation-ready rationalization records. For multi-unit or site-wide campaigns, we structure phased approaches that maintain consistency across the program. Our Alarm Rationalization Facilitation services include: Facilitation of structured alarm rationalization activities with cross-functional teams Review and validation of existing alarms for necessity and purpose Definition of alarm priorities based on consequence and required response time Documentation of alarm causes, consequences, and operator response actions Establishment of alarm setpoints, deadbands, and classification criteria Identification and elimination of duplicate, nuisance, or low-value alarms Development of rationalization records to support implementation and auditability Alignment with alarm philosophy and lifecycle requirements aeSolutions works closely with your operations, engineering, process safety, and control system teams to ensure rationalization outcomes are practical, consistent, and aligned with real-world operating conditions. Whether supporting a new alarm management initiative or improving an existing system, our facilitation expertise helps create a streamlined alarm set that enhances operator effectiveness and supports safer, more resilient operations. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Learn More About aeSolutions — Let's Discuss Your Alarm Rationalization Facilitation Needs —

Layers of Protection Analysis (LOPA) is a semi quantitative method of risk assessment analyzing the frequency of occurrence of events that can produce a hazard associated with handling of hazardous chemicals. To ensure safety, a LOPA considers the applicability of safeguards, the potential for individual layers of protection to fail, and the potential consequences that are consistent with the organization's risk tolerance Acronyms & Terms Glossary <- More Definitions What is LOPA in safety Layers of Protection Analysis (LOPA) is a semi quantitative method of risk assessment analyzing the frequency of occurrence of events that can produce a hazard associated with handling of hazardous chemicals. To ensure safety, a LOPA considers the applicability of safeguards, the potential for individual layers of protection to fail, and the potential consequences that are consistent with the organization's risk tolerance Our Services Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. 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.

We know that our success is a result of having talented, dedicated and passionate team members driving our projects. If working for a company that takes on complex challenges in nearly every capacity interests you, we would love to talk to you about possible career with us. work environment. Working at aeSolutions View Current Openings > At aeSolutions, our team members solve some of the most complex automation and process safety engineering challenges in industry. We foster a collaborative wo rk environment comprised of talented and dedicated individuals who strive to realize their full potential while also contributing to the success of our clients. We lead the way in critical fields that others avoid by staying authentic to our core values – Results-Driven, Inclusive, and Relentless. Employees Are VALUED At aeSolutions you won’t get lost in the crowd. Each employee’s contribution makes a difference and helps us improve industry and guide clients to increasingly resilient operations and safer communities. Employees Are CHALLENGED We provide stimulating career development opportunities including working on complex projects in a quality-driven, fast-paced environment. You will be challenged to bring your creativity, problem-solving skills, high-integrity, and professional insight to everything you do. Employees Are DEVELOPED New team members join a collaborative, supportive, and inclusive work culture which will encourage you to develop to your full potential. You will learn from others, and they will learn from you. Your success is our success, and you will be supported in setting and achieving your professional goals. Employees Are REWARDED We provide competitive salaries, opportunities for advancement, and a comprehensive Total Rewards package, including: Medical, Prescription Drug, Dental, & Vision insurance HSA, FSA, and Dependent Care FSA options Mental health & counseling benefits through our confidential Employee Assistance Program (EAP) for employees and their family members Company-provided Employee Life and Disability Coverage with buy-up options 401(k) retirement plan with Roth or Traditional options and company contribution 1-on-1 retirement planning and financial advice for all stages of life Flexible paid time off accrual program Flex-time schedules, Half-Day Fridays, & Office, Hybrid, and Remote work options Incentive bonus programs, including for performance, professional development, employee referrals, repeat business, and more Resources and support for career and skills development, including a Learning Management System with access to thousands of high-quality learning courses, and a peer-to-peer Coaching Program Applicant Notices aeSolutions values the contributions of a diverse and inclusive workforce and is an Equal Employment Opportunity employer. This means we do not discriminate on the basis of actual or perceived race, creed, color, religion, national origin, ancestry, citizenship status, age, disability, sex, marital status, veteran status, uniformed services, sexual orientation, gender identity, genetic information, or any other characteristic protected by applicable federal, state, or local laws. Our management team is dedicated to this policy with respect to recruitment, hiring, placement, promotion, transfer, training, compensation, benefits, employee activities, and general treatment during employment. Access the “Know Your Rights” information from the Equal Employment Opportunity Commission here: Know Your Rights: Workplace Discrimination is Illegal. aeSolutions participates in E-Verify. We will provide the federal government with new employee’s Form I-9 information to confirm work authorization. Please note that we do not use this information to pre-screen applicants: E-Verify Notice — Right to Work Notice . Consistent with the Americans with Disabilities Act (ADA) and state disability laws, it is the policy of aeSolutions to provide reasonable accommodation when requested by a qualified applicant or employee with a disability, unless such accommodation would cause an undue hardship. If reasonable accommodation is needed to participate in the job application or interview process, to perform essential job functions, and/or to receive other benefits and privileges of employment, please contact the HR Director at 864-404-3022 or resumes@aeSolutions.com This link leads to the machine-readable files that are made available in response to the federal Transparency in Coverage Rule and includes negotiated service rates and out-of-network allowed amounts between health plans and healthcare providers. The machine readable files are formatted to allow researchers, regulators, and application developers to more easily access and analyze data: Transparency in Coverage – Machine Readable Files *aeSolutions does not solicit resumes from territories covered by the GDPR. View Current Openings >

aeSolutions detail design services support moving industrial manufacturing facilities from Risk to Resilience by developing complete control system design documentation. Detail Design Services Click Here to Chat With Our Detail Design Experts Translating Project Concepts Into Complete, Executable Control System Designs aeSolutions provides Detail Design services to develop the comprehensive engineering deliverables required to move automation and control system projects into execution. Building on conceptual and preliminary engineering, this phase defines the specific configurations, documentation, and design details needed for implementation. With a well-developed design documentation, projects avoid inconsistencies, rework, and delays during later stages. aeSolutions works with clients to produce clear, complete design packages that support accurate implementation, effective coordination, and reliable system performance. Our Detail Design services include: Development of detailed control system design documentation Creation of system architecture drawings and network layouts Specification of control system components and configurations Coordination of system interfaces and integration requirements Preparation of documentation to support implementation and commissioning Alignment of design deliverables with project scope and requirements aeSolutions works closely with your engineering, operations, and project teams to ensure design deliverables are clear, consistent, and ready for execution. Whether supporting new installations or system upgrades, our detail design expertise helps reduce uncertainty, improve coordination, and supports a successful and resilient project delivery. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Learn More About aeSolutions — Let's Discuss Your Detail Design Needs —

aeSolutions conceptual and preliminary engineering services support moving industrial manufacturing facilities from Risk to Resilience by defining scope, system concepts, and project direction. Conceptual & Preliminary Engineering Service Click Here to Chat With Our Conceptual & Preliminary Engineering Experts Establishing a Clear, Defensible Path Forward for Automation and Control System Projects aeSolutions provides Conceptual and Preliminary Engineering services to help organizations define a clear, structured approach to automation and control system safety projects. Early project phases are critical for aligning scope, identifying risks, and setting the foundation for successful execution. With a well-defined conceptual plan, facilities eliminate the risk of scope gaps, unclear requirements, and project uncertainty. aeSolutions works with clients to develop practical, well-documented engineering strategies that support informed decision-making and align with project objectives, operational needs, and safety expectations. Our Conceptual and Preliminary Engineering services include: Development of project scope definitions and preliminary system concepts Identification of key risks, constraints, and project considerations High-level architecture development for control and automation systems Preliminary input to system selection, design approach, and execution strategy Alignment of project objectives with operational and safety requirements Coordination with stakeholders to define expectations and priorities Establishment of a clear basis for subsequent detailed engineering phases Documentation to support project planning, budgeting, and decision-making aeSolutions works closely with your engineering, operations, and project teams to establish a strong foundation for automation and control system initiatives. Whether supporting new projects or early-stage evaluations, our conceptual and preliminary engineering expertise helps reduce uncertainty, improve alignment, and support a more predictable and resilient path from project definition through execution. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Learn More About aeSolutions — Let's Discuss Your Conceptual and Preliminary Engineering Needs —

aeSolutions' has been a trusted provider of facility siting study and modeling needs for over 25 years. Let's discuss how we can positively impact your sustainable risk management program. Facility Siting Studies & Modeling Solutions Facility siting studies are advised as part of new projects (green or brown field) and modification of existing facilities (buildings, population and process changes, introduction of new chemicals or products). In cases where a facility has applicability to the OSHA PSM and/or EPA RMP standards, conducting baseline and revalidation facility siting studies are required by these regulatory authorities to assess the consequences of potential incidents such as fires, explosions, or toxic exposure on individuals both onsite and off. Evaluating the impact of these facility operational risks is vital when creating a comprehensive safety plan. aeSolutions' facility siting and consequence modeling experts work hand in hand with your team to identify potential process hazards, accounting for your operation's specific siting protocols and goals. aeSolutions is an industry-trusted provider of risk-based and consequence-based facility siting studies in addition to gas dispersion modeling, gas sensor mapping, and gas detector placement. Why Partner With Us? At aeSolutions, we believe one of the greatest influences on operational excellence is a comprehensive, sustainable risk management program that addresses both conformance and compliance. For over 25 years, aeSolutions has served as a multi-faceted safety solutions provider across a wide gamut of industries. When it comes to facility siting studies, we leave no stone unturned. aeSolutions' team of trained facilitators execute the hazard recognition and risk reduction process while our experienced modelers apply the appropriate methodology in line with API 752/753/756 in addition to industry best management practices. In short, we provide results that enable effective allocation of resources to minimize facility siting risks by your site leadership team. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results Facility Siting Study & Analysis Our Facility Siting Capabilities Risk-Based & Consequence-Based Studies Gas Dispersion Modeling Fire Modeling Computational Fluid Dynamics (CFD) Modeling Gas Sensor Mapping Gas Detector Placement Explosion Modeling In accordance to API 752, 753, 756 recommended practices and the Center for Chemical Process Safety (CCPS) Guidance. The aeSolutions Six Step Approach Identify chemicals of concern Identify site-specific conditions Identify potential hazard event scenarios from review of site data Identify & classify occupied buildings Perform the hazard and consequence analysis Perform the risk management analysis aeSolutions utilizes DNV-GL's PHAST to provide quantitative fire and toxic effect data for pool fires, vapor cloud fires, vapor cloud explosions, jet fires, and toxic vapor clouds. Results are illustrated on a site plot plan with hazard endpoint circles for radiant heat, toxic concentrations, and pressure/impulse waves. Additionally, aeSolutions may perform computational fluid dynamics (CFD) models for highly hazardous scenarios upon request. — Trusted By Industry Leaders — Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Ag Chem Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Click Here to Chat With Our Industry Experts About Facility Siting Studies A Facility Siting Analysis is intended to evaluate the potential hazards and consequences of uncontrolled releases of flammable and toxic substances; to assess their potential for injuring the occupants of fixed and temporary structures on or offsite; to identify existing safeguards; and to determine measures to reduce the risk posed by these potential events. Within the United States, facility siting is required as an element of Process Hazard Analysis (PHA) for sites covered by the Occupational Safety and Health Administration's (OSHA) Process Safety Management (PSM) Standards under 29 CFR 1910.119 (e)(3)(v). aeSolutions' Facility Siting Studies are conducted in accordance with methods listed in the American Petroleum Institute's (API) Recommended Practices 752, 753, and 756, and published guidance from the Center for Chemical Process Safety (CCPS). Facility Siting is a multi-faceted analysis of potential fire, explosion, and toxic hazards to personnel from releases of hazardous chemicals. These chemicals of concern include those that vaporize quickly, are highly toxic to personnel or the environment, have low flash points and boiling points, are highly reactive, and/or are present at temperatures, pressures, and/or in quantities significant enough to pose a hazard of concern. Ready to Discuss Your Facility Siting Study? Recent Posts Understanding How Burner Management Systems Work Understanding how burner management systems (BMS) work and how they can benefit your facility's safety and regulatory compliance. Evolution of Fired Equipment Protective Systems in the Chemical Sector Several years ago, aeSolutions started our fired equipment business. This business is focused on safeguarding burners and furnaces,... Enhanced Reliability and Safety Through Standardization Fired equipment such as industrial boilers, incinerators, process furnaces, and fluid heaters are used everywhere. They are a crucial, compl

aeSolutions' aeRemoteConnect (aeRC) provides robust security controls that meet the high security bar set by today's IT professionals. aeRemoteConnect Simple, Secure, Responsible Remote Access Industrial clients, like all employers, are grappling with the significant loss of experienced staff, particularly in technical roles. The continually increasing complexity and specialization of today’s automation systems compound the challenge of replacing skilled automation personnel. This results in the inability to swiftly deploy qualified technical staff for troubleshooting and recovery from unforeseen system shutdowns which can lead to substantial downtime and costs. High-profile cyber attacks make companies cautious about permitting remote connections. Industrial manufacturers are faced with balancing the necessity and efficiency of using remote technicians with the security risks to their internal systems. aeRemoteConnect (aeRC™) allows engineers to remotely connect directly to on-site systems reducing response times when troubleshooting or modifications are urgently needed. A secure, end-to-end encrypted tunnel is established via cellular or existing on-site network and key-switch authorization from on-site staff. A wall-mounted panel houses all required components Modern security threats demand a Defense in Depth strategy to protect industrial operations aeSolutions provides a complete solution with all the necessary equipment, licenses, and services. Based on Siemens' SINEMA Remote Connect software and proven industrial networking equipment, this solution is ready for use with any control system platform. aeRC provides robust security controls that meet the high security bar set by today’s IT professionals. Certificate-based VPN tunnel Multi-Factor Authentication Role-based access control Account auditing System logging SOC 2 compliant data center Have More Questions About aeRemoteConnect? Recent Posts Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone. 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. 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

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