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aeSolutions Safety Requirements Specification services support moving industrial manufacturing facilities from Risk to Resilience by defining SIS requirements and ensuring IEC 61511 compliance. Safety Requirements Specification Service Click Here to Chat With Our Safety Requirements Specification Experts Defining Clear, Complete, and Defensible Requirements for Safety Instrumented Systems aeSolutions provides Safety Requirements Specification (SRS) services to define the functional and performance requirements of Safety Instrumented Systems (SIS) in accordance with IEC 61511. Our structured, lifecycle-based approach ensures that safety requirements are clearly documented, traceable, and aligned with hazard and risk analysis outcomes. Our SRS Capabilities Include: Development of SRS documents aligned with IEC 61511 requirements Translation of PHA and LOPA results into defined Safety Instrumented Functions (SIFs) Definition of SIL targets, functional requirements, and performance criteria Specification of process safety time, response time, and trip setpoints Documentation of system architecture, interfaces, and design assumptions Identification of proof test intervals, diagnostics, and maintenance requirements Establishment of cause and effect logic and functional narratives Gap assessment and improvement of existing SRS documentation aeSolutions works closely with your engineering, operations, and safety teams to develop SRS documents that are clear, complete, and aligned with how your facility operates. Whether supporting new projects or improving existing documentation, our SRS expertise helps ensure your safety systems are designed, implemented, and maintained in line with your facility’s risk tolerance. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Learn More About aeSolutions — Let's Discuss Your Safety Requirements Specification Needs —

Mechanizing in Real Time Factory Automation Systems Mechanizing in Real Time aeSolutions has delivered automation solutions with Programmable Logic Controllers for nearly two decades. In the 1970's, a PLC was a programmable emulator of relay ladder logic. Today, a PLC is a scaled down controller, often stand alone, but with much of the power and some of the functions of controllers used in DCS process automation. Multiple PLC's are often networked somewhat like a DCS with fewer features. aeSolutions can provide the right PLC automation system when a client needs highly reliable and very fast real time response to events in a manufacturing cell or an electromechanical panel. Ruggedized operator displays and touch screens allow local HMI control. The PLC can also be interfaced to a supervising DCS. • High speed I/O and processing • Ruggedized environment • Basic networking and communications • Ladder logic programming familiar to I&E staff • Scalable in size and cost Automation Services Previous Next

A condition during which the alarm rate is greater than the operator can effectively manage. An alarm flood is normally defined to begin when the alarm rate exceeds ten (10) alarms in a ten-minute period and ends when it returns as a reduced alarm rate. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Acronyms & Terms Glossary <- More Definitions Alarm Flood A condition during which the alarm rate is greater than the operator can effectively manage. An alarm flood is normally defined to begin when the alarm rate exceeds ten (10) alarms in a ten-minute period and ends when it returns as a reduced alarm rate. aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. 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.

Protecting Personnel with Practical Gas Detector Placement A pharmaceutical company needed to implement gas detectors at their facility to protect personnel from potential leaks of toxic and combustible gases. aeSolutions evaluated the gas detector placement and number of detectors that would provide the earliest warning to personnel based on the expected dispersion and behavior of specific gas release scenarios. Challenge To design a gas detection system for a multitude of uncommon gases and vapors in a pharmaceutical clean environment with the possibility of both indoor and outdoor releases. The goal was to detect a release at a level as low as reasonably possible, taking into account internal ventilation influences on gas releases. Solution Computational Fluid Dynamics (CFD) scenario modeling was performed to justify the number and placement of gas detectors. The CFD models helped ensure the effectiveness of the gas detection system and provided an auditable record of the assumptions made (e.g., leak location, leak size, ventilation rate, etc.) that could be referred to and updated throughout the life of the facility Results The CFD models revealed some unexpected behaviors from the vapors of concern compared to what might have been reasonably predicted by their physical properties. CFD modeling revealed: • Lighter than air gases were pulled downward, and gas detector locations were revised accordingly • Gas leaks dispersed farther than expected and affected originally unprotected warehouse buildings; therefore, gas detectors were placed on the ventilation intakes of the warehouse • An ammonia leak from a sphere under pressure dispersed vertically and was not detected by ammonia detectors around the sphere; coverage was augmented by the use of an open path ammonia gas detector aimed across the top of the sphere The facility owner now has greater confidence that they are protecting their personnel with an optimal number of detectors in the right locations thereby minimizing long-term maintenance costs for the gas detection system. CFD modeling is the best investment for large facilities with specialty gases to ensure gas detectors are appropriately located for optimum performance. Learn more about our gas detection services Industry: Pharma Geography: Pacific Northwest Unit Operation: Gas Detectors Previous Story Next Story

Levels of Hardware Fault Tolerance (HFT) are established in functional safety standards IEC 61508 and IEC 61511, as the ability of a component or subsystem to continue to be able to undertake the required safety instrumented function in the presence of one or more dangerous faults in hardware. A hardware fault tolerance of 1 means that there are, for example, two devices and the architecture is such that the dangerous failure of one of the two components or subsystems does not prevent the safety action from occurring. In other words, HFT allows a safety system to let the process continue even with a designated failure in the hardware. Acronyms & Terms Glossary <- More Definitions Hardware Fault Tolerance Levels of Hardware Fault Tolerance (HFT) are established in functional safety standards IEC 61508 and IEC 61511, as the ability of a component or subsystem to continue to be able to undertake the required safety instrumented function in the presence of one or more dangerous faults in hardware. A hardware fault tolerance of 1 means that there are, for example, two devices and the architecture is such that the dangerous failure of one of the two components or subsystems does not prevent the safety action from occurring. In other words, HFT allows a safety system to let the process continue even with a designated failure in the hardware. 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.

PSM stands for Process Safety Management, a process that helps prevent/reduce risk of hazardous chemical releases. Acronyms & Terms Glossary <- More Definitions What does PSM stand for in safety PSM stands for Process Safety Management, a process that helps prevent/reduce risk of hazardous chemical releases. 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' Burner Management Systems help improve safe startup, operation, shutdown, code compliance, and lifecycle support for fired equipment. Burner Management Systems Services Click Here to Chat With Our Burner Management System Experts Supporting Safe Startup, Operation, and Shutdown of Fired Equipment Burner Management Systems play a critical role in reducing fired equipment hazards and supporting safe, reliable, and resilient operations. When BMS design, documentation, or configuration does not align with current equipment needs or applicable requirements, facilities can face increased operational risk, compliance challenges, and uncertainty during startup or upset conditions. aeSolutions helps clients develop practical BMS solutions that support safer operation, improved reliability, and the path from Risk to Resilience. aeSolutions provides Burner Management System services to help facilities manage the safe startup, operation, monitoring, and shutdown of fired equipment. A properly designed BMS supports critical burner functions, including interlocks, trips, flame monitoring, ignition sequencing, and shutdown logic. Our Burner Management System services include: Development and implementation of Burner Management System strategies BMS design support for fired equipment startup, operation, and shutdown Configuration of interlocks, trips, flame monitoring, ignition sequencing, and shutdown logic Evaluation of existing BMS performance, limitations, and documentation Support for BMS upgrades, modifications, and replacement projects Integration of BMS functionality with combustion control systems Documentation to support operation, maintenance, and lifecycle management Alignment with applicable project requirements and fired equipment safety objectives aeSolutions works closely with your engineering, operations, and project teams to develop Burner Management Systems that are practical, reliable, and aligned with your facility’s fired equipment needs. Whether supporting a new installation, system upgrade, or existing BMS challenge, our expertise helps improve operational confidence, reduce uncertainty, and support safer fired equipment performance. — DON'T JUST TAKE OUR WORD FOR IT — Evidence-Backed Results — Trusted By Industry Leaders — Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Battery Materials & Minerals Processing Ag Chem Utilities & Critical Infrastructure Specialty Chemicals & Advanced Materials Renewable Fuels & Bioenergy Pharmaceutical & Life Sciences Manufacturing Petrochemicals & Hydrocarbon Processing Metals & Mining Processing Oil & Gas Production & Processing Learn More About aeSolutions — Let's Discuss Your Burner Management System Needs —

Computational Fluid Dynamics (CFD) is the computational software simulation of fluid-flow phenomena. It uses applied mathematics, physics, and numerical analysis to generate 3D models that can help visual the flow of gas or liquid. aeSolutions uses CFD for modeling to determine consequences of an accidental release for facility siting or hazard scenarios. It is also used for gas detection sensor placement as an alternative method to the Graphical Approach that justifies a more accurate number and placement of combustible and toxic gas detectors. Acronyms & Terms Glossary <- More Definitions Computational Fluid Dynamics (CFD) Computational Fluid Dynamics (CFD) is the computational software simulation of fluid-flow phenomena. It uses applied mathematics, physics, and numerical analysis to generate 3D models that can help visual the flow of gas or liquid. aeSolutions uses CFD for modeling to determine consequences of an accidental release for facility siting or hazard scenarios. It is also used for gas detection sensor placement as an alternative method to the Graphical Approach that justifies a more accurate number and placement of combustible and toxic gas detectors. 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.

Mean Time Between Failures (MTBF) is a reliability metric that represents the average time between failures of a system or component. MTBF is used to predict the reliability and performance of equipment over time. Acronyms & Terms Glossary <- More Definitions Mean Time Between Failures (MTBF) Mean Time Between Failures (MTBF) is a reliability metric that represents the average time between failures of a system or component. MTBF is used to predict the reliability and performance of equipment over time. 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.

Shaping a Successful Result from the Start Automation Project Management Shaping a Successful Result from the Start aeSolutions manages every project with a comprehensive set of tools for planning and tracking tasks, deliverables, and milestones. Clear communications and rigorous documentation ensure that client expectations are met throughout the project. • Dedicated project management group • Project scheduling and tracking • Resource allocation • Scope and budget control • Project execution planning • Risks, roles, and accountabilities identification • Meetings, action lists, and reporting • Project deliverable approval cycles • Gate reviews between approval stages • Purchasing and shipping Automation Services Previous Next

A fire that spreads by means of a flame front rapidly through a diffuse fuel, such as a dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. Flash fires produce relatively short term thermal hazards with negligible overpressure (blast wave) and burn through a pre-mixed vapor cloud largely horizontally as a vertical ""wall of flame"". Flash fires are considered during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Acronyms & Terms Glossary <- More Definitions Flash Fire A fire that spreads by means of a flame front rapidly through a diffuse fuel, such as a dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. Flash fires produce relatively short term thermal hazards with negligible overpressure (blast wave) and burn through a pre-mixed vapor cloud largely horizontally as a vertical ""wall of flame"". Flash fires are considered during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. 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 offers performance-based process safety engineering, fired equipment, and automation solutions with proven processes that ensure consistent project execution, while helping customers optimize safety, quality and production. We are committed to providing engineering services that Our Story Over 25 years ago, the founders of aeSolutions had a vision of doing great things in a very different way with a very different approach. That vision lives on today, to create a highly talented and engaged team passionately driven to solve the very real and very difficult challenges our industrial clients face. We are so proud of the progress we’ve made towards that vision. Over the course of time, we have steadily built a team that organizations depend on to view their problems holistically and create long-term sustainable and resilient solutions. Every day, we work on problems that matter to industrial asset owners and to their local communities. These are complex problems that are only overcome by having a great team. Today, aeSolutions is where every stakeholder is supported to pursue their full potential. All leaders recognize that creating anything meaningful and lasting requires an empowered team of informed, engaged individuals. As we advance in the years ahead, we are committed to the long-term growth and development of our employees. If we empower our employees with more information and the education to understand and apply that information and if we do this consistently, we will be successful by every measure. Locations Leadership Careers Partners Success Stories Social Responsibility Realizing employee potential through the achievement of client success About Us Redirect Locations Mission & Vision What drives us What we are driving towards What we do How we succeed To support every stakeholder in the pursuit of their full potential Realizing employee potential through the achievement of client success To improve industry by guiding our clients to increasingly resilient operations and safer communities. We succeed in critical fields that others avoid by remaining authentic to our core values. Results-Driven: Success Demands Tangible Results – We strive for excellence in all we do. Inclusive: Value From All – We encourage, seek out, and leverage the diversity in knowledge and perspective of all stakeholders, knowing the team delivers greater value than any individual. Relentless: Unwavering Commitment – We drive forward with passion and purpose. Locations Greenville, South Carolina aeSolutions Corporate Headquarters 250 Commonwealth Drive, Suite 200 Greenville, SC 29615 PO Box 26566 Greenville, SC 29616 Phone: 864-676-0600 Panel Fabrication Shop 124 Woodruff Industrial Lane Greenville, SC 29607 Houston Office 757 N Eldridge Parkway, Suite 520 Houston, Texas 77079 Phone: 713-292-0000