Articulating the Project Vision and Characterizing the Control System Project Assessment and Conceptual Design Articulating the Project Vision and Characterizing the Control System aeSolutions engages clients to determine project goals, scope boundaries, assumptions, and customer requirements. A common conceptual design for the project is formulated in a project assessment report. The conceptual design includes a budgetary estimate and schedule. • Site and field investigations • Current state quantification • Client requirements • Scope and boundaries • Project assumptions • Conceptual design • Assessment report • Conceptual system architecture • Preliminary I/O counts • Project cost and schedule estimates aeSolutions' experienced professionals work closely with the client's engineers to map out the preliminary scope of work for the project and propose a high-level view of the system requirements. The conceptual design includes a budgetary estimate and schedule to support the feasibility and business case reviews. • Conceptual system architecture • Migration strategies • Operational philosophy • Preliminary I/O counts • Preliminary Bill of Material • Wiring philosophy • Project cost and schedule estimates +/- 30% Automation Services Previous Next

The Risk Reduction Factor (RRF) is the inverse of PFD (RRF = 1/PFD) and is used to establish the associated Safety Integrity Level (SIL) rating required for a Safety Instrumented Function (SIF) to reduce the hazard risk to an acceptable risk tolerance level. Once a Process Hazard Analysis (PHA) has been completed and Independent Protection Layers (IPL) have been applied, any SIF that serves as an IPL must have an established RRF. Over-specification of devices to be used in a SIF is not uncommon because it is a SAFETY Instrumented Function. However, over-specification does not necessarily improve safety significantly and can reduce the resources available for overall safety. aeSolutions can help you identify the best devices to use in SIFs and assist you in the purchasing process. Acronyms & Terms Glossary <- More Definitions Risk Reduction Factor (RRF) The Risk Reduction Factor (RRF) is the inverse of PFD (RRF = 1/PFD) and is used to establish the associated Safety Integrity Level (SIL) rating required for a Safety Instrumented Function (SIF) to reduce the hazard risk to an acceptable risk tolerance level. Once a Process Hazard Analysis (PHA) has been completed and Independent Protection Layers (IPL) have been applied, any SIF that serves as an IPL must have an established RRF. Over-specification of devices to be used in a SIF is not uncommon because it is a SAFETY Instrumented Function. However, over-specification does not necessarily improve safety significantly and can reduce the resources available for overall safety. aeSolutions can help you identify the best devices to use in SIFs and assist you in the purchasing process. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

The probability that a system will fail to perform a specified function on demand (i.e., when challenged or needed). Independent Protection Layers (IPLs) are assigned a PFD based on industry or site-specific data. Refer to Safety Integrity Level (SIL) Calculations and Risk Reduction Factor definition. Acronyms & Terms Glossary <- More Definitions Probability of Failure on Demand (PFD) The probability that a system will fail to perform a specified function on demand (i.e., when challenged or needed). Independent Protection Layers (IPLs) are assigned a PFD based on industry or site-specific data. Refer to Safety Integrity Level (SIL) Calculations and Risk Reduction Factor definition. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Multi-Fuel Boiler BMS Upgrade for Chlor Alkali Production Facility A multi-fuel boiler project for a chlor alkali production facility resulted in significant modernization and operational improvements. The client's legacy relay-based Burner Management System (BMS) was upgraded to a DeltaV CHARM Safety Logic Solver, providing enhanced visibility, safety, and operational flexibility. This project not only modernized the client's system but also ensured compliance with NFPA 85 codes and met all Safety Instrumented Systems (SIS) requirements. Challenge The client’s existing BMS was based on outdated relay logic technology, limiting visibility into critical boiler parameters. Operators struggled with frequent system trips but lacked the ability to identify the root causes. Their legacy system provided no direct diagnostics, forcing operators to visually inspect equipment and restart the system manually. Additionally, the client required operational flexibility to switch between multiple fuel types — natural gas, hydrogen, and oil — without system shutdowns. The client sought improved support and expertise with a configuration provider with SI-BMS experience. Their need for seamless integration, combined with complex fuel-switching requirements, posed significant technical challenges. Solution aeSolutions successfully delivered a comprehensive upgrade of the client’s BMS, integrating it into the existing DeltaV platform. Key elements of the solution included: • Integration with DeltaV: The new BMS was implemented using DeltaV’s CHARM Safety Logic Solver, ensuring compatibility with the client’s existing system and reducing the learning curve for operators. • Enhanced System Visibility: Operators gained real-time insight into key metrics such as pressure levels and temperature through custom Dynamos on the control room interface. First-out diagnostics were also added, enabling quicker root-cause analysis and reducing downtime. • NFPA 85 Code Compliance: The upgrade ensured the boiler system met the latest NFPA 85 safety codes, enhancing both safety and reliability. • Multi-Fuel Flexibility: The system was designed to allow seamless fuel switching between hydrogen, natural gas, and oil without requiring shutdowns. Custom Safety Instrumented Functions (SIFs) were implemented to manage the complexities of multiple fuel types safely. • Close Client Support: aeSolutions was able to provide prompt, on-site technical support as needed, ensuring smooth project delivery and ongoing assistance. Results The results of this project provided significant benefits to the client by improving both safety and operational efficiency. The upgraded BMS ensured compliance with NFPA 85 codes, enhancing safety and reducing the risk of boiler-related incidents. With the ability to switch seamlessly between hydrogen, natural gas, and oil, the system offered the client greater operational flexibility. The inclusion of real-time diagnostics and first-out alarms allowed for faster troubleshooting, reducing downtime, and improving system availability. Additionally, the operators benefited from a streamlined process, as they could now manage startups from the control room, minimizing manual interventions. To ensure a smooth transition, aeSolutions replicated the client's existing control graphics through custom Dynamos, maintaining familiarity for operators and preventing workflow disruptions. These enhancements collectively improved safety, reliability, and ease of operations for the client. Learn more about how aeSolutions could help you with a similar project Industry: Chlor Alkali Production Geography: Southeast Unit Operation: Burner Management System (BMS), DeltaV Previous Story Next Story

The lower explosive limit (LEL) refers to the lowest concentration of a gas or vapor in air that can ignite or explode when an ignition source is present. Acronyms & Terms Glossary <- More Definitions Lower Explosive Limit (LEL) The lower explosive limit (LEL) refers to the lowest concentration of a gas or vapor in air that can ignite or explode when an ignition source is present. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

aeSolutions can supply expertise for multiple stages of the alarm management lifecycle specializing in: Philosophy development Gap assessment of current alarm philosophy Alarm management and rationalization training Facilitation of alarm rationalizations  Including our alarm rationalization tool, aeAlarm™​ Alarm management program gap assessment. We can help with Kpi – 5 year review – training requirements – audits – operator – plant – operations – alarm champion – control system. Alarm Management aeSolutions provides services and systems to bring the client’s alarm management practices into compliance with the current ISA 18.2 standards. Poor alarm management has been a critical factor in major process safety incidents throughout history. Successful alarm management is key in achieving effectiveness of alarms and the ability of operating personnel to respond promptly and correctly. aeSolutions can supply expertise for multiple stages of the alarm management lifecycle specializing in: Philosophy development Gap assessment of current alarm philosophy Alarm management and rationalization training Facilitation of alarm rationalizations Including our alarm rationalization tool, aeAlarm™ Alarm management program gap assessment The goal of our alarm management services is to help clients improve the performance of their alarm systems and increase the situational awareness of their operators. Our clients recognize there is a direct relationship between the process safety performance of their facilities and the implementation of their effective alarm management techniques. Featured : How to Keep the Alarm Management Lifecycle Evergreen Blog & Whitepaper Alarm Management Lifecycle aeSolutions’ alarm management services are designed to support our clients’ desires to encourage a culture of sustainable alarm management as an important component to their overall process safety strategy. Download our Flyer ( PDF ) Alarm Management Services The aeSolutions developed alarm rationalization tool, aeAlarm™, delivers the ability to efficiently and consistently execute alarm rationalization. This unique tool provides customizable templates, and drop downs for severities and maximum time to respond, with automatic population of alarm priority. Download our Flyer ( PDF ) aeAlarm™ Rationalization Tool

Delivering Safety on Demand Safety Instrumented Systems - Automation Applications Delivering Safety on Demand aeSolutions is especially qualified with Certified Functional Safety Experts to quantify process hazard risks and develop the safety requirements specifications for a process. National and international standards and regulations require that a safety interlock must meet a prescribed safety integrity level SIL-1 thru SIL-4 to have an acceptable probability of failure on demand for its associated hazard. There are many aspects to supplying the required SIL level, including the logic solver, I/O cards, redundancies, program blocks, networks, and the operator interactions. aeSolutions satisfies a project's safety interlock SIL requirements with independent, SIL-certified safety PLC's that can be integrated with the process automation DCS for monitoring and alarming. Our engineering specialists will design, configure, test, and install documented Safety Instrumented Systems that verifiably meet the client's Safety Requirements Specifications. • Logic solver hardware and software, TUV or Exida certified • Operator interaction through Cause and Effect matrix • Controlled access and modification protections • Secure fail safe communications for distributed safety • Verification test plans Automation Services Previous Next

A burn-in process is a testing method where components of a system are tested prior to being put in use in process, to detect failures early and ensure reliability of the components. Acronyms & Terms Glossary <- More Definitions Burn-In A burn-in process is a testing method where components of a system are tested prior to being put in use in process, to detect failures early and ensure reliability of the components. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Proportional control is a control mode where controller output (the action taken) is proportional to the difference between the setpoint and the process variable (the degree to which system diverges from ideal point). Other control modes include on-off control and proportional-integral-derivative (PID) mode. Acronyms & Terms Glossary <- More Definitions Proportional control Proportional control is a control mode where controller output (the action taken) is proportional to the difference between the setpoint and the process variable (the degree to which system diverges from ideal point). Other control modes include on-off control and proportional-integral-derivative (PID) mode. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

A Maintenance Override Switch (MOS) is a device that allows temporary bypassing of safety interlocks or alarms during maintenance activities. MOS must be used carefully to ensure that safety is not compromised while performing necessary maintenance tasks. Acronyms & Terms Glossary <- More Definitions Maintenance Override Switch (MOS) A Maintenance Override Switch (MOS) is a device that allows temporary bypassing of safety interlocks or alarms during maintenance activities. MOS must be used carefully to ensure that safety is not compromised while performing necessary maintenance tasks. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

A failure mode is a specific way in which a system or component can fail to perform its intended function. Understanding failure modes helps in designing preventive measures and improving system reliability. Acronyms & Terms Glossary <- More Definitions Failure Mode A failure mode is a specific way in which a system or component can fail to perform its intended function. Understanding failure modes helps in designing preventive measures and improving system reliability. Our Services 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 Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Please use this form. We'd like to hear from you. info@aesolutions.com Phone: 864-676-0600 Greenville, South Carolina Corporate Headquarters Contact aeSolutions Contact us regarding your pr oject or question and the appropriate team member will be in touch. Emal Us 864-676-0600 Email: info@aesolutions.com Greenvill e, S C Corporate Headquarters 250 Commonwealth Drive Ste 200 Greenville, SC 29615 Regional Office Phone numbers: Houston, TX 713-292-0000 757 N Eldridge Parkway Ste 520 Houston, TX 77079 aeSolutions offers performance-based process safety PSM engineering, and automation (system integration) solutions with proven processes that ensure consistent project execution, while helping clients optimize safety, quality and production. We are committed to providing services that enable our clients to sustainably own, operate, and maintain their process facilities. Following its original vision of providing Value-Driven Engineering, aeSolutions continues to anticipate and exceed the expectations of their customers, employees, and the market. To provide consulting and engineering services to make industrial operations smarter, more resilient, and communities safer. Consulting engagements help us build a strong trusted-advisor connection with our clients, which is in line with our Inclusive core value and penchant for collaborating as partners. Consulting services allow us to build relationships with higher-level decision-makers in our clients' businesses that extend beyond specific project engagements. Our consulting services enable us to obtain insight