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aeSolutions - A consulting, engineering and system integration company that provides industrial process safety, fired equipment and automation lifecycle solutions and tools. We can help with Toxic Gas Detection, Machinery Safety, Alarm Management, Safety Instrumented Systems, and more. An engineering and systems integration company specializing in automation and industrial process safety. — Resilience Isn't a Bonus, It's a Benchmark — We provide critical system solutions that empower our clients through more resilient operations and safer communities where they operate. Our unique approach is to pair risk-focused industry experts with a proven project delivery team. Speak With One of Our Experts Today About Your Facility's Resilience — If It’s Critical, We Have it Covered — At aeSolutions we help clients reduce project chaos and strengthen performance by integrating the safety lifecycle with the full project lifecycle, and our PMO professionals ensure structure, accountability, and measurable progress. We work with your team to close gaps, clarify responsibilities, and convert fragmented practices into a unified approach that protects people, assets, and uptime. We help you move from risk to resilience with clarity and confidence. — 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 Click Here to Chat With Our Industry Experts — 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 — News & Resources — What Are Tomorrow's Leaders Learning From Us Today? A Lesson in Ethical Leadership Whitepaper: The Courage to Intervene | Developing Ethical Leadership in the Next Generation of Process Safety Professionals aeSolutions Recognized with 2026 CSIA Social Responsibility Award Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard The PHA Recommendation Playbook | Part 3 | Managing Scheduling and Operational Disruptions Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study — Let's Discuss Your Facility's Needs —

Process safety and automation for fertilizer and agricultural chemical plants, helping you protect people, stay compliant, and keep production running. Ag Chem Facilities Partner With Us For Anhydrous Ammonia Exposure Let's Discuss Your Facility's Needs — Integrated Solutions for Ag Chem Operations — Safety Systems Automation & Control Agricultural chemical production sits at the intersection of highly hazardous materials, continuous public exposure, and relentless seasonal demand. Facilities producing ammonia, urea, nitric acid, and finished crop inputs operate under OSHA PSM 1910.119 and EPA RMP, often on assets that have changed hands, expanded in phases, and years of modifications. Add anhydrous ammonia inventories with offsite consequence potential, combustible dust in dry blending and bagging, and control systems well past vendor support, and the breadth of risks become difficult to manage from any single discipline. aeSolutions helps ag chem producers understand where their real hazards are, size the protection those hazards actually require, and then we design, build, and support commissioning of the automation and safety systems. Process safety, functional safety, alarm management, combustion systems, fire and gas detection systems, and automation all come from the same team, so the hazard identified in a PHA is the same hazard traced through the SIF, into the panel on our shop floor, and out to a commissioned system on your unit. — Ag Chem By the Numbers — 25+ Years Serving Ag Chem Clients 35 Ag Chem Sites Supported 348 Ag Chem Projects Delivered View More Success Stories Here — Where We Work in Ag Chem — Nitrogen & Fertilizer Production Ammonia synthesis, urea, nitric acid, and UAN units, where high-pressure reaction, fired equipment, and toxic release potential converge. Crop Input Formulation & Packaging Batch formulation, solvent handling, and filling operations that combine reactive chemistry with recipe-driven production. Anhydrous Ammonia Storage & Terminals Pressurized and refrigerated storage, rail and truck loading, and bulk transfer, where the dominant risk is offsite consequence. Fired Equipment & Steam Utilities Boilers, process heaters, kilns, dryers, and thermal oxidizers governed by NFPA 85, NFPA 86, and NFPA 87. Dry Blending, Granulation & Bagging Granulators, dryers, coolers, screening, and packaging lines, where combustible dust and material handling drive the hazard profile. Legacy & Acquired Facilities Recently acquired or long-tenured plants carrying incomplete process safety information and undocumented control systems. Click Here to Speak with an Ag Chem Expert — The Challenges We Solve — And The Capabilities We Bring FIRE & GAS DETECTION Anhydrous ammonia with offsite consequence potential Ammonia storage and transfer near property lines makes worst-case release modeling a business question, not just a compliance exercise. We run dispersion and consequence modeling, map detector coverage against it, and design detection, isolation, and mitigation systems sized to the scenario rather than to a rule of thumb. Learn more about our Fire & Gas Capabilities → DUST HAZARD ANALYSIS Combustible dust in blending, granulation, and bagging Dry fertilizer handling generates dust in dryers, coolers, elevators, screens, and baghouses. A Dust Hazard Analysis under NFPA 652 identifies where deflagration is credible, and the resulting protection has to be engineered into the equipment and the control system, not bolted on afterward. Learn more about our Dust Hazard Analysis capabilities → FUNCTIONAL SAFETY Safety functions nobody can prove still work Interlocks accumulate across decades and expansions, often without a Safety Requirements Specification, SIL verification, or proof test record. Our CFSEs determine required SIL, verify achieved SIL, write the SRS, and build the proof test procedures that make the claim defensible under ANSI/ISA 61511. Learn more about our Functional Safety capabilities → BURNER MANAGEMENT Burner management systems running past their support life Dryers, kilns, and waste heat boilers often run on burner management logic that predates current NFPA 86 practice, with hardwired interlocks nobody has verified in years. Nuisance trips cost production during the seasons you can least afford them, and a real demand may not find a working safety function. We design, fabricate, and commission BMS and combustion control systems to code, and factory acceptance test them before they reach your site. Learn more about our Burner Management System capabilities → PROCESS SAFETY PSM and RMP obligations on a plant you inherited Acquired sites frequently arrive without complete process safety information, current P&IDs, or a defensible PHA. Closing that gap under a corporate deadline requires more than a document review. We rebuild the process safety basis, facilitate the PHA and LOPA, and carry the findings into engineering so the compliance case is supported by real design. Learn more about our Process Safety capabilities → AUTOMATION AND CONTROL Control systems past vendor support during peak season Ag chem demand is seasonal, which compresses every outage window and raises the cost of an unplanned trip. We plan DCS and PLC migrations around production reality, with I/O cutover planning, staged commissioning, and documentation that survives the people who built it. Learn more about our Automation & Control capabilities → ALARM MANAGEMENT Operators buried under alarms during upsets When a nitric acid or ammonia unit upsets, alarm floods take away the situational awareness operators need most. Alarm philosophy development, rationalization facilitation, and advanced alarming restore a manageable alarm load and a clear operator response for each one. Learn more about our Alarm Management capabilities → — One Team, Not Five Vendors — Most firms serving ag chem do one thing. A process safety consultant facilitates your PHA and hands you a report. An integrator programs your PLC. A panel builder ships you a cabinet. Each is competent and none of them owns the seam between the others, which is exactly where projects fail and where risk quietly survives. aeSolutions covers the full lifecycle with one accountable team. The hazard scenario identified in your PHA becomes a Layer of Protection Analysis, which sets the required SIL, which drives the Safety Requirements Specification, which becomes a design, which is fabricated and factory acceptance tested in our own UL and FM certified panel shop in Greenville, South Carolina, and then installed and commissioned on your unit. No handoff between companies. No requirement lost in translation. One party responsible for the outcome. DISCIPLINE APPLIED IN AG CHEM Process Safety PHA, HAZOP, LOPA, QRA, PSM/RMP auditing, facility siting, Dust Hazard Analysis, electrical area classification, mechanical integrity Learn more → Functional Safety SIL determination and verification, Safety Requirements Specifications, Functional Safety Assessments, proof test procedures, functional safety management Learn more → Automation & Control DCS and PLC migration, I/O cutover planning, systems integration, HMI design, control narratives, instrument and electrical conceptual design Learn more → Combustion Systems Burner management and combustion control system design for boilers, process heaters, kilns, dryers, incinerators, and thermal oxidizers Learn more → Fire & Gas Plume dispersion modeling, detector coverage modeling, conceptual and detail design, FM approved system fabrication, commissioning Learn more → Alarm Management Alarm philosophy, rationalization facilitation, program audits, advanced alarming, implementation support Learn more → Project Development FEL 1 through 3, total installed cost estimating, scope definition, risk planning, PMO-led execution Learn more → Click Here to Speak with an Ag Chem Expert — Automation & Control Systems for Ag Chem — An ag chem site is rarely one kind of plant. A nitrogen complex runs continuously. The formulation building next to it runs recipes in batches. The bagging and palletizing line at the end runs discrete. Each demands a different control strategy, and the integration between them is where visibility and traceability are usually lost. MODE 01 Continuous Ammonia synthesis, nitric acid, and urea units run steady-state with tight interaction between pressure, temperature, and composition loops. Our work centers on regulatory control performance, safe operating limits, and the interface between the BPCS and the SIS, so the protective layer stays independent of the layer doing the controlling. TYPICAL SCOPE DCS and PLC migration with staged I/O cutover Control narrative and functional requirements Advanced regulatory control and loop performance BPCS and SIS independence verification Safe operating limit definition Learn more about our Automation & Control Capabilities → MODE 02 Batch Formulation, reaction, and blending operations run to recipe, where the sequence itself carries the hazard. Charge order, temperature ramp, and hold time are safety parameters, not just quality parameters. We build batch control that is structured, auditable, and able to fail safe mid-sequence. TYPICAL SCOPE Structured batch control and recipe management Sequence and phase logic with interlock alignment Reactive chemistry review feeding control strategy Batch reporting, electronic records, genealogy Safe-state definition and sequence hold or abort Learn more about our Systems Integration Capabilities → MODE 03 Discrete Granulation, screening, coating, bagging, and palletizing behave like discrete manufacturing lines, with the added complications of combustible dust and equipment that is difficult to guard. Machine safety, dust-rated design, and throughput reliability all have to hold at once, particularly during seasonal peaks. TYPICAL SCOPE Machine safeguarding and safety-rated control design Robotic and automated system risk assessment Packaging and material handling integration Dust hazard controls in the control system Line performance and downtime analysis Learn more about our Machine Safety Capabilities → — Platforms and Fabrication — — Siemens — aeSolutions has been a Siemens Solution Partner since 1999 and was the first company in the Americas to earn Siemens' PCS 7 Safety Specialist certification. Learn more about our Siemens Solution Partner credentials → — Rockwell — aeSolutions is a certified Rockwell Systems Integrator. This allows us to ensure we can provide the best possible solution and exceptional support with the least amount of risk for your company. Learn more about our Rockwell Systems capabilities → We work across Siemens, Rockwell, and other major platforms, and we fabricate, configure, and factory acceptance test complete systems in our own certified panel shop before anything ships to your site. Learn more about our panel fabrication capabilities → — 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 chaos and strengthen performance by embedding safety into the full project lifecycle. This is enhanced by our PMO professionals who ensure structure, accountability, and measurable progress. Our integrated services span PHA facilitation, compliance audits, facility siting, and risk management planning, supported by domain expertise and a focus on practical implementation. We work with your team to close gaps, clarify responsibilities, and convert fragmented practices into a unified approach that protects people, assets, and uptime. Whether you're navigating a revalidation or rethinking your 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 Success Stories 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 Success Stories Here — 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 Click Here to Chat With Our Industry Experts — Let's Discuss Your Ag Chem Facility Needs —

Discover how aeSolutions delivers cutting-edge process safety and industrial automation solutions across process industries like oil & gas, chemicals, pharmaceuticals, batteries, and more. Explore our expertise today! Industries Served — Solutions For Critical Industries — 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 aeSolutions provides deep expertise in the control and process safety management for the agrochemical industry, ensuring production stability and compliance with stringent environmental and safety regulations. We help clients manage the processes and hazards associated with fertilizers, pesticides, and other agricultural chemicals, including the safe handling of anhydrous ammonia and highly reactive substances. Learn More Battery Materials & Mineral Processing The production of battery materials requires safe handling of critical minerals, chemical processing, and fire/explosion risk management. aeSolutions delivers expertise in thermal runaway prevention, gas detection, and process hazard analysis to help clients mitigate risks and maintain regulatory compliance in lithium, nickel, and cobalt processing operations. Chemical Manufacturing Chemical production involves hazardous materials, stringent regulations, and high-risk processes. aeSolutions provides process automation, burner management, fire and gas detection, and process hazard analysis (PHA) to improve safety, efficiency, and regulatory compliance in bulk and specialty chemical production. Energy & Power Generation Energy production facilities, including traditional power plants, cogeneration units, and emerging alternative energy facilities, face complex control and safety challenges. aeSolutions provides fire and gas system design, combustion control and safety, and process hazard analysis to help clients maintain stable control, mitigate risks, enhance system reliability, and comply with industry standards. Hydrogen Production & Processing The hydrogen industry faces flammability risks, high-pressure storage challenges, and evolving regulatory requirements. aeSolutions specializes in the control, fire and gas detection, explosion protection, and quantitative risk analysis (QRA) to support the safety and efficiency of blue, green, and gray hydrogen production and processing facilities. Learn More Metals & Mining Processing Heavy industrial operations in metals refining, mineral extraction, and processing require robust control and safety solutions to address risks like combustible dust, high-temperature reactions, and hazardous material handling. aeSolutions provides dust hazard analysis (DHA), fire and gas detection, and process risk assessment to ensure safe and stable operations. Oil & Gas Production & Processing From upstream extraction to downstream refining, the oil and gas industry must navigate complex safety and regulatory challenges, including high-pressure systems, flammable materials, and mechanical integrity risks. aeSolutions delivers expertise in layers of protection analysis (LOPA), safety instrumented systems (SIS), and emergency relief system evaluation to enhance operational integrity and regulatory compliance. Petrochemicals & Hydrocarbon Processing Petrochemical plants handle highly hazardous chemicals that require advanced control and safety measures to maintain process stability and to prevent fires, explosions, and toxic releases. aeSolutions provides process automation, consequence modeling, relief system evaluation, and process safety engineering to improve reliability, protect personnel, and ensure compliance with safety regulations. Pharmaceutical & Life Sciences Manufacturing The pharmaceutical industry must balance product purity, process safety, and regulatory compliance while handling flammable solvents, high-potency chemicals, and strict environmental controls. aeSolutions delivers ventilation system design, containment strategies, and process hazard analysis (PHA) to support safe and compliant manufacturing. Renewable Fuels & Bioenergy Renewable fuel production — including biofuels, biogases, synthetic fuels, and waste-to-energy processes — introduces safety challenges such as combustion risks, toxic gas emissions, and complex reaction chemistry. aeSolutions provides process control, hazard identification (HAZID), fire and gas detection, and safety instrumented systems (SIS) design to mitigate these risks and enhance operational efficiency. Specialty Chemicals & Advanced Materials Specialty chemicals require precision in process control and stringent safety management to prevent hazardous incidents. aeSolutions provides continuous and batch control, process hazard analysis (PHA), fire and gas system design, and SIS implementation to protect personnel, optimize operations, and maintain regulatory compliance. Utilities & Critical Infrastructure Utility providers — including power generation, water treatment, and industrial gas distribution—must manage safety risks related to combustion systems, hazardous gas handling, and emergency response. aeSolutions delivers expertise in burner management systems (BMS), alarm management, and process safety engineering to ensure reliable and secure operations. Why aeSolutions? Trusted Go-To Partner for Our Clients' Tough Challenges Innovative, Sustainable Solutions to Create Client Value Professional Project Management to Drive Client Business Results Consistent Performance and Delivery on Our Commitments Recognized Extensively Credentialed Professionals (PE, CFSE, PMP) Active in Leadership of Professional Organizations (ISA, AIChE, CSIA) Involved in Development of International Standards & Industry Best Practices Deep Technical Acumen, Thought Leadership

Learn how the aeSolutions ResiliencePath Method can take your facility from risk to resilience. The aeSolutions ResiliencePath™ Method Designing robust systems that balance short-term objectives with long-term safety and operability — Reducing Chaos Through Predictable Execution — Aligned Execution that Drives ROI Scope, Schedule, & Budget Safety & Compliance Unit Production & Operability Project Objectives In industrial environments, unpredictability creates risk and stress. That’s why aeSolutions developed ResiliencePath™ , a methodology that pairs our risk-focused industry experts with our Project Management Office (PMO) professionals. Together, they bring structure, discipline, predictability, and control to even the most complex projects. This is especially important for projects delivering critical systems, where project misses can result in severe consequences. Whether we’re managing internal teams, collaborating with an EPC, or integrating subcontractors, our PMO ensures that every moving part is aligned, alleviating you from the stress of holding it all together. We Understand Your Pain Points With ResiliencePath™, scope creep and last-minute surprises become the exception, not the norm. More and more, it seems, projects are failing due to unclear expectations, role clarity, vague scopes, shrinking timelines, and shifting team priorities. Our team, backed by our ResiliencePath™ methodology, is countering this trend, bringing predictability to your projects and relief to your team. We drive long-term outcomes that are resilient by design, not piecemealed along the way. The ResiliencePath™ Three-Phase Approach We’ve helped countless clients go from risk findings to real-world resilience — without the chaos. You’re not left managing the mess. You’re not stuck bridging five vendors. You get a smoother project and, ultimately, a system that’s stable, documented, and easier to support. Ultimately, ResiliencePath™ moves your projects forward with less friction — and with results that last. Want to Learn More About the Impact ResiliencePath Can Make on Your Facility? Integrating the ResiliencePath™ Method We’re an integrative solutions provider with a proven methodology that pairs our risk-focused industry experts with our PMO professionals. Our ResiliencePath™ method 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 step of our unique methodology is driven by one goal: empowering resilient, value-aligned decisions that stand the test of time. EPC & Subcontractor Integration Our ResiliencePath™ methodology allows us 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 chaos and strengthen performance by embedding safety into the full project lifecycle. This is enhanced by our PMO professionals who ensure structure, accountability, and measurable progress. Our integrated services span PHA facilitation, compliance audits, facility siting, and risk management planning, supported by domain expertise and a focus on practical implementation. We work with your team to close gaps, clarify responsibilities, and convert fragmented practices into a unified approach that protects people, assets, and uptime. Whether you're navigating a revalidation or rethinking your strategy, aeSolutions helps you move from risk to resilience with clarity and confidence. ResiliencePath™ In Action — 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 Click Here to Chat With Our Industry Experts — Let's Discuss Moving Your Facility From Risk2Resilience —

The latest online content put into a monthly email newsletter from aeSolutions, an integrated lifecycle partner in process safety, combustion / fired equipment and automation. aeSolutions' Email Newsletter The latest online content from aeSolutions, an integrated lifecycle partner in process safety, automation and fired equipment, emailed straight to you every other month. Past Month's Newsletters: aeSolutions August 2026: PHA Revalidations - Beyond Checking Boxes | Can a Stage 3 FSA Confirm Your SIS is Ready to Use? | Protecting Your Personnel & Plant with Facility Siting aeSolutions July 2026: Case Study: Achieving a High-Risk Systems Overhaul on an Accelerated Schedule | How to Prevent the Most Common Industrial Alarm Management Issues | Scoping Your Industrial Project: Best Practices for Success aeSolutions June 2026: PHA Revalidations | 2026 CSIA Social Responsibility Award | 6 Strategies for Boiler Fuel Conversion Projects aeSolutions May 2026: PHA Recommendations Playbook Blog Series Pt. 3 | aeSolutions Designated Chemical Expert Within Siemens Solutions Partner Network | Control Systems Migrations Blog Series Pt. 7 R egister to Receive Monthly Emails Sign Up Now By providing this information, you agree to the processing of your personal data as described in our Privacy Policy. Sign Up Today! Keep up with aeSolutions Industry articles, upcoming events, and new ideas. Examples include topics such as Regulatory Compliance with Fire and Gas, Alarm Rationalization Whitepapers, Videos on Systematic Failures and what that really means, taking credit for protection layers, understanding protection layers and risk layering, and gas detection front end loading project management. What is LOPA and Lopa safety? Random failure of operator error due to human factors. Expert Engineers in Process Safety Management Services answers these with a PHA LOPA audit. We also often feature content on Burner Management systems. Our team understands the market and vendors.

Our professional staff ranges from recent college graduates to professional engineers with our more experienced professionals mentoring our newer staff. Many members of our team are industry leaders, serving in leadership positions on key industry committees. Our principals and employees have active The Leadership Team Warren Johnson Managing Director Roland Stock Managing Director Sarah Manelick Director of Sales & Marketing Ben Krisher Director of People Enablement Ashley Bull Director of Project Delivery Carolyn Bott Process Safety Group Manager Keith Brumbaugh Functional Safety Group Manager Jessica Bennett Networking & Systems Integration Group Manager Ken O'Malley Founder & President Joel Read Chief Financial Officer Our professional staff ranges from recent college graduates to professional engineers with our more experienced professionals mentoring our newer staff. Many members of our team are industry leaders, serving in leadership positions on key industry committees. Our employees actively participate in the development of industry codes and standard practices for engineering and implementation of control and safety-related system solutions. Our clients trust the aeSolutions team to deliver consulting and engineering expertise for smarter, more resilient industrial operations and safer communities.

Learn how aeSolutions was able to help our clients overcome their unique and challenging difficulties. Also see the Industry, Geography, Unit Operation, Governing Autority of the site Project Success Stories Learn how aeSolutions was able to help our clients overcome their challenges. Heater Controls Upgrade Improves Safety and Resilience of Arctic Pipeline Pump Stations The client engaged aeSolutions to evaluate and modernize their aging heater and heater control systems supporting critical pipeline pump station operations in an Arctic environment. These heaters provide essential building heat, ensuring pump stations remain operational during extreme cold conditions. Through a phased, lifecycle-based approach, aeSolutions supported the client from... Read More Custom SI-BMS Solution Enhances Reliability and Safety for Critical Pipeline Transportation Facility A critical pipeline transportation facility required a custom Safety Instrumented Burner Management System (SI-BMS) upgrade for their incinerator operations. The project involved implementing a SI-BMS compliant with NFPA 86, integrating alarm and first-out features, and establishing seamless communication with their existing Distributed Control System (DCS)... Read More Achieving a High-Risk Systems Overhaul on an Accelerated Schedule When TGES America, Ltd. needed a critical overhaul of the complex control system and instrumentation for the central utilities plant (CUP) of a specialty materials manufacturing plant, they turned to aeSolutions, a Siemens Solution Partner. Subsequently, due to the need to complete the project four months early, the planned cold cutover to the new systems had to be done as a hot cutover without disrupting production. TGES America, aeSolutions, and Siemens made it happen, much to the delight of the customer. Read More 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. Read More Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities aeSolutions was tasked to provide Front-End Loading (FEL) and Detail Design for a newly acquired legacy agricultural chemical facility in order to meet full compliance with PSM OSHA 1910.119 standards and the client’s corporate safety requirements. Read More Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant aeSolutions was challenged to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Read More A Strategic Integration of SIS, BMS, and PSM in a Boiler Fuel Conversion Project Implementing Safety Instrumented Systems (SIS) and Burner Management Systems (BMS) within tight deadlines and supply chain disruptions is challenging. A recent project converting boiler fuel from coal to natural gas with a Safety Instrumented BMS met strict safety standards despite these hurdles. Read More Alarm Management for a Greenfield LNG Facility A Liquefied Natural Gas (LNG) facility was being newly constructed (i.e., Greenfield) and the company wanted to conduct an alarm rationalization on the process prior to initial startup. Existing facilities (i.e., Brownfield) have the benefit of historical operating trends and data during a rationalization session to recognize whether setpoints are effective and which alarms might give troubles. Read More Pharma Company Detecting Natural Gas Leaks in Boiler House A pharmaceutical client determined they needed a natural gas leak detection and isolation system for a utility building based on a PHA recommendation. aeSolutions installed a combustible gas leak detection system to shut off the gas supply to the boiler, bringing the facility into compliance with the safety program requirements. Read More Large Specialty Chemical Company Reduces Alarm Floods A large specialty chemical company was facing alarm floods in their utility unit. With aeSolutions guidance, the site was able to effectively prioritize and reduce alarms through the rationalization process, which includes reviewing, validating, and justifying alarms needed for avoiding potential process upsets or abnormal deviations from normal operation. Read More Simplified, Cost-Effective, and Consistent Acidic Compound Detection New acid detector placement philosophy led to reduced maintenance , lowered costs, a reduced the likelihood of confusion during leaks, and helped create a uniform response strategy. Read More Energy Company Reduces Regulatory Compliance Costs Saving Almost $50 Million A client was facing a lengthy compliance process to upgrade a fleet of fired heaters. With aeSolutions guidance, the client reduced their compliance scope by 50%. Focusing on the NFPA 86 prescriptive design applicable to waste gas thermal oxidizers and applying our experience in Process Safety Management (PSM)... Read More Water Cannons Protect Community from Anhydrous Ammonia Leaks Client needed to reduce liability and risk associated with anhydrous ammonia storage tanks. aeSolutions provided a leak detection and suppression system that alerts personnel and provides the means to contain the resulting vapor cloud to the storage tank area using high-pressure, high-volume water cannons integrated with the control system. Read More Pharmaceutical Company Required Toxic & Combustible Gas Detection System A large-scale pharmaceutical manufacturing facility needed to develop and implement a gas detection system at their site to mitigate risk to personnel and equipment from a potential combustible or toxic gas leak. The project progressed from the assessment stages of developing a gas detection philosophy to ultimately integrating an industrially designed GDS 1400 MK II panel for the gas detection control and alarm system. Read More Complex Hot Cutover of Large Natural Gas Processing Facilities Due to facility siting factors, control rooms of one of the world’s largest natural gas (NG) processing and compression facilities were relocated from a possible blast zone to a Blast Resistant Modules (BRMs). This complex cutover for personnel relocation needed to be accomplished without a shutdown (S/D) of either interdependent ... Read More Specialty Chemical Site’s Increasingly Complicated Cutover When a project that began with standard safety system upgrades quickly expanded to a much broader scope of engineering with tight deadlines, aeSolutions responded with an experienced engineering workforce to deliver above-quality expectations while meeting key deadlines. Read More “Fit for Purpose” Solution Reduces Planned Downtime by 66% aeSolutions’ hybrid safety system design enabled the client to maintain safe continuity of their fired equipment, meet NFPA compliance, and significantly lower planned downtime. Read More 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. Read More Alarm System Rationalization and Safe Operating Limit for Energy Production A current client was adding a new energy production unit with an innovative process to an existing site and wanted to ensure the new design incorporated the site’s existing alarm management practices that were previously set up by the aeSolutions alarm management team. Read More

A small industrial computer originally designed to perform the logic functions executed by electrical hardware (relays, drum switches, and mechanical timer/counters). PLCs have evolved into controllers capable of controlling very complex processes. aeSolutions satisfies a project's safety interlock Safety Integrity Level (SIL) requirements with independent, SIL-certified safety PLC's that can be integrated with the process automation Distributed Control System (DCS) for monitoring and alarming. Acronyms & Terms Glossary <- More Definitions Programmable Logic Controller (PLC) A small industrial computer originally designed to perform the logic functions executed by electrical hardware (relays, drum switches, and mechanical timer/counters). PLCs have evolved into controllers capable of controlling very complex processes. aeSolutions satisfies a project's safety interlock Safety Integrity Level (SIL) requirements with independent, SIL-certified safety PLC's that can be integrated with the process automation Distributed Control System (DCS) for monitoring and alarming. 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.

NFPA 87 is the standard from the National Fire Protection Association that provides safety guidance for fluid heaters and related equipment to minimized fire and explosion hazards that can endanger the equipment, building, or personnel. A piece of equipment is considered to be a fluid heater if it includes any of the following features: fluid is flowing under pressure, fluid is indirectly heated, and/or a release of energy from combustion of a fuel or an electrical source occurs within the unit. Acronyms & Terms Glossary <- More Definitions NFPA 87 NFPA 87 is the standard from the National Fire Protection Association that provides safety guidance for fluid heaters and related equipment to minimized fire and explosion hazards that can endanger the equipment, building, or personnel. A piece of equipment is considered to be a fluid heater if it includes any of the following features: fluid is flowing under pressure, fluid is indirectly heated, and/or a release of energy from combustion of a fuel or an electrical source occurs within the unit. 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.

Area classification is the process of determining and designating specific zones within a facility where flammable gases, vapors, or combustible dusts may be present, potentially leading to hazardous conditions. These classified areas help guide safety measures and equipment installation, ensuring compliance with safety standards and reducing the risk of explosions or fires. Acronyms & Terms Glossary <- More Definitions Area Classification Area classification is the process of determining and designating specific zones within a facility where flammable gases, vapors, or combustible dusts may be present, potentially leading to hazardous conditions. These classified areas help guide safety measures and equipment installation, ensuring compliance with safety standards and reducing the risk of explosions or fires. 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.

Alarm management is a process to increase operator efficiency by decreasing workload, errors and uncertainty. It typically consists of designing an alarm philosophy, rationalizing alarms, implementing rationalization results, and monitoring and auditing alarm system performance and procedures. aeSolutions' integrated approach can supply expertise for all 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 Acronyms & Terms Glossary <- More Definitions Alarm Management Alarm management is a process to increase operator efficiency by decreasing workload, errors and uncertainty. It typically consists of designing an alarm philosophy, rationalizing alarms, implementing rationalization results, and monitoring and auditing alarm system performance and procedures. aeSolutions' integrated approach can supply expertise for all 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 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.

Software and hardware that allows human operators to monitor the state of a process under control, modify control settings to change the control objective, and manually override automatic control operations in the event of an emergency. The HMI also allows a control engineer or operator to configure set points or control algorithms and parameters in the controller. The HMI also displays process status information, historical information, reports, and other information to operators, administrators, managers, business partners, and other authorized users. Operators and engineers use HMIs to monitor and configure set points, control algorithms, send commands, and adjust and establish parameters in the controller. aeSolutions designs and configures human machine interfaces for control and safety systems. HMI varieties range from DCS vendors' hefty client-server systems to small touch screens engineered with special purpose panels. aeSolutions also develops alarm management philosophies which include HMI design guidance; a facility's various alarms and alert states are properly managed and prioritized to help operators maintain situational awareness. Acronyms & Terms Glossary <- More Definitions Human Machine Interface (HMI) Software and hardware that allows human operators to monitor the state of a process under control, modify control settings to change the control objective, and manually override automatic control operations in the event of an emergency. The HMI also allows a control engineer or operator to configure set points or control algorithms and parameters in the controller. The HMI also displays process status information, historical information, reports, and other information to operators, administrators, managers, business partners, and other authorized users. Operators and engineers use HMIs to monitor and configure set points, control algorithms, send commands, and adjust and establish parameters in the controller. aeSolutions designs and configures human machine interfaces for control and safety systems. HMI varieties range from DCS vendors' hefty client-server systems to small touch screens engineered with special purpose panels. aeSolutions also develops alarm management philosophies which include HMI design guidance; a facility's various alarms and alert states are properly managed and prioritized to help operators maintain situational awareness. 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.