A project management process during early stages of a project designed to minimize risk for investors and other stakeholders by developing adequate project definition & scope. aeSolutions uses front end loading in multiple types of projects. We invite you explore our service types to learn more. Acronyms & Terms Glossary <- More Definitions What is front end loading A project management process during early stages of a project designed to minimize risk for investors and other stakeholders by developing adequate project definition & scope. aeSolutions uses front end loading in multiple types of projects. We invite you explore our service types to learn more. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

Distributing Monitoring and Control Network Design Distributing Monitoring and Control aeSolutions designs industry standard as well as vendor specific networks for distributing controllers, I/O, data servers, and operator stations. Networks like Industrial Ethernet can be a composite of cables, fiber optics, and wireless systems, with managed switches and routers. aeSolutions recommends products and standards that we have tested for reliability, bandwidth, redundancy, distance, and industrial environments. Access points between the wide area enterprise networks and the critical control system networks must be managed carefully. Installation quality and signal testing are critical to achieving a fast, reliable control network. • Distributed I/O networks • Controller communication networks • HMI servers and client networks • Switches, routers, and firewalls • Single mode and multimode fiber optics • Coaxial and twisted pair cables • Drawings and Bills of Material Automation Services Previous Next

Shutdown logic refers to the programmed sequences and conditions under which a system or process will automatically shut down to prevent unsafe situations. This logic is embedded in safety systems to ensure quick and reliable response during emergencies. Acronyms & Terms Glossary <- More Definitions Shutdown Logic Shutdown logic refers to the programmed sequences and conditions under which a system or process will automatically shut down to prevent unsafe situations. This logic is embedded in safety systems to ensure quick and reliable response during emergencies. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

A hypothetical explosion, fire, or toxic event that has the potential maximum consequence to the occupants of the building under consideration from among the major scenarios evaluated. The major scenarios are realistic and have a reasonable probability of occurrence considering the chemicals, inventories, equipment and piping design, operating conditions, fuel reactivity, process unit geometry, industry incident history, and other factors. Each building may have its own set of MCEs for potential explosion, fire, or toxic material release impacts. Maximum Credible Events (MCEs) are considered during facility siting studies conducted by aeSolutions' experienced modelers. to help companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Acronyms & Terms Glossary <- More Definitions Maximum Credible Event (MCE) A hypothetical explosion, fire, or toxic event that has the potential maximum consequence to the occupants of the building under consideration from among the major scenarios evaluated. The major scenarios are realistic and have a reasonable probability of occurrence considering the chemicals, inventories, equipment and piping design, operating conditions, fuel reactivity, process unit geometry, industry incident history, and other factors. Each building may have its own set of MCEs for potential explosion, fire, or toxic material release impacts. Maximum Credible Events (MCEs) are considered during facility siting studies conducted by aeSolutions' experienced modelers. to help companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

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 Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

The systematic application of management policies, procedures, and practices to the tasks of analyzing, assessing, and controlling risk in order to protect employees, the general public, the environment, and company assets, while avoiding business interruptions. Acronyms & Terms Glossary <- More Definitions Process Risk Management The systematic application of management policies, procedures, and practices to the tasks of analyzing, assessing, and controlling risk in order to protect employees, the general public, the environment, and company assets, while avoiding business interruptions. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

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 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

An event or sequence of events that results in undesirable consequences. Scenarios are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Acronyms & Terms Glossary <- More Definitions Scenario An event or sequence of events that results in undesirable consequences. Scenarios are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

Optimizing Fuel Air Operation Combustion Control Systems - Automation Application Optimizing Fuel Air Operation aeSolutions' family of products includes industrial Combustion Control Systems in several packages. The pre-engineered packages are configurable to meet the client's operational requirements. The CCS is readily configured to implement a variety of fuel-saving optimization techniques, including fully metered / cross-limited fuel air control with oxygen trim, and interfacing to a wide variety of field sensors, analyzers, and valves. The CCS is often supplied as an integrated Combustion Management System package, which includes an aeSolutions BMS for safe startup, shutdown, and interlocking. • Graphical HMI common to CCS and BMS • Alarming, tuning, and diagnostic displays • Communications to BMS and DCS • Multiple fuel optimization • Cross-limiting, Oxygen trim • Boilers, heaters, dryers, thermal oxidizers • Combustion Management Engineering Automation Services Previous Next

Device failure, system failure, external event, or improper human action that begins a sequence of events leading to one or more undesired consequences of definable severity. Initiating events are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Acronyms & Terms Glossary <- More Definitions Initiating Event Device failure, system failure, external event, or improper human action that begins a sequence of events leading to one or more undesired consequences of definable severity. Initiating events are considered during Process Hazard Analyses (PHAs) conducted by aeSolutions' trained facilitators. PHAs help companies identify hazard scenarios that could lead to a release of highly hazardous chemicals that can cause negative impact on people, the environment, and property. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

To use an instrument or component that has not been designed in accordance with IEC 61508, the "proven in use" concept can be applied given that a system for gathering reliability data and ways to assess the recorded data to determine the safety integrity of the system, as well as recorded historical evidence of device hours in use are present. Acronyms & Terms Glossary <- More Definitions Proven in Use To use an instrument or component that has not been designed in accordance with IEC 61508, the "proven in use" concept can be applied given that a system for gathering reliability data and ways to assess the recorded data to determine the safety integrity of the system, as well as recorded historical evidence of device hours in use are present. Our Services Processing Magazine: The Need for a Control System Migration: Building the Case to Upper Management Check out our article in Processing Magazine where Tom McGreevy discusses tips to earn the support of leadership when proposing a control system migration. Chemical Processing: How They Made It Work: aeSolutions' FGS 1300 Fire and Gas Alarm Controller Check out our coverage in Chemical Processing's "How They Made It Work" series. PHA Revalidations | Beyond Checking Boxes Keep your facility safe and compliant — don’t let your PHA become a “check-the-box” task. Regular, well-executed PHA revalidations identify evolving risks and turn findings into action, ensuring lasting protection for your people, assets, and operations.

Testing and Turnover Site Acceptance Testing and Startup Testing and Turnover After the control system and I/O have been installed and commissioned, aeSolutions works with the client to deliver Site Acceptance Testing in accordance with aeSolutions' generated SAT plan. SAT is similar to the FAT but includes testing of actual field devices and foreign device interfaces. Site Acceptance Testing proves that the supplied system, including the control logic and operator stations, is interfaced to the field I/O correctly and performs in accordance with the project specifications. aeSolutions offers startup support after the client has accepted the system. • Approved SAT test plan • SAT test results and punch list disposition • Startup assistance support Automation Services Previous Next