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

The process of simulating potential outcomes of hazardous events, such as chemical releases, explosions, or fires, to assess their impact on people, property, and the environment. It helps organizations predict the severity and extent of these events, informing safety measures and risk mitigation strategies. Acronyms & Terms Glossary <- More Definitions Consequence Modeling The process of simulating potential outcomes of hazardous events, such as chemical releases, explosions, or fires, to assess their impact on people, property, and the environment. It helps organizations predict the severity and extent of these events, informing safety measures and risk mitigation strategies. Our Services 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. Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone.

NFPA 85 is the standard from the National Fire Protection Association that outlines operating safety and how to prevent explosions and implosions in boilers with greater than 12.5 MMBTUH, pulverized fuel systems, and heat recovery steam generators. This code also addresses the minimum guidelines for the installation, operation, and maintenance of this equipment. Acronyms & Terms Glossary <- More Definitions NFPA 85 NFPA 85 is the standard from the National Fire Protection Association that outlines operating safety and how to prevent explosions and implosions in boilers with greater than 12.5 MMBTUH, pulverized fuel systems, and heat recovery steam generators. This code also addresses the minimum guidelines for the installation, operation, and maintenance of this equipment. Our Services 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. Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone.

Cause & Effect (C&E) diagrams show the relationship between sensor inputs and their required outputs. C&Es provide a clear and concise visual representation in tabular form, allowing users to quickly and easily view multiple functions within a process area or logic solver. They are commonly used as functional specifications for PLC-based programs, such as a Safety Requirement Specification (SRS) for a Safety Instrumented System (SIS). As such, they are of critical importance to successful implementation of the Safety Instrumented Functions (SIFs) in any functional safety project. While C&Es are not directly required by the ANSI/ISA-61511-2-2018 / IEC 61511-2:2016 standard, they are often included as an extension of the SRS, making them a part of the Safety Lifecycle. aeSolutions C&E diagrams use standard industry terms or terms that the client has clearly defined and are named, formatted, tracked, issued, controlled, and checked per aeSolutions company procedures unless superseded by specific client requirements. Our C&E templates have been developed from many years of experience to optimize ease-of-use for configuration, testing, operator training and turnover effectiveness. In cases where the functional complexity exceeds the capacity of C&Es, our staff is capable of selecting the most efficient alternate format. Acronyms & Terms Glossary <- More Definitions Cause and Effect Cause & Effect (C&E) diagrams show the relationship between sensor inputs and their required outputs. C&Es provide a clear and concise visual representation in tabular form, allowing users to quickly and easily view multiple functions within a process area or logic solver. They are commonly used as functional specifications for PLC-based programs, such as a Safety Requirement Specification (SRS) for a Safety Instrumented System (SIS). As such, they are of critical importance to successful implementation of the Safety Instrumented Functions (SIFs) in any functional safety project. While C&Es are not directly required by the ANSI/ISA-61511-2-2018 / IEC 61511-2:2016 standard, they are often included as an extension of the SRS, making them a part of the Safety Lifecycle. aeSolutions C&E diagrams use standard industry terms or terms that the client has clearly defined and are named, formatted, tracked, issued, controlled, and checked per aeSolutions company procedures unless superseded by specific client requirements. Our C&E templates have been developed from many years of experience to optimize ease-of-use for configuration, testing, operator training and turnover effectiveness. In cases where the functional complexity exceeds the capacity of C&Es, our staff is capable of selecting the most efficient alternate format. Our Services 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. Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone.

A relatively new risk assessment model based on systems theory. It helps understand all factors involved in accidents, including human social and organizational structures. Acronyms & Terms Glossary <- More Definitions Systems Theoretic Accident Model and Processes (STAMP) A relatively new risk assessment model based on systems theory. It helps understand all factors involved in accidents, including human social and organizational structures. Our Services 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. Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone.

An independent protection layer (IPL) is a a system of logic solvers, a human action, or a device that reduces risk of a chemical /energy release while being independent of the initiating event. The Center for Chemical Process Safety (CCPS) requires a protection layer to achieve the following seven core attributes to be considered an IPL: independent, functional; integrity; reliable; validated; maintained and audites; access security; and management of change. Acronyms & Terms Glossary <- More Definitions Independent Protection Layer An independent protection layer (IPL) is a a system of logic solvers, a human action, or a device that reduces risk of a chemical /energy release while being independent of the initiating event. The Center for Chemical Process Safety (CCPS) requires a protection layer to achieve the following seven core attributes to be considered an IPL: independent, functional; integrity; reliable; validated; maintained and audites; access security; and management of change. Our Services 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. Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone.

An alarm that annunciates excessively, unnecessarily, or does not return to normal after the correct response is taken (e.g., chattering, fleeting, false, or stale alarms). aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Acronyms & Terms Glossary <- More Definitions Nuisance Alarm An alarm that annunciates excessively, unnecessarily, or does not return to normal after the correct response is taken (e.g., chattering, fleeting, false, or stale alarms). aeSolutions can supply expertise at all stages of alarm management including consulting, training, and facilitating rationalization teams, followed by full design and implementation services. Our Services 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. Whitepaper: Six Feet Under | How to Dig Yourself Out of a Recommendations Graveyard Have you felt buried under six feet of safety study recommendations that must be closed? Does it feel impossible to follow Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) to convert recommendations into engineered design reality? You are not alone.

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

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 —

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. Engineering smarter, safer operations. — 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 — 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 Scoping Your Industrial Project: Best Practices for Success — Let's Discuss Your Facility's Needs —

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

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