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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 integration of diverse control systems (e.g., BPCS, SIS, ESD, F&G, etc.) into a unified system; this includes interfacing hardware, software, and services from multiple vendors and client stakeholders to improve quality and performance and add value (e.g., reducing operational costs and improving response time). aeSolutions' controls experts design complete construction and panel packages which interface the existing facility controls with the new controls systems. aeSolutions orchestrates the system integration model by providing the Automaton Support Matrix and Schedule documents which coordinate resources and personnel throughout the project execution phase. Acronyms & Terms Glossary <- More Definitions Systems Integration The integration of diverse control systems (e.g., BPCS, SIS, ESD, F&G, etc.) into a unified system; this includes interfacing hardware, software, and services from multiple vendors and client stakeholders to improve quality and performance and add value (e.g., reducing operational costs and improving response time). aeSolutions' controls experts design complete construction and panel packages which interface the existing facility controls with the new controls systems. aeSolutions orchestrates the system integration model by providing the Automaton Support Matrix and Schedule documents which coordinate resources and personnel throughout the project execution phase. 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.

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

API 525 is a recommended practice developed by the American Petroleum Institute for conducting tests to determine performance characteristics of a given design of pressurerelieving device which is required to operate under variable superimposed back-pressure conditions with compressible fluids. Acronyms & Terms Glossary <- More Definitions API 525 API 525 is a recommended practice developed by the American Petroleum Institute for conducting tests to determine performance characteristics of a given design of pressurerelieving device which is required to operate under variable superimposed back-pressure conditions with compressible fluids. 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 enclosed unit that users can access to control or monitor instruments and equipment. Each panel is designed for a specific equipment arrangement and includes devices that allow an operator to control specified equipment. aeSolutions operates its own 10,000 square foot FM-approved and UL 508a-certified panel fabrication and testing facility. The aeSolutions team designs and builds sophisticated panels both for a wide variety of projects, from small operator PLC cabinets, to large multi-bay safety and control systems designed to run large facilities. Process simulation test beds are built to prove that controls and operator interfaces will function in accordance with project requirements. Acronyms & Terms Glossary <- More Definitions Control Panel An enclosed unit that users can access to control or monitor instruments and equipment. Each panel is designed for a specific equipment arrangement and includes devices that allow an operator to control specified equipment. aeSolutions operates its own 10,000 square foot FM-approved and UL 508a-certified panel fabrication and testing facility. The aeSolutions team designs and builds sophisticated panels both for a wide variety of projects, from small operator PLC cabinets, to large multi-bay safety and control systems designed to run large facilities. Process simulation test beds are built to prove that controls and operator interfaces will function in accordance with project requirements. 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.

Failure of more than one device, function, or system due to the same cause. Acronyms & Terms Glossary <- More Definitions Common Cause Failure Failure of more than one device, function, or system due to the same cause. 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.

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 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 systematic review to identify and evaluate the potential fire, flash fire, or explosion hazards associated with the presence of one or more combustible particulate solids in a process or facility. Acronyms & Terms Glossary <- More Definitions Dust Hazard Analysis (DHA) A systematic review to identify and evaluate the potential fire, flash fire, or explosion hazards associated with the presence of one or more combustible particulate solids in a process or facility. 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.

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 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.

In reliability engineering, availability refers to the proportion of time a system or component is operational and able to perform its required function. It is a key performance indicator that combines reliability, maintainability, and maintenance support aspects. Acronyms & Terms Glossary <- More Definitions Availability (reliability engineering) In reliability engineering, availability refers to the proportion of time a system or component is operational and able to perform its required function. It is a key performance indicator that combines reliability, maintainability, and maintenance support aspects. 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.

Control rooms, ergonomic multi-window stations Field panels, touch screen HMI Situational awareness Contextual data and trends Intuitive navigation Meaningful dynamics Single HMI for multiple control platforms and migrations Project specific HMI style guide Rockwell, Siemens PC7, Safety systems and critical controls, Triconex Human Machine Interfaces - SCADA Interacting with Intuitive Information 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. To avoid incidents, an operator needs to quickly comprehend and react appropriately to changing conditions in the plant. Flashy graphics of the 1990's had too many distractions and made it hard to comprehend abnormal situations. Standards working groups like ASM, and ISA101-HMI are driving toward industry consensus. Control rooms, ergonomic multi-window stations Field panels, touch screen HMI Situational awareness Contextual data and trends Intuitive navigation Meaningful dynamics Single HMI for multiple control platforms and migrations Project specific HMI style guide Automation Services

An Emergency Shutdown System (ESD) is a safety system designed to rapidly shut down processes or equipment in response to unsafe conditions, such as a gas leak or fire. ESD systems are crucial for preventing accidents, limiting damage, and protecting personnel. Acronyms & Terms Glossary <- More Definitions Emergency Shutdown System (ESD) An Emergency Shutdown System (ESD) is a safety system designed to rapidly shut down processes or equipment in response to unsafe conditions, such as a gas leak or fire. ESD systems are crucial for preventing accidents, limiting damage, and protecting personnel. 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.