Our system design services include developing wiring plans, functional test plans, factory acceptance and site acceptance test plans (FAT/SAT Plans).  During the Factory Acceptance Testing (FAT) we confirm that all aspects of the control system are in full compliance with the final design documentation. Gas detection compliance  toxic gas detection and toxic gas monitoring Fire and Toxic & Combustible Gas - Detailed Engineering aeSolutions utilizes first-hand industry experience to design clients' Fire and Gas Systems to the latest FM Approved standards. Our system design services include developing wiring plans, functional test plans, factory acceptance and site acceptance test plans and facilitation(FAT/SAT Plans). During the Factory Acceptance Testing (FAT) we confirm that all aspects of the control system are in full compliance with the final design documentation. Written Narrative Riser Diagram Floor Plan Layout Sequence of Operation Field Design Deliverables Manufacturer’s Published Instructions Battery Calculations Voltage Drop Calculations Detector Final Placement End Device Selection I/O Assignment Panel Design Architecture Block Diagram Cable Schedule / Cable Block Diagrams Detailed Design Deliverables Installation Details for End Devices Engineering and Design calculations Completion Test Forms HMI screen requirements Installation Support Fire & Gas Products NRTL Approved Fire Panels NRTL Approved Power Supplies NRTL Approved Proprietary Supervisor Stations Ensure toxic gas detection Ongoing Maintenance Training - to Operate, Maintain, and More Fire & Gas Lifecycle Services Contact Us

The Safety Requirement Specification (SRS) (clause 10 of ISA/IEC 61511) takes the results of the hazard and risk assessments and defines the requirements of the Safety Instrumented Functions (SIFs) that have to be performed by the Safety Instrumented Systems (SIS). aeSolutions is qualified with Certified Functional Safety Experts to quantify process hazard risks and develop the Safety Requirement Specification (SRS) for a process. The SRS is an input to the SIS design process but not all of the required information is available when design starts. Our SIS Specialists have configuration, instrumentation, and operations experience, allowing them specify feasible solutions to complex SIF implementation problems. Acronyms & Terms Glossary <- More Definitions Safety Requirement Specification (SRS) The Safety Requirement Specification (SRS) (clause 10 of ISA/IEC 61511) takes the results of the hazard and risk assessments and defines the requirements of the Safety Instrumented Functions (SIFs) that have to be performed by the Safety Instrumented Systems (SIS). aeSolutions is qualified with Certified Functional Safety Experts to quantify process hazard risks and develop the Safety Requirement Specification (SRS) for a process. The SRS is an input to the SIS design process but not all of the required information is available when design starts. Our SIS Specialists have configuration, instrumentation, and operations experience, allowing them specify feasible solutions to complex SIF implementation problems. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

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. Challenge Established facilities 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. Without any data to fall back on for the process with newfound sciences, however, the alarm program and rationalization process based alarm setpoints; on cause and effects, the site’s PHA, and research-based engineering design for this new innovative technology. Setting up an alarm system for the new energy production unit with no real operating experience required relying on good engineering practices and experience. The alarm rationalization sessions required very proficient engineers, instrumentation personnel, and senior-level operators to ensure a knowledge base strong enough to appropriately identify alarms and the actions to be taken. A heavily experienced and technical team was necessary to understand the process hazards and responses to those hazards. The project timeliness also presented challenges to meet all the schedule deadlines of the multiple vendors involved. There was a higher sense of urgency for the new energy production unit with reduced timeline flexibility as the alarm system needed to be completed prior to startup. Solution aeSolutions organized and facilitated team meetings to capture process knowledge and hazard identification with adherence to industry guidelines and standards. An engagement meeting was performed where previously developed templates were applied and new templates specific to the energy production unit were developed prior to the alarm rationalization activities. During the alarm rationalization meetings, a checklist of specific questions was analyzed and documented for each unique alarm. The questions generated team discussion on alarm basis (e.g., setpoint, response time, etc.), characteristics (class, attributes, etc.), and whether alarms met the definition of the alarm specified in the alarm philosophy. Effective alarm points were established to mitigate identified hazards and inefficiencies for increased safety, environmental, and operability of the site. Results The new energy production unit had a completed master alarm database able to be imported into the site’s alarm management software. The master alarm database included all ISA 18.2 required information as well as the site-specific alarm response requirements for the process. The alarm data deliverables had the ability to be converted and uploaded into the client’s existing alarm management software to provide consistency from previous rationalization activities. Although the new energy production unit had an unfamiliar cutting-edge process, basic alarm management principles were effectively applied to effectively guide the team to a successful product. Learn more about how aeSolutions could help you with a similar alarm project. Industry: Green Energy Geography: Southwest Unit Operation: Alarm Rationalization, Alarm Management Previous Story Next Story

The graphic model of Fault Tree Analysis (FTA) is a type of failure analysis in which an undesirable condition of a system is explored. By use of Boolean logic, a Fault Tree Diagram shows the logical interrelation of events that, taken apart or together, may lead to a system or device failure. Acronyms & Terms Glossary <- More Definitions Fault Tree Diagram The graphic model of Fault Tree Analysis (FTA) is a type of failure analysis in which an undesirable condition of a system is explored. By use of Boolean logic, a Fault Tree Diagram shows the logical interrelation of events that, taken apart or together, may lead to a system or device failure. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Failure related in a deterministic way to a certain cause, which can only be eliminated by a modification of the design or of the manufacturing process, operational procedures, documentation, or other relevant factors. Acronyms & Terms Glossary <- More Definitions Systematic Failure Failure related in a deterministic way to a certain cause, which can only be eliminated by a modification of the design or of the manufacturing process, operational procedures, documentation, or other relevant factors. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

An alarm that remains in the alarm state after the process has returned to normal and requires that an Operator reset it before it will clear. 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 Latching Alarm An alarm that remains in the alarm state after the process has returned to normal and requires that an Operator reset it before it will clear. 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: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Site Acceptance Testing occurs at a client’s site after equipment delivery to verify whether equipment meets the functionality and performance requirements specified by the client. This testing occurs after all equipment commissioning tasks but before installation. This differs from a Factory Acceptance Test (FAT) since it occurs after delivery. AKA: What is a site acceptance test? or What is a sat acceptance test? Acronyms & Terms Glossary <- More Definitions Site Acceptance Testing (SAT) Site Acceptance Testing occurs at a client’s site after equipment delivery to verify whether equipment meets the functionality and performance requirements specified by the client. This testing occurs after all equipment commissioning tasks but before installation. This differs from a Factory Acceptance Test (FAT) since it occurs after delivery. AKA: What is a site acceptance test? or What is a sat acceptance test? Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

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). aeSolutions provided an Allen-Bradley control system featuring a GuardLogix controller with POINT Guard Safe I/O, a new Human-Machine Interface (HMI), and extensive on-site support, significantly improving the reliability and safety of the client’s operations. Challenge The client faced numerous challenges with their existing incinerator burner management system. The previous system lacked first-out indications and alarm features, making troubleshooting operational shutdowns time-consuming and inefficient. Additionally, there were challenges in implementing a new BMS. Handling multiple burners and switching fuel sources between fuel oil and waste gas added further complexity to operations. Moreover, integration between the new BMS and existing DCS required extensive on-site testing and validation. The remote geographic location compounded these challenges, requiring extended on-site support due to logistical constraints related to weather and travel. Solution Leveraging dual expertise in safety engineering and control systems integration, aeSolutions implemented a tailored SI-BMS that significantly enhanced operational transparency and control. The new SI-BMS solution provided clear first-out alarms, pinpointing exact causes for shutdowns and drastically reducing troubleshooting time. aeSolutions ensured NFPA 86 compliance and delivered a robust solution capable of managing the complex operational scenarios involving four burners with interchangeable fuel sources. One of the key factors in the success of this project was aeSolutions’ project delivery team, which brought together our risk-focused industry experts and hands-on technical specialists. This enabled real-time responsiveness to client needs during commissioning. Changes to the Safety Requirements Specification (SRS) and system configuration were executed seamlessly, including on-site, in direct response to client feedback and operating conditions. The team’s ability to evaluate safety impacts and implement adjustments quickly, without compromising compliance, demonstrated the strength of integrating safety and controls expertise within one provider. aeSolutions worked closely with the client’s DCS programmer to resolve integration challenges, coordinating communication protocols and aligning system behaviors across platforms. This flexibility not only helped overcome technical hurdles but also ensured that the final system supported the client’s preferred operational practices. Results The client’s operational efficiency, reliability, and resilience substantially improved upon commissioning of the new BMS solution. Operators gained immediate clarity from the introduction of first-out alarms, resulting in quicker resolutions and significantly reduced downtime. The upgraded system consistently achieved reliable startups, eliminating previous issues related to intermittent operational failures. Furthermore, aeSolutions’ flexible and collaborative approach in adjusting and refining system configurations during commissioning directly supported the client’s unique operational needs. This approach not only ensured safety and compliance but also provided tangible time savings, thereby delivering immediate and ongoing value. Following this project’s success, the client has continued to engage aeSolutions for additional critical infrastructure projects, highlighting the sustained value and effectiveness of our tailored solutions. Industry: Oil & Gas Geography: Pacific Northwest Unit Operation: Customized Safety Instrumented Burner Management System (SI-BMS), POINT Guard Safe I/O, Human-Machine Interface (HMI) Previous Story Next Story

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: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

Converting Concept to Design Basis Preliminary Engineering Converting Concept to Design Basis aeSolutions works with clients to form preliminary engineering documentation based on the conceptual design and assists clients in choosing an appropriate control system vendor. Client review and approval cycles assure the quality of the functional requirements specification. • Instrument data sheets • Functional requirements specification • Instrument list and I/O count • Operating ranges, alarm and trip setpoints • Plant drawings (P&I, I&E, Loop, LAN, Arrangement) • Preliminary project architecture and migration drawings • Vendor platform evaluations • Bills of Material - hardware and software • Project cost and schedule estimates +/- 10% Automation Services Previous Next

Functional Safety is the process of reducing the risks of both simple and complex systems so that they function safely if a hardware, operational, or human failure occurs. When every safety function is carried out as prescribed and the performance standards for each safety function are met, “Functional Safety” has been achieved. Acronyms & Terms Glossary <- More Definitions Functional Safety Functional Safety is the process of reducing the risks of both simple and complex systems so that they function safely if a hardware, operational, or human failure occurs. When every safety function is carried out as prescribed and the performance standards for each safety function are met, “Functional Safety” has been achieved. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.

A Variable Frequency Drive (VFD) is an electronic device that controls the speed and torque of an electric motor by varying the frequency and voltage of the power supplied to the motor. VFDs improve energy efficiency, enhance motor performance, and allow for precise control in applications such as HVAC systems, pumps, and conveyors. Acronyms & Terms Glossary <- More Definitions Variable Frequency Drives (VFD) A Variable Frequency Drive (VFD) is an electronic device that controls the speed and torque of an electric motor by varying the frequency and voltage of the power supplied to the motor. VFDs improve energy efficiency, enhance motor performance, and allow for precise control in applications such as HVAC systems, pumps, and conveyors. Our Services Whitepaper: Achieving 84-92% Urgent Alarm Reduction Through Comprehensive Lifecycle Implementation: A Dual-Unit Midstream Case Study Awarded Best Paper Award at the 2025 TEES Mary Kay O'Connor Process Safety Center-TAMU (MKO) Safety & Risk Conference Abstract November 2025 — Greg Pajak, aeSolutions Senior Specialist, ICA — A midstream facility implemented a systematic alarm rationalization program across two critical units, achieving unprecedented reductions in urgent alarm loads. Unit A reduced urgent alarms from 45% to 7% (84% reduction), while Unit B decreased from 62% to 5% (92% reduction). This paper Scoping Your Industrial Project: Best Practices for Success Scoping your industrial project is more than a kickoff step—it’s the foundation for budget, schedule, and long-term success. From aligning stakeholders to pressure-testing assumptions, a dynamic scoping strategy helps prevent costly missteps, manage risks, and keep your project on track from concept to completion. Control System Migrations | Part 7 | Best Practices for Installation, Testing, & Commissioning The cutover phase is the defining moment of a control system migration, where planning meets execution. From thorough backups and pre-shutdown prep to mechanical completion and commissioning, every step must be precise. Skipping even small details can lead to costly setbacks, while disciplined execution ensures a smooth, successful transition.