aeSolutions is a total process automation provider with extensive experience in turnkey solutions. We've earned aeSolutions was the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification. ​aeSolutions' President, Ken O’Malley, holds a position on Siemens’ User Advisory Boar Siemens Solution Partner - aeSolutions aeSolutions is a process automation engineering company with extensive experience in delivering turnkey automation solutions and is a leading provider of critical systems such as Safety Instrumented Systems, Fire and Gas Systems, and Combustion Control and Safeguarding Systems in the country. The company maintains a team of experienced Professional Engineers and Certified Functional Safety Experts (CFSE). aeSolutions joined Siemens Solution Partner Program in 1999 and has earned the Solution Partner Specialist designation after achieving technical and commercial milestones associated with year-over-year quality performance delivering solutions in both brownfield migrations and greenfield expansions for over two decades. We're proud to have been the first company in the Americas to earn Siemens’ PCS 7 Safety Specialist certification. Siemens.com Partner Detail Page aeSolutions' President, Ken O’Malley , holds a position on Siemens’ User Advisory Board as well as Siemens’ national Solution Partner Council. Service Portfolio: Consulting for process safety and automation conceptual design Automation of process manufacturing facilities Training on PSM and process automation and safety systems Integration, Engineering, and Commissioning of DCS, SIS, BMS and fire & gas systems FM and UL certified panel fabrication shop Migrations & upgrades of automation & safety systems aeSolutions: Certificates: Solution Partner Process Control System SIMATIC PCS 7 Advanced Factory Automation PCS 7 Safety Specialist Systems Intergration - Automation Services Combustion - Burner Management Systems aeSolutions & Siemens Media aeSolutions is the First in Americas to earn S iemens SIMATIC PCS 7 Safety Specialist Certifications “As customers require PCS 7 safety instrumented systems, we can recommend aeSolutions, our certified Process Safety Specialist Solution Partner, knowing that they have the engineering and quality practices to execute the project right the first time using best practices,” says Rich Chmielewski, Siemens USA PCS 7 Solution Partner Program Manager. Learn More Using the cloud to secure the cloud https://www.controlglobal.com Best practices for gas detection system design https://www.controlglobal.com aeSolutions is First in the Americas to Earn Siemens SIMATIC PCS 7 Safety Specialist Certification https://www.automationworld.com aeSolutions & Siemens Case Studies Ammonia isolation and mitigation safety system based on FGS 1400 MK II platform. Uses S7-400 safety controllers and S7-300 safety IO. Ammonia suppression safety system that is NRTL approved for toxic gas. FGS 1400 MK II product provides leak detection, occupant notification, equipment isolation, and hazard suppression capability for a pressurized ammonia storage facility. View Details aeSolutions applies our expertise to help you produce Hydrogen safely. Expertise is required to produce hydrogen safely especially indoors with electrolyzers. You are working with a dangerous chemical and with modeling of the gas, especially indoors, you can properly place the detectors. Fire and Gas, Safety Shutdown systems as well as overall process automation best practices, are critical to safely product hydrogen. View Details Optimizing Integration of Life-Saving Gas Detection Systems for the Pharmaceutical Industry Leverage the expertise of Solution Partner aeSolutions to provide plants with turnkey gas detection systems including all control system components, detectors and computational fluid dynamics modeling. Benefits can include: •Ensures OSHA compliance to reduce risk of overexposure, fire or explosion •Simplified integration of gas detection systems into plants •Minimized footprint due to modern I/O technology View Details Siemens PCS7 Implemented as SI-BMS for Utility Boilers at Chemical Plant Designed, fabricated, configured, tested and performed start-up services for seven burner management systems (BMS) on seven coal and gas fired process boilers for a chemical manufacturing plant. View Details Fire & Gas Safety System using SIMATIC S7-400F provides highly scalable flexibility for industrial Fire and Gas applications. FM approved Fire and Gas safety system based on S7-400 safety controllers and ET200MF safety IO. System provides detection, notification, suppression, and process ESD shutdowns. System also has FM approved power supply system capable of supplying OSHA and NFPA 72 power requirements. View Details Meeting Customer Demand by Doubling Production PCS 7 Simatic Batch and PCS 7 Failsafe were used to automate a new reactor and associated equipment to double production View Details Safety Shutdown and BMS needs met with Compliant System Refineries burner management and safety shutdown needs are met with rack-to-rack redundant PCS 7 Failsafe System and Safety Matrix. View Details Siemens PCS 7 TIA Success: Instrumentation and Motor Control Centers as a Modular and Scalable Solution The SEFA Group plant gives a local supply of a premium recycled product available for sustainable construction. Siemens PCS 7 was successfully integrated using TIA with all instrumentation and motor control centers to aid in elimination of up to 400,000 tons of fly ash per year transported to landfills. This also improved reliability with PCS7 tools View Details www.usa.siemens.com/process

An organization that implemented Section 112(r) of the 1990 Clean Air Act amendments and requires facilities that use extremely hazardous substances to develop a Risk Management Plan (RMP) per 40 CFR 68.150 to 68.185. aeSolutions has the knowledge and experience to assist with all elements of RMP development and implementation required by the EPA RMP Standard, 40 CFR 68, from high level gap and applicability assessments to complete RMP site program development, including drafting procedures and creating mechanical integrity programs. Acronyms & Terms Glossary <- More Definitions Environmental Protection Agency (EPA) An organization that implemented Section 112(r) of the 1990 Clean Air Act amendments and requires facilities that use extremely hazardous substances to develop a Risk Management Plan (RMP) per 40 CFR 68.150 to 68.185. aeSolutions has the knowledge and experience to assist with all elements of RMP development and implementation required by the EPA RMP Standard, 40 CFR 68, from high level gap and applicability assessments to complete RMP site program development, including drafting procedures and creating mechanical integrity programs. 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.

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. Challenge This pharmaceutical facility had a large number of uncommon toxic and combustible gases and vapors. The gas detection philosophy document needed to account for the physical properties of the gases present at the site. The previously developed gas detection philosophy document did not account for the required gas detection alarm levels and sensor ranges. It also did not account for the limitations of the available detection technologies. Additionally, the document needed to describe how to address cross-sensitivity when multiple gases are present in the same area. Solution We developed a gas detection philosophy in compliance with the latest industry standards. The document addressed all of the following: • The physical characteristics of the gases and vapors at the facility • Industry-recognized exposure levels for the gases • Preferred gas detection technologies • Minimum requirements for gas detection including leak sizes • Addressed gas detection cross sensitivities aeSolutions designed and provided a comprehensive gas detection system to monitor all of the toxic and combustible gases and alert personnel to the hazards. Once established, the gas detection philosophy was used as the basis for integrating the GDS 1400 MK II gas detection control and alarm system. This unit utilizes the Siemens Simatic PCS7 series hardware/software platform and interfaces to the facility’s building management system and fire alarm panel. Its SIL 3-capable logic solver was scalable to a large I/O count, which ended up totaling 650 I/O counts distributed among seven (7) remote I/O panels for the large number of chemicals. The following were delivered: • Gas Detection Philosophy Document • Gas Detection Plot Plan and placement within the client 3D model • GDS 1400 MK II Gas Detection System • Specified and procured all of the gas detectors • Interface with building management system for HVAC control (e.g., overriding the HVAC control to dilute and/or remove explosive gases from the facility) • Interface with Fire Alarm panel for mass notification messaging • Interface with process control system for process shutdowns, where applicable Results The pharmaceutical company now has a scalable gas detection system capable of reducing the risk to personnel and equipment and complying with their corporate safety program requirements. The system also provides long term data collection of gases that have been measured in the facility. Learn more about how aeSolutions could help you with a similar project Industry: Pharmaceuticals Geography: Southeast Unit Operation: GDS 1400 MK II, Gas Detection System, PCS7, SPHA I/O, FGS Previous Story Next Story

Mitigating Fired System Hazards Burner Management Systems (BMS) - Automation Application Mitigating Fired System Hazards aeSolutions' family of products includes industrial BMSs in several packages. The pre-engineered packages are configurable to meet the client's safety requirements. Under current standards a BMS must meet prescriptive interlock requirements, depending on the type of combustion system. In addition, SIS interlock performance standards must be met. The aeSolutions BMS meets all prescriptive and performance standards for dependable protection of people and property, during startup, shutdown, and operation. The safety BMS is often supplied as an integrated Combustion Management System (CCS) package, which includes an aeSolutions CCS for operating and optimizing the plant. • Meets FM 7605, IEC 61508, IEC 61511, ANSI/ISA 84.00.01 • NFPA 85, NFPA 86 API 556 and/or API 14C • Available up to SIL-3 • Graphical HMI and automated local light-off • Support for function testing • Communications to CCS and DCS • Combustion management engineering Automation Services Previous Next

Delivering Safety on Demand Safety Instrumented Systems - Automation Applications Delivering Safety on Demand aeSolutions is especially qualified with Certified Functional Safety Experts to quantify process hazard risks and develop the safety requirements specifications for a process. National and international standards and regulations require that a safety interlock must meet a prescribed safety integrity level SIL-1 thru SIL-4 to have an acceptable probability of failure on demand for its associated hazard. There are many aspects to supplying the required SIL level, including the logic solver, I/O cards, redundancies, program blocks, networks, and the operator interactions. aeSolutions satisfies a project's safety interlock SIL requirements with independent, SIL-certified safety PLC's that can be integrated with the process automation DCS for monitoring and alarming. Our engineering specialists will design, configure, test, and install documented Safety Instrumented Systems that verifiably meet the client's Safety Requirements Specifications. • Logic solver hardware and software, TUV or Exida certified • Operator interaction through Cause and Effect matrix • Controlled access and modification protections • Secure fail safe communications for distributed safety • Verification test plans Automation Services Previous Next

A collective term used to describe different types of control systems (e.g., SCADA, DCS, etc.) and associated instrumentation, which include the devices, systems, networks, and controls used to operate and/or automate industrial processes. For advanced control systems, aeSolutions process control specialists solve problems with Advanced Regulatory Control (ARC) when single variable PID control is not adequate. Cascade, feed forward, ratio, Smith predictor, and override controls are standard methods to include an additional process variable in PID loops to compensate for process dead time, or non-linearity. Multivariable and model-based controls are employed for more complex process automation challenges encountered in chemical plants and refineries. Acronyms & Terms Glossary <- More Definitions Industrial Control Systems A collective term used to describe different types of control systems (e.g., SCADA, DCS, etc.) and associated instrumentation, which include the devices, systems, networks, and controls used to operate and/or automate industrial processes. For advanced control systems, aeSolutions process control specialists solve problems with Advanced Regulatory Control (ARC) when single variable PID control is not adequate. Cascade, feed forward, ratio, Smith predictor, and override controls are standard methods to include an additional process variable in PID loops to compensate for process dead time, or non-linearity. Multivariable and model-based controls are employed for more complex process automation challenges encountered in chemical plants and refineries. 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.

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. Challenge A global manufacturer of agricultural chemicals stores 30,000 tons of anhydrous ammonia on-site in two large storage tanks. A large leak from one of these tanks would be hazardous and potentially fatal to on-site personnel and to the public in the surrounding areas. The client needed the ability to detect and alert personnel of leaks and allow operators to contain the resulting vapor cloud from a safe remote location. Solution After a thorough corporate safety review of the pressurized ammonia storage facility, aeSolutions provided an innovative safety shutdown and suppression system utilizing water cannons capable of manual or automatic operation from the safety system. Fourteen 2000 GPM water cannons capable of knocking the ammonia cloud to the ground and neutralizing its caustic characteristics were integrated, giving control room operators control over each cannon: • 340 Degree rotational movement • Vertical movement • Nozzle pattern control from fog to stream • Water flow control Results The client now has an effective means of monitoring and controlling an accidental release of ammonia and minimizing the impact to personnel, the public, and to the environment. aeSolutions increased the safety by providing leak detection and notification, equipment isolation, and large-scale leak dispersion containment through perimeter water cannons. Learn more about how aeSolutions could help you with a similar gas detection project. Industry: Agricultural Chemicals Geography: Southeast US Unit Operation: Beam type gas detectors, point type gas detectors, product isolation valves, and electronically operated water cannons Governing: FM Approvals Previous Story Next Story

Discover aeSolutions’ proven playbook for successful project development, focusing on achievable scopes, risk management, and seamless transitions to execution. Project Development Efficient & Resilient Project Execution Turning ambitious ideas into successful outcomes demands more than effort — it requires clarity, alignment, and the ability to anticipate challenges before they arise . At aeSolutions, we understand the unique challenges that complex projects bring — from tight budgets and timelines to aligning stakeholder expectations and managing risks. Our project development team will not only guide your project from concept to execution but will also enhance the resilience and efficiency of each phase. Leveraging our 25+ years of industry-trusted expertise, we implement a proven playbook to drive results. We Understand the Drivers for Change Growth Environmental, Social, Governance Cost Competitiveness We Believe Strategic Foresight Drives Flawless Execution aeSolutions has developed proven methods to anticipate, identify, mitigate, and resolve project challenges before they impact your goals. We understand that effective project development demands more than part-time attention or divided focus. In-house operating personnel often face the challenge of balancing their core responsibilities with the demands of project management — a task that requires dedicated expertise and continuous practice. This is where the aeSolutions project development team steps in with structured, methodical approaches to eliminate project pitfalls. We believe project development is a specialized, high-level process focused on setting clear goals, defining scope, aligning resources, and ensuring risk management best practices are in place from the outset. By addressing these critical elements, aeSolutions transforms complex projects into streamlined, successful outcomes. Some of the most often sited reasons for project failure are highlighted in the graph below. With the guidance of our experienced project development team, you will be able to better understand and avoid these pitfalls, while proactively positioning your project for success. Poor Communication Insufficient Resource Planning Unrealistic Schedules Poor Project Requirements Lack of Stakeholder Buy-In Undefined Project Closure Criteria Unrealistic Budgets Insufficient or No Risk Planning Lack of Change Control Process aeSolutions has a Playbook for Successful Project Development Discovery Allocation of Resources Kickoff Execution Study Gap Closure System Definition Detailed Design Procurement Fabrication Test, Deliver, Install Commission, Start-up Discovery Define/Clarify Goals Establish Drivers for Achievement Align Expectations Allocation Kickoff Execution Achievable Scope/Budget/Schedule Risk Management Planning Division of Responsibilities (DOR) Transition from Project Development to Project Execution Team Alignment with DOR Project Development Acts as Quality Assurance Guide Project Team to Client Success Why Partner With aeSolutions? In today’s industrial landscape, the success of complex projects hinges on precise planning, resilient design, and adaptable execution. At aeSolutions, we pair risk-focused experts with a project delivery team that helps industrial facilities overcome common project challenges. Our approach integrates robust risk management and team alignment from the outset, transforming project planning into a strategic advantage. From the initial discovery and gap analysis to detailed system design and final commissioning, our experts ensure that every phase aligns with your business goals, driving efficiency and maximizing ROI. Let aeSolutions elevate your project from concept to completion with a development process built on quality, resilience, and client success. aeSolutions sets the foundation for your project's success from discovery to start-up. Contact Us for More Information About Our Project Development Capabilities

Developing Hardware Details Hardware Design Specifications Developing Hardware Details aeSolutions works with clients to establish specific project standards for the detailed hardware design of the system and field I/O. • Input / Output database and signal types • Control system cabinet layout practices • Controller, I/O, and interface modules • HMI operator interface equipment • Control networks, switches, fiber optics, and cabling • Marshalling cabinets and interposing relays • Servers and clients • Engineering workstations • Purging, temperature, smoke and fire detection Automation Services Previous Next

The lower explosive limit (LEL) refers to the lowest concentration of a gas or vapor in air that can ignite or explode when an ignition source is present. Acronyms & Terms Glossary <- More Definitions Lower Explosive Limit (LEL) The lower explosive limit (LEL) refers to the lowest concentration of a gas or vapor in air that can ignite or explode when an ignition source is present. 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.

Functional Safety Assessments (FSA) are a part of the safety lifecycle of a process that ensures the system meets the specified level of safety, typically performed by a senior engineer. The goal of an FSA is to determine how confident you are that our functional safety system will consistently achieve the risk reduction that's required. Performing an FSA is a mandatory requirement of many international standards that govern functional safety. An FSA is carried out in five (5) stages throughout the SIS lifecycle: - Stage 1: After the hazard and risk assessment has been carried out, the required protection layers have been identified and the safety requirement specification has been developed. - Stage 2: After the safety instrumented system has been designed. - Stage 3: After the installation, pre-commissioning and final validation of the safety instrumented system has been completed and operation and maintenance procedures have been developed. - Stage 4: After gaining experience in operating and maintenance. - Stage 5: After modification and prior to decommissioning of a safety instrumented system. aeSolutions’ experienced professionals can help you decide when conducting each FSA stage is appropriate for your facility, and then can help you plan and execute it. Acronyms & Terms Glossary <- More Definitions Functional Safety Assessments (FSA) Functional Safety Assessments (FSA) are a part of the safety lifecycle of a process that ensures the system meets the specified level of safety, typically performed by a senior engineer. The goal of an FSA is to determine how confident you are that our functional safety system will consistently achieve the risk reduction that's required. Performing an FSA is a mandatory requirement of many international standards that govern functional safety. An FSA is carried out in five (5) stages throughout the SIS lifecycle: - Stage 1: After the hazard and risk assessment has been carried out, the required protection layers have been identified and the safety requirement specification has been developed. - Stage 2: After the safety instrumented system has been designed. - Stage 3: After the installation, pre-commissioning and final validation of the safety instrumented system has been completed and operation and maintenance procedures have been developed. - Stage 4: After gaining experience in operating and maintenance. - Stage 5: After modification and prior to decommissioning of a safety instrumented system. aeSolutions’ experienced professionals can help you decide when conducting each FSA stage is appropriate for your facility, and then can help you plan and execute it. 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 project management process during early stages of a project designed to minimize risk for investors and other stakeholders by developing adequate project definition & scope. Key Deliverables of FEL: 1. Execution Strategy and Plan 2. Resource Plan 3. Risk Management Plan 4. Change Management Plan FEL can be multiple stages: FEL 1, FEL 2, and FEL 3. Some owners opt to only do a single FEL. However, the key is to consider all factors and engage in a level of FEL that is reasonable. Regardless of the number of FEL phases performed, all business needs should be evaluated, and a complete business case should be identified to minimize cost schedule budget (scope risk). Acronyms & Terms Glossary <- More Definitions Front End Loading (FEL) A project management process during early stages of a project designed to minimize risk for investors and other stakeholders by developing adequate project definition & scope. Key Deliverables of FEL: 1. Execution Strategy and Plan 2. Resource Plan 3. Risk Management Plan 4. Change Management Plan FEL can be multiple stages: FEL 1, FEL 2, and FEL 3. Some owners opt to only do a single FEL. However, the key is to consider all factors and engage in a level of FEL that is reasonable. Regardless of the number of FEL phases performed, all business needs should be evaluated, and a complete business case should be identified to minimize cost schedule budget (scope risk). 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.