A trip point is a specific value or condition that, when reached, triggers an automatic shutdown or safety action. Trip points are set to protect systems from operating outside safe or permissible limits. Acronyms & Terms Glossary <- More Definitions Trip Point A trip point is a specific value or condition that, when reached, triggers an automatic shutdown or safety action. Trip points are set to protect systems from operating outside safe or permissible limits. 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 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. Challenge The objective was to implement an SI-BMS using a Siemens PCS 7 Platform within a compressed schedule, meeting all Safety Lifecycle requirements. Traditionally, projects follow a sequential process, but due to time constraints, a concurrent development strategy was necessary. This included early procurement of long-lead items and expedited planning to ensure the BMS was built and commissioned during the scheduled plant outage. Solution • Concurrent development of PHA/LOPA and SIS deliverables • Early identification and procurement of long-lead items • Integrated planning with client and boiler equipment supplier • Close collaboration between SMEs in SIS and BMS • Rapid approval processes for drawings and system fabrication Results The project developed an integrated schedule to manage activities effectively, significantly reducing the risk of late changes. Collaboration between the client, the boiler equipment supplier, and SMEs in SIS and BMS maintained the fast-tracked schedule while meeting all Safety Lifecycle requirements. Effective planning and cooperation among stakeholders were key to achieving project objectives, offering valuable insights for future projects. Learn more about how aeSolutions could help you with a similar project Industry: Metals & Mining Geography: West Unit Operation: SI-BMS, Safety Instrumented Burner Management Systems Previous Story Next Story

Detailed planning and coordination to ensure a successful installation and start-up of Fire and Gas Systems. We develop a Construction Scope of Work (SOW) suitable for collecting contractor bids and assisting the contractor in the interpretation of the design package.   Installation support includes: Site Acceptance Testing (SAT) Installation & Commissioning Oversight Field Devices Calibration  Start-up Assistance NFPA 72 Final Sign-offs Training Fire & Gas System Installation Support aeSolutions supports clients with detailed planning and coordination to ensure a successful installation and start-up of Fire and Gas Systems. We develop a Construction Scope of Work (SOW) suitable for collecting contractor bids and assisting the contractor in the interpretation of the design package. Installation support includes: . Site Acceptance Testing (SAT) Installation & Commissioning Oversight Field Devices Calibration Start-up Assistance NFPA 72 Final Sign-offs Our expert team can help ensure the Fire and Gas System is delivered standards compliant, on-spec and safe. As part of the comprehensive installation support we also offer training to ensure end users can operate and maintain their new systems. Contact us to talk to one of our fire and gas detection and suppression system experts today. Fire & Gas Products NRTL Approved Fire Panels NRTL Approved Power Supplies NRTL Approved Proprietary Supervisor Stations Fire & Gas Lifecycle Services Ongoing Maintenance Training - Operate Maintain, and more Contact Us

Creating Consistently Correct Control Control System Configuration Creating Consistently Correct Control aeSolutions' qualified specialists configure control logic and operator stations (HMI) to perform the required process functionality in accordance with industry and project standards. Individual control loops are configured and tested to the software design specifications. Software quality standards lead to consistent, correct, maintainable control systems. • Function block, function chart, ladder, and structured text languages • Engineering workstation configuration and productivity tools • Alarm management logic, summaries, and indications • Displays, faceplates, screen navigation, dynamics, trends • Regulatory and advanced control loops • Process interlocks, alarms, first-outs, and resets • Batch management and phase logic • Process historian, alarm archives, reports • Foreign device interfaces • Asset management and maintenance system Automation Services Previous Next

Fault tolerance allows a safety system to let the process continue despite a failure, removing the risk of having a single point of failure. Acronyms & Terms Glossary <- More Definitions Fault Tolerance Fault tolerance allows a safety system to let the process continue despite a failure, removing the risk of having a single point of 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.

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: 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.

Layers of Protection Analysis (LOPA) is a semi quantitative method of risk assessment analyzing the frequency of occurrence of events that can produce a hazard associated with handling of hazardous chemicals. LOPA considers the applicability of safeguards, the potential for individual layers of protection to fail, and the potential consequences that are consistent with the organization's risk tolerance. During LOPA, Independent Protection Layers (IPLs) are identified. Claiming credit for one or more IPLs that do not provide the protection claimed will result in under-designed SIFs, increasing risk to the facility. Claiming less credit for IPLs than is actually provided will result in over-designed SIFs, increasing capital cost. aeSolutions has the expertise and experience to help you perform this critical task most effectively. Acronyms & Terms Glossary <- More Definitions Layers Of Protection Analysis (LOPA) Layers of Protection Analysis (LOPA) is a semi quantitative method of risk assessment analyzing the frequency of occurrence of events that can produce a hazard associated with handling of hazardous chemicals. LOPA considers the applicability of safeguards, the potential for individual layers of protection to fail, and the potential consequences that are consistent with the organization's risk tolerance. During LOPA, Independent Protection Layers (IPLs) are identified. Claiming credit for one or more IPLs that do not provide the protection claimed will result in under-designed SIFs, increasing risk to the facility. Claiming less credit for IPLs than is actually provided will result in over-designed SIFs, increasing capital cost. aeSolutions has the expertise and experience to help you perform this critical task most effectively. 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.

Sequential Function Charts (SFCs) are an example of logic diagrams that can be used to illustrate the functioning of a Safety Instrumented System (SIS). SFCs are frequently used to document the various operating modes of fired equipment. The aeSolutions staff is capable of selecting the best format, or combination of formats, to best meet the requirements of our clients. Acronyms & Terms Glossary <- More Definitions Sequential Function Chart (SFC) Sequential Function Charts (SFCs) are an example of logic diagrams that can be used to illustrate the functioning of a Safety Instrumented System (SIS). SFCs are frequently used to document the various operating modes of fired equipment. The aeSolutions staff is capable of selecting the best format, or combination of formats, to best meet the requirements of our clients. 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.

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: 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.

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PSM stands for Process Safety Management, a process that helps prevent/reduce risk of hazardous chemical releases. Acronyms & Terms Glossary <- More Definitions What does PSM stand for in safety PSM stands for Process Safety Management, a process that helps prevent/reduce risk of hazardous chemical releases. 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.

Immediately dangerous to life or health (IDLH) means an atmospheric concentration of any toxic, corrosive or asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse health effects or would interfere with an individual's ability to escape from a dangerous atmosphere. IDLH concentrations are considered for endpoint distances during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. Acronyms & Terms Glossary <- More Definitions Immediately Dangerous to Life and Health (IDLH) Immediately dangerous to life or health (IDLH) means an atmospheric concentration of any toxic, corrosive or asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse health effects or would interfere with an individual's ability to escape from a dangerous atmosphere. IDLH concentrations are considered for endpoint distances during facility siting studies or consequence modeling conducted by aeSolutions' experienced modelers. Modeling helps companies identify the flammable and/or toxic consequences and impacts to receptors due to a chemical release. 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.