Fire and Gas Products 20 years of delivering FM Approved industrial PLC Fire & Gas products The aeSolutions FM Approved family of Fire & Gas systems ensures compliance with the latest NFPA 72 standards and FM 3010 standard for fire alarm signaling systems to meet all of OSHA’s requirements. FM Approved to be in compliance with FM Approval's Combustible Gas Standard 6320, Toxic Gas Detection standard 6340, and ANSI/ISA 12.13.01 Performance Requirements for Combustible Gas Detectors standard. Are you Compliant? With aeSolutions on your team, you can rest assured that your Fire and Gas System is designed to the latest FM Approve d Fir e and Gas standards utilizing our first-hand industry experience. Product Benefits: • Scalability provides you with customization options • Listed for use with a wide variety of end devices for maximum flexibility • Customized functionality and listings available • Industrial PLC platform for plant-wide integration • Options for both SIL capable and non-SIL capable • FM-Listed for Fire & Gas detection and suppression to satisfy regulations • Industrial grade hardware for increased reliability in plant applications • Factory training available to enable end users to maintain their systems FGS 1400 MK II Industrial designed system, SIL 3-capable logic solver, scalable to large I/O count. FGS 1400 MK II is FM Approved for combination system I/O this allows the end user to control HVAC, process ESD, SIS safety functions, and other non fire processes from the fire panel. The FGS 1400 MK II is listed for Fire Command Center and proprietary Supervising Station functions. Download datasheet FGS 1300 FM-approved for lower I/O count applications. Class I Division 2 area classification status. Download datasheet PS 1 400 20 / 50 / 100 / 150 Power supplies that meet NFPA 72 requirements. The power you need, when you need it. Download datasheet : PS 1400 20A - PS 1400 50A - PS 1400 100A PS 1400-20-DIV2 Battery set FM-listed for Class I Div 2 areas. Rugged and reliable. Download datasheet FGS 5000 NEW! aeSolutions’ next generation of fire and gas alarm and control solutions for the industrial market. The FGS 5000 combines the required functionality into a Rockwell control logix control platform. Download datasheet Understanding How Burner Management Systems Work FGS 5000 Fire & Gas System: Rockwell control logix control platform Featured Design, fabrication, commissioning aeSolutions can Partner with Siemens to provide a turnkey system from philosophy, fabrication, FAT, field installation of equipment, and SAT.

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 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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 ... Challenge At the time it was built, the NG facility was the largest in the world. Some sections of piping are approximately 5 foot diameter and compression is achieved with enormous gas turbines - jet engines. The number of drawings, valves, wires, and control schemes that needed to be evaluated and understood was extensive and complex. Additionally, the magnitude and complexity of migrating the controls was tremendous. Normal gas operation controls such as turbine controls, panel boards, and valve interfaces needed to be migrated, as well as process safety controls such as the Basic Process Control System (BPCS), safety systems, Fire & Gas (F&G) systems, Halon fire suppressant circuits, and Emergency Shutdown (ESD) circuits. Furthermore, the NG facility equipment spanned 50 years of modifications and many upgrades were needed to universalize and modernize the many generations of equipment, including digitalizing hardwired signals into a the BPCS and installing a new PLC-based BPCS Honeywell C300 control system. Yet the biggest challenge was migrating the hard-wired emergency stop (E-stop) button from the old to new control room with minimal transition time and without a widespread outage. The circuit was designed fail-safe, meaning if the circuit opened up the relay, an activated emergency event could result in several effects: relieve gas pressure to flare, isolate system in place, or a plant S/D. Solution aeSolutions not only designed the new control room but took responsibility for all stages of the project, managing tasks from the conceptual and preliminary engineering to detailed design to managing on-site activity and personnel during the complex cutover. Specifically, aeSolutions: • Developed detailed cutover procedures and checklists and an integration schedule that identified specific people and detailed daily tasks for the next year for both NG facilities • Performed a detailed option analysis to evaluate potential best solutions • Analyzed every wire to understand what it does and temporary bypasses to be put into place; maintained a well-documented log to track what had been completed • Developed a contingency plan to guard against emergency events and mitigate risk of valve position changing during cutover process for safety purposes • Set up a local integration center, i.e., Factory Acceptance Test (FAT) lab, to convene equipment and everyone involved; determined ways to install additional panels; designed, fabricated, and tested the new control panels that were needed for the E-stops and F&G system and provided cabinets that were needed; developed a scheme of transitioning existing terminations to new termination locations without causing a S/D • Managed on-site activities helping direct the cutover process while implementing the cutover plan, including directing facility operators, engineers, support staff, construction, and even IT staff Results aeSolutions’ role evolved from system integrator and helping move the control rooms to becoming the focal point of coordinating schedules and staffing and choreographing the entire cutover project. We developed an execution strategy and found ways to integrate multiple teams into the plan. The FAT lab particularly provided a tremendous benefit to establish how components worked, verify detailed FAT plans and test procedures, and develop methods to quickly (dis)connect test panels with everyone in the same room. This integration strategy saved time and travel costs to successfully cutover the controls on a NG operating plant without impact to production. Learn more about how aeSolutions could help you with a similar project. Industry: Natural Gas Geography: Pacific Northwest Unit Operation: Control Center, Compressed Gas Valves Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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)... Challenge The National Fire Protection Association (NFPA) issued a prescriptive design requiring the client to upgrade 79 fired heaters’ Programmable Logic Controllers (PLCs). This would mean shutting down the plant resulting in a significant production loss and possible unexpected Process Hazards. Solution Focusing on the NFPA 86 prescriptive design applicable to waste gas thermal oxidizers and applying our experience in Process Safety Management (PSM), we worked with the client to target and isolate several areas of risk not readily apparent in the NFPA-prescribed design. We then conducted an options analysis and implemented a strategic risk reduction model, which included: • Upgrades to flame scanners and other sensing elements • Replacing generic relays with SIL-2 capable relays • End-device leak testing • Strategic upgrades to SIL-rated logic solvers These modifications formed an Equivalent Design Package which was evaluated and approved by the Authority Having Jurisdiction (AHJ). Results The client’s capital expenditure was reduced by $48 million while enhancing safety and reliability. aeSolutions slashed the compliance scope from a 10-year process of PLC upgrades of 79 fired heaters to just 20, with a credit taken for the remaining 59 heaters due to existing protection layers and minor upgrades to instrumentation and control equipment over a five-year upgrade program. Learn more about how aeSolutions could help you with a similar Combustion project. Industry: Oil & Gas Geography: Pacific Northwest Unit Operation: Fired Heaters, Boilers Governing: NFPA 85, NFPA 86 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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. Challenge The client’s existing BMS was based on outdated relay logic technology, limiting visibility into critical boiler parameters. Operators struggled with frequent system trips but lacked the ability to identify the root causes. Their legacy system provided no direct diagnostics, forcing operators to visually inspect equipment and restart the system manually. Additionally, the client required operational flexibility to switch between multiple fuel types — natural gas, hydrogen, and oil — without system shutdowns. The client sought improved support and expertise with a configuration provider with SI-BMS experience. Their need for seamless integration, combined with complex fuel-switching requirements, posed significant technical challenges. Solution aeSolutions successfully delivered a comprehensive upgrade of the client’s BMS, integrating it into the existing DeltaV platform. Key elements of the solution included: • Integration with DeltaV: The new BMS was implemented using DeltaV’s CHARM Safety Logic Solver, ensuring compatibility with the client’s existing system and reducing the learning curve for operators. • Enhanced System Visibility: Operators gained real-time insight into key metrics such as pressure levels and temperature through custom Dynamos on the control room interface. First-out diagnostics were also added, enabling quicker root-cause analysis and reducing downtime. • NFPA 85 Code Compliance: The upgrade ensured the boiler system met the latest NFPA 85 safety codes, enhancing both safety and reliability. • Multi-Fuel Flexibility: The system was designed to allow seamless fuel switching between hydrogen, natural gas, and oil without requiring shutdowns. Custom Safety Instrumented Functions (SIFs) were implemented to manage the complexities of multiple fuel types safely. • Close Client Support: aeSolutions was able to provide prompt, on-site technical support as needed, ensuring smooth project delivery and ongoing assistance. Results The results of this project provided significant benefits to the client by improving both safety and operational efficiency. The upgraded BMS ensured compliance with NFPA 85 codes, enhancing safety and reducing the risk of boiler-related incidents. With the ability to switch seamlessly between hydrogen, natural gas, and oil, the system offered the client greater operational flexibility. The inclusion of real-time diagnostics and first-out alarms allowed for faster troubleshooting, reducing downtime, and improving system availability. Additionally, the operators benefited from a streamlined process, as they could now manage startups from the control room, minimizing manual interventions. To ensure a smooth transition, aeSolutions replicated the client's existing control graphics through custom Dynamos, maintaining familiarity for operators and preventing workflow disruptions. These enhancements collectively improved safety, reliability, and ease of operations for the client. Learn more about how aeSolutions could help you with a similar project Industry: Chlor Alkali Production Geography: Southeast Unit Operation: Burner Management System (BMS), DeltaV Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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. Challenge The client has to contend with detecting a multitude of toxic acidic vapors in order to keep their people safe. Initially, their plan involved using 5 to 6 individual toxic gas detectors in each area to detect these acidic vapors separately in each room. This approach would have led to a high number of detectors, increased maintenance, more I/O (input/output) to contend with, and elevated costs for replacing sensor elements. Additionally, the use of multiple detectors could result in confusion if there was a leak, as all the detectors would respond, making it impossible to pinpoint the specific acidic vapor released. Solution Upon closer review, it was realized that the client did not need to differentiate between the specific acidic vapors The single detector would tell them they had an acid leak, no matter which one. When a detector was triggered, the action was the same, evacuate to a safe area. A more efficient solution was devised by using a single acidic vapor detector in each room instead of multiple individual detectors. This philosophy reduced the number of detectors from 5 to 1 in each room, leading to an 80% reduction in the total number of detectors across the entire facility. Results By implementing the revised gas detection philosophy, the client achieved significant benefits. They collected a comprehensive list of all the chemicals of concern and determined the levels at which they wanted to detect these vapors. This allowed them to model the vapor releases and strategically position the gas detectors in a 3D model for optimal coverage. The client no longer needed to be specific as to the type of acidic vapor being detected, focusing solely on the detection of acidic vapors in general. Furthermore, it reduced possible confusion, ensuring the safety of individuals on the premises by enabling timely evacuation in case of any acid leak, regardless of the specific acidic vapor involved. The new approach resulted in simplified maintenance, cost reduction, decreased risk of confusion in case of a leak, and established a consistent action plan for evacuation. See how we can help you with a similar detector placement project. Keywords: formic acid, hydrocoloric acid, detection, detector, evactuation, acid vapor, acidic compounds, gas detection Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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. Challenge A global pharmaceutical company’s corporate standards mandated a local manufacturing site install a combustible gas leak detection system in its boiler house to mitigate risk to personnel and equipment. The client needed the ability to detect and isolate gas leaks within a utility building containing multiple large natural gas-fired boilers to lessen the risk to personnel and reduce the potential for extended production disruption due to significant equipment damage. Solution aeSolutions designed and provided an FM approved industrial fire alarm and gas detection system to automatically isolate the main natural gas feed to the building when a leak is detected. aeSolutions also provided detector placement consulting services based on the physical location of potential leak sources. Delivered: • FGS 1300 fire alarm and gas detection/isolation system • Automatic isolation valve installed in natural gas supply line • Eight point gas detectors • Detector placement services Results The client now has an industrial grade system for detecting and isolating a release of natural gas, reducing the risk to personnel and equipment, and complying with their corporate safety program requirements. Learn more about how aeSolutions could help you with a similar gas detection project. Industry: Pharmaceuticals Geography: Southeast Unit Operation: FGS 1300 Governing: FM Approvals Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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. Without any operating data for the Greenfield LNG facility, however, the alarm program and rationalization process based alarm setpoints; on cause and effects, the site’s PHA, and RAGAGEP engineering design for the LNG industry. Challenge Setting up an alarm system for a new facility with no real site experience required relying on both the client’s and the aeSolutions team’s experience from other LNG facilities. 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 in the LNG process startup, with consideration that stakeholder activities were contingent on one another. There was a higher sense of urgency than in a Brownfield facility as a result of reduced flexibility in the sense that the alarm system and training 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. The following tasks were accomplished: • Reviewed the client alarm philosophy and performed a gap assessment with the requirements in the International Society of Automation (ISA) 18.2 standard. An effective alarm philosophy is the foundation of an alarm management program and covers all its elements, including design principles, key performance indicators, roles and responsibilities, alarm presentation standards, alarm priority assignment, alarm system maintenance, management of change, auditing, and escalation policies. • Developed the client’s documentation and rationalization (D&R) site protocol; the D&R site protocol is a guideline created to ensure consistent and effective expectations on future rationalization activities. • Performed a rules of engagement meeting where templates were developed prior to the alarm rationalization activities. Templates were created for similar alarm types (e.g., bad PV) and similar process alarms (e.g., ESD, PSD, and safety showers). • Performed a training on the alarm management lifecycle prior to rationalizing the LNG process systems and utilities. During the 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. Results The Greenfield LNG facility was prepared and trained with a well-established alarm system prior to startup. The site had a finalized version of the alarm philosophy, D&R site protocol, and completed master alarm database, which included all ISA 18.2 required information and alarm response requirements for the process. The alarm philosophy is customizable to establish rules for improving and managing the alarm system and should be utilized as a reference to guide a site’s strategy for sustained improvement. With the Greenfield LNG facility alarm philosophy in place, alarm system design and/or improvement can proceed with maximum benefits, including reduced costs, improved safety, and improved reliability. See how we can help you with a similar alarm project. Industry: LNG Geography: Gulf Coast Unit Operation: Alarm Rationalization, Alarm Management Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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. Challenge The initial project scope included providing the client with instrumentation specifications and wiring and cutover plans to facilitate the cutover to a new system. Due to incomplete and outdated instrument lists, a significant and unexpected change in scope became required to include instrument specification services, which nearly doubled the time and manpower needed to reach the goal by the client’s deadline. Solution aeSolutions efficiently identified and conveyed the necessary adjustments to the project with clear and concise communication, enabling the client to swiftly make informed decisions, modify the scope, and adjust staffing accordingly. Our team quickly deployed resources to provide the following deliverables within the original schedule: • Instrument Specifications • Instrument Field Wiring • Cutover Mapping • Cutover Wiring In addition, aeSolutions designed custom cabinets for the cutover at the request of the client once it became apparent that the field loops would be doubled. During construction, aeSolutions assisted the client with locating and providing quality drawings for cutover installation and commissioning. Results Upon completion, the clients informed aeSolutions that the provided support was indispensable for a smooth start-up, and the subcontractors confirmed that aeSolutions specifically contributed to one of the most efficient cutovers they’ve ever commissioned. The client had large projects going on, and aeSolutions was able to save them costs by hitting their shutdown dates and not requiring additional shutdown time. Learn more about how aeSolutions could help you with a similar a Systems Integration / Migration & Upgrade project. Industry: Specialty Chemical Geography: Southeast Unit Operation: Safety System Upgrade Governing: ISA/IEC 61511 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities A globally recognized chemical producer that had recently acquired a legacy plant used to produce highly hazardous agricultural chemicals turned to aeSolutions’ multi-disciplinary capabilities for a comprehensive solution to bring their legacy plant into compliance. The client was faced with a tight schedule to meet their corporate process safety standards through a functional safety upgrade, with the goal of bringing the facility into PSM OSHA 1910.119 compliance. Once awarded the project, aeSolutions successfully delivered the client’s FEL3 and Detail Design goals. As part of the FEL3 project, aeSolutions collaborated with the client to establish an estimate basis. This helped ensure the accuracy of the total installed cost estimate, with the project coming in slightly under the estimated value. The success and quality of this project’s outcome serves as an example of aeSolutions’ unrivaled capabilities as a comprehensive lifecycle solutions provider within the industry. Challenge This complex project posed numerous challenges during the Front-End Loading (FEL) phase for the client’s newly acquired agricultural chemical production facility. The legacy facility did not meet the client’s corporate process safety standards, nor was it PSM OSHA 1910.119 compliant. aeSolutions was tasked with providing Front End Loading (FEL) level III engineering design services for the Process Control Technology (PCT) discipline. Basic design for Phase 1 at the legacy facility was to cover a kiln, a hydro clarifier, a waste heat boiler, and multiple coal mills. The final challenge was developing an accurate total installed cost estimate that the client then used to secure funding. Solution • By implementing processes and project sponsorship to promote efficient communication between the client’s remote stakeholders and the management team of the legacy facility, aeSolutions was able to foster an environment that proved to be essential in meeting the client’s goals of achieving PSM OSHA 1910.119 compliance within their schedule. • aeSolutions successfully provided cross-discipline deliverables within the client’s timeline, while accommodating several scope revisions from the client. • aeSolutions’ recognition of the importance of not only being aware of a project’s information but having the experience to also know where the information needs to flow helped facilitate the overall success of the project. • By utilizing aeSolutions’ team of experienced subject matter experts across multiple disciplines, we were able to provide the level of knowledge, understanding, competency, and dedication required to meet the client’s strict requirements. • By educating the client’s operations team about the rationale of actions throughout the project, aeSolutions helped to facilitate better alignment between the client’s corporate/capital project team and the facility operations team. • Through the meticulous attention to detail and quality of services provided, aeSolutions’ was able to bring a highly hazardous chemical production facility into PSM OSHA 1910.119 compliance. - aeSolutions worked closely with the client to establish a comprehensive and accurate total installed cost estimate for the project. • The accuracy of aeSolutions’ estimate meant that the client did not have to request supplemental funding, that no change orders were required, and that the project was ultimately completed slightly under the total installed cost budget. • Adherence to the client’s aggressive timeline relied on the versatility of aeSolutions to integrate with the client’s newly implemented document control system. This adaptability proved to be an integral part of aeSolutions’ ability to complete the project roughly two months ahead of schedule — relative to other groups that were working in parallel. • In the face of the complexities and evolving requirements of this project, aeSolutions was able to deliver FEL3 and the Detailed Design results that the client was thrilled with. • aeSolutions’ assignment of appropriate resources based on alignment with the requirements of the project’s complexity and risks — contributed to the high productivity rate realized during this project. Results This project’s successful execution serves as a textbook example of the results clients hope for. From the initial development of front-end loading (FEL3), a highly accurate total installed cost estimate, and Detail Design deliverables, every aspect of our contribution to this project helped bring the client’s legacy facility into compliance with PSM OSHA 1910.119 regulations as well as the client’s own corporate safety standards. The aeSolutions multi-disciplinary team and their ability to adapt to the client’s evolving needs played a pivotal role in achieving the project’s success. By integrating seamlessly with the client’s document control system and maintaining strict adherence to safety and regulatory requirements, aeSolutions delivered results that represented an — according to the client — excellent quality of deliverables. Industry: Hazardous Agricultural Chemical Production Geography: West Unit Operation: Front End Loading Level III (FEL3), Detail Design Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

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 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story