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

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

Large Specialty Chemical Company Reduces Alarm Floods A large specialty chemical company was facing alarm floods in their utility unit. With aeSolutions guidance, the site was able to effectively prioritize and reduce alarms through the rationalization process, which includes reviewing, validating, and justifying alarms needed for avoiding potential process upsets or abnormal deviations from normal operation. Challenge As a result of the alarm floods, the Operators were reluctant or delayed in responding to the current alarm system because they were unable to determine which alarms were important and which were much less urgent or unnecessary. This reduced the time that staff had to respond to urgent or high priority operating conditions and diverted their attention from other important duties. The site had not yet performed alarm rationalization of their utility unit. As a result, the control room Operators were overwhelmed with nuisance alarms, incorrectly prioritized alarms, and alarms with no Operator action. This produced an operating environment susceptible to safety or environmental hazards that could have resulted in an incident. Solution aeSolutions facilitated a rationalization process with site operations and engineering staff to identify and prioritize the most effective alarms to detect a process upset within the utility unit while ensuring alarms met the definition and requirements defined within the client’s existing site Alarm Management Philosophy. By using the aeAlarm™ Rationalization Tool, the team was able to efficiently and functionally perform the following tasks: • Incorporate Process Hazard Analysis (PHA) and Layers of Protection Analysis (LOPA) data, such as required Operator responses used as Independent Protection Layers (IPLs) to reduce scenario risk to a tolerable level • Document alarm attributes based on the International Society of Automation (ISA) 18.2 and the Alarm Philosophy which addresses how alarms will be managed throughout the ISA 18.2 lifecycle • Review alarm parameters and setpoints to ensure they were aligned with the unit’s safe operating limits • Create templates for similar alarms within similar equipment trains Results The client’s control room achieved a two-thirds reduction in alarms configured for the utility unit which increased operator performance and production efficiency. The optimization of the alarm system also returned the client to compliance with Recognized and Generally Acceptable Good Engineering Practices (RAGAGEP) for Alarm Management. Overall, the operating staff became more focused on safe and effective operations because Operators were finally able to trust that the alarms they were addressing were accurate, necessary and important. Learn more about how aeSolutions could help you with a similar Alarm project. Industry: Chemicals Geography: Gulf Coast Unit Operation: Utilities Governing Authority: ISA 18.2 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

“Fit for Purpose” Solution Reduces Planned Downtime by 66% aeSolutions’ hybrid safety system design enabled the client to maintain safe continuity of their fired equipment, meet NFPA compliance, and significantly lower planned downtime. Challenge Several challenges related to strict National Fire Protection Association (NFPA) requirements arose as part of our client’s multi-stream waste incinerator’s annual leak testing. Any solutions would include navigating between NFPA-compliant and SIS-based systems and could lead to loss of revenue associated with destabilizing shutdowns, the likelihood of spurious trips, and planned downtime. Solution aeSolutions’ team of engineers and subject matter experts customized a “Fit for Purpose” engineering and equivalent risk-reduction solution that would meet or exceed NFPA codes as well as engaged the Authority Having Jurisdiction (AHJ) for approval of this customized approach. Among other efforts, our experts performed detailed configuration and integration of the client’s new Triconex process safety system with their existing DCS (distributed control system). Results Our approach enabled the client to select a hybrid, compliance/risk-based solution. aeSolutions identified and engaged the AHJ for approval of this customized approach, which proved to: • Implement compliance solutions that encourage system-wide risk reduction • Sustain reliability and availability of equipment to maintain operations • Increase leak test intervals with online testing reducing planned downtime by 66% Learn more about how aeSolutions could help you with a similar Combustion project. Industry: Chemicals Geography: Gulf Coast Unit Operation: Thermal Oxidizer Governing: NFPA 86 Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant In the rapidly expanding field of hydrogen production and storage, safety is paramount. aeSolutions was presented with the complex challenge of designing and installing a fire & gas (F&G) detection system for a greenfield hydrogen production plant. This case study explores how aeSolutions overcame the unique hazards associated with hydrogen to create a robust and efficient detection system, ensuring the protection of both personnel and assets. Through a combination of advanced modeling techniques and strategic detector placements, aeSolutions delivered a solution that not only met safety requirements but also optimized system performance and cost-efficiency. Challenge aeSolutions was tasked with designing and installing a Fire & Gas (F&G) detection system for a new hydrogen production plant, which presented unique challenges due to the flammable nature of hydrogen. The plant included both indoor and outdoor processes, with hydrogen production occurring inside a ventilated building and other processes like filtration, compression, and storage taking place outdoors. The key challenge was to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Solution aeSolutions implemented a multi-step approach to optimize the gas detection system layout. The process began with preliminary geographic placements based on recognized standards and was followed by scenario-based placements using consequence modeling software. When initial models indicated uncertainties regarding potential explosion severity, aeSolutions employed Computational Fluid Dynamics (CFD) modeling to refine detector placements, reducing the number of detectors required while ensuring comprehensive coverage. Additionally, the design included strategic placements of both catalytic bead and ultrasonic gas detectors indoors and outdoors to efficiently detect leaks and mitigate potential hazards. Results The final design resulted in a robust detection system that optimized the placement and number of detectors, ensuring reliable detection of hydrogen leaks with minimal risk of undetected releases. The CFD modeling confirmed that with proper mitigation measures, hydrogen leaks could be controlled, preventing catastrophic explosions. The project concluded with the successful installation of 18 lower explosive limit (LEL) indoor detectors and 7 outdoor detectors, along with additional safety features like ultrasonic detectors and flame detectors. This approach not only enhanced safety but also minimized system costs and maintenance needs, providing a scalable solution for this hydrogen production facility. Learn more about how aeSolutions could help you with a similar project Industry: Hydrogen Geography: Southeast Unit Operation: Hydrogen production including the use of electrolyzers Read more about aeSolutions' comprehensive hydrogen risk management and hazard mitigation services Previous Story Next Story

Acronyms & Terms Glossary <- More Definitions Consequence Modeling The process of simulating potential outcomes of hazardous events, such as chemical releases, explosions, or fires, to assess their impact on people, property, and the environment. It helps organizations predict the severity and extent of these events, informing safety measures and risk mitigation strategies. Our Services Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un

Acronyms & Terms Glossary <- More Definitions Independent Protection Layer An independent protection layer (IPL) is a a system of logic solvers, a human action, or a device that reduces risk of a chemical /energy release while being independent of the initiating event. The Center for Chemical Process Safety (CCPS) requires a protection layer to achieve the following seven core attributes to be considered an IPL: independent, functional; integrity; reliable; validated; maintained and audites; access security; and management of change. Our Services Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un

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 Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un

Acronyms & Terms Glossary <- More Definitions Cause and Effect Cause & Effect (C&E) diagrams show the relationship between sensor inputs and their required outputs. C&Es provide a clear and concise visual representation in tabular form, allowing users to quickly and easily view multiple functions within a process area or logic solver. They are commonly used as functional specifications for PLC-based programs, such as a Safety Requirement Specification (SRS) for a Safety Instrumented System (SIS). As such, they are of critical importance to successful implementation of the Safety Instrumented Functions (SIFs) in any functional safety project. While C&Es are not directly required by the ANSI/ISA-61511-2-2018 / IEC 61511-2:2016 standard, they are often included as an extension of the SRS, making them a part of the Safety Lifecycle. aeSolutions C&E diagrams use standard industry terms or terms that the client has clearly defined and are named, formatted, tracked, issued, controlled, and checked per aeSolutions company procedures unless superseded by specific client requirements. Our C&E templates have been developed from many years of experience to optimize ease-of-use for configuration, testing, operator training and turnover effectiveness. In cases where the functional complexity exceeds the capacity of C&Es, our staff is capable of selecting the most efficient alternate format. Our Services Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un

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 Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un

Acronyms & Terms Glossary <- More Definitions Systems Theoretic Accident Model and Processes (STAMP) A relatively new risk assessment model based on systems theory. It helps understand all factors involved in accidents, including human social and organizational structures. Our Services Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un

Acronyms & Terms Glossary <- More Definitions Fail Closed - Fail Open A Fail Closed device, typically a valve, is set to close automatically when a failure state occurs. A Fail Open device works in the opposite way and is set to open automatically when a failure state occurs. These failures are typically can be caused by a power or pressure loss. Our Services Control System Migrations | Procurement Specification & Vendor Selection aeSolutions discusses the complexities of control system migrations with a focus on procurement specifications and vendor selection. Leverage Unplanned Shutdowns to Enhance Safety Testing | ChemicalProcessing.com Discover how unplanned shutdowns can facilitate proof testing of safety instrumented functions, improving safety protocols and minimizing do ISS Source - Functional Safety Assessment Stage 1 Can Discover Critical Flaws Early Imagine discovering a critical flaw in your safety system design before your plant goes operational. This scenario, while nerve-wracking, un