Acronyms & Terms Glossary <- More Definitions Spurious Trips A spurious trip refers to an unplanned or unintended shutdown of a system, often triggered by false alarms or erroneous signals from monitoring equipment. These incidents can cause operational disruptions, safety risks, and unnecessary downtime in industrial processes such as power plants, oil and gas facilities, or manufacturing systems. 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 Shutdown An action to open or close valves, isolate, and/or blowdown systems to control a process parameter that has deviated from its normal operating range. Types of shutdown include an Operational Shutdown (OSD), Emergency Shutdown (ESD), Selective Emergency Shutdown (SESD), and Blowdown Emergency Shutdown (BESD). 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

Project Success Stories Learn how aeSolutions was able to help our clients overcome their challenges. 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. Read More Chemical Facility FEL3 & Detail Design Achieves PSM OSHA Compliance Under Total Installed Cost Budget | A Masterclass In aeSolutions’ Lifecycle Solutions Capabilities aeSolutions was tasked to provide Front-End Loading (FEL) and Detail Design for a newly acquired legacy agricultural chemical facility in order to meet full compliance with PSM OSHA 1910.119 standards and the client’s corporate safety requirements. Read More Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant aeSolutions was challenged to create an effective detection system that could handle the complexities of hydrogen's properties while ensuring the safety of personnel and the facility. Read More 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. Read More 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. Read More 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. Read More 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. Read More 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. Read More 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)... Read More 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. Read More 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. Read More 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 ... Read More 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. Read More “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. Read More 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. Read More 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. Read More

Simulation and Factory Acceptance Testing Approving the Configurations aeSolutions builds process simulation test beds to prove that controls and operator interfaces will function in accordance with project requirements. A FAT plan with checklists lets the client's representatives test every loop and HMI screen against the software design specifications. Quality of workmanship can be reviewed. Punch list items are resolved before shipping the system. aeSolutions offers multiple options for FAT simulation: Option 1. Simulation panels hardwired to the real system I/O cards to emulate field devices. Option 2. Simulation logic configured in the real controllers while ignoring real I/O racks. Option 3. Simulation computers that interface to the real controller's I/O bus in place of the real I/O racks Option 4. Simulation platforms that emulate the real controllers and I/O (for testing logic configurations without controller hardware). Automation Services Previous Next

Acronyms & Terms Glossary <- More Definitions Hardware Fault Tolerance Levels of Hardware Fault Tolerance (HFT) are established in functional safety standards IEC 61508 and IEC 61511, as the ability of a component or subsystem to continue to be able to undertake the required safety instrumented function in the presence of one or more dangerous faults in hardware. A hardware fault tolerance of 1 means that there are, for example, two devices and the architecture is such that the dangerous failure of one of the two components or subsystems does not prevent the safety action from occurring. In other words, HFT allows a safety system to let the process continue even with a designated failure in the hardware. 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 IEC 61511 - ISA 84 Note: ISA 84 was a previous edition of the standard. Please see ANSI ISA-16511 (IEC 61511) ANSI/ISA-16511 (IEC 61511) is an industry standard for best practices related to safety instrumented systems (SIS), Covering over the activities involved in the design, operation and maintenance of instrumented systems, from sensor through final element, used to achieve functional safety in the process industries. 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

Project Assessment and Conceptual Design Articulating the Project Vision and Characterizing the Control System aeSolutions engages clients to determine project goals, scope boundaries, assumptions, and customer requirements. A common conceptual design for the project is formulated in a project assessment report. The conceptual design includes a budgetary estimate and schedule. • Site and field investigations • Current state quantification • Client requirements • Scope and boundaries • Project assumptions • Conceptual design • Assessment report • Conceptual system architecture • Preliminary I/O counts • Project cost and schedule estimates aeSolutions' experienced professionals work closely with the client's engineers to map out the preliminary scope of work for the project and propose a high-level view of the system requirements. The conceptual design includes a budgetary estimate and schedule to support the feasibility and business case reviews. • Conceptual system architecture • Migration strategies • Operational philosophy • Preliminary I/O counts • Preliminary Bill of Material • Wiring philosophy • Project cost and schedule estimates +/- 30% Automation Services Previous Next

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 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 Central Utilities Plant (CUP) A system that manages the generation and distribution of essential utilities such as electricity, steam, chilled water, and compressed air for large facilities or industrial complexes. It centralizes utility production and control to optimize efficiency, reduce operational costs, and ensure reliable service across multiple buildings or operational units. 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 Management of Change (MOC) A system to identify, review, and approve all modifications to equipment, procedures, raw materials, and processing conditions other than replacement-in-kind, prior to implementation. 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 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 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 Fire and Gas Philosophy The Fire and Gas philosophy drives the design basis of the entire gas detection system. The philosophy should provide general direction, intent, specific performance goals, and effective strategies on how to implement the gas detection system. It clearly specifies the chemicals of concern and the intended purposes, i.e., detection of toxic or combustible levels, voting requirements, alarm rationalization, and control actions. aeSolutions' Fire and Gas team can support gas detection systems from conceptual design through field installation. This includes developing a Fire and Gas philosophy, technology selection, ensuring an appropriately sized system, and fire and gas mapping using the Geographic coverage approach and/or Computational Fluid Dynamics (CFD) scenario-based modeling to determine gas detector placement. 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