aeSolutions - A consulting, engineering and system integration company that provides industrial process safety, fired equipment and automation lifecycle solutions and tools. Applied Engineering Solutions Toxic Gas Detection, Machinery Safety, Alarm Management, Safety Instrumented Systems Improving industry by empowering resilient operations and safer communities How We Can Help Our Story Engineering Company Integrating Process Safety, Automation & Fired Equipment Success Stories 25+ Years Strong 40+ Certified Experts 2000+ Clients Served 600+ Projects per Year Our Services Process Safety Automation & Control Functional Safety Fired Equipment Alarm Management Fire & Combustible Toxic Gas Feature Stories Case Study: Achieving a High-Risk Systems Overhaul on an Accelerated Schedule Engineered Systems News: 6 Strategies for Boiler Fuel Conversion Projects: How to Maximize Efficiency and Strategic Alignment Control System Migrations | Part 5 | Training Making a Difference: Our 2024 Charitable Giving Initiative Safety Culture: Examining Common Shortcomings | Industrial Equipment News Unplanned Shutdowns as Proof Test Credits: What to Know and Steps to Take | OH&S Client Success Built With Trusted Expertise aeSolutions is an engineering consulting and systems integration company that provides industrial process safety and automation products and services. We specialize in helping industrial clients achieve their site’s risk management and operational excellence goals. Process Safety As a supplier of complete process safety management (PSM) solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities. Alarm Managem ent Our clients recognize the relationship between the process safety performance of their facilities and the implementation of effective alarm management techniques and alarm philosophy. Our alarm management services help clients improve the performance of their alarm systems and increase the situational awareness of their operators. Machinery Safety Clients who operate and maintain machinery and robotics list safety is a top priority. We help manufacturing facilities achieve safe machine operation through risk assessments, application of the hierarchy of control, and sensible safeguard design. Our scalable programs address client’s specific needs and the machinery lifecycle to provide tailored solutions aligned with international and United States’ standards. DCS/PLC Migrations and Upgrades aeSolutions can provide the system integration methodology, technical services, and resources to accomplish the objectives of your automation project. We work with you from project inception to final commissioning through a proven project delivery model integrating diverse hardware, software, and services from multiple vendors and stakeholders into a unified, integrated system. Safety Instrumen ted Systems aeSolutions has a unique process to design and implement ISA84/IEC 61511-compliant safety instrumented systems (SIS). We integrate our knowledge and experience in PHA/LOPA along with control system hardware and field instrumentation to ensure that Safety Instrumented Functions (SIFs) are clearly defined. We define, design, and document the safety functions to meet your safety and online reliability requirements for 61511 and regulatory compliance. Fired Equipment From up-front engineering to end-user compliance testing, aeSolutions has helped clients create and maintain safe, efficient fired equipment and associated processes. With our extensive engineering knowledge of the National Fire Protection Agency (NFPA) and other regulations, aeSolutions is uniquely qualified to advise on virtually all combustion-related codes and other hazard assessments. Combustible & Toxic Gas The aeSolutions Fire and Combustible & Toxic Gas Detection team deliver a unique blend of experience in philosophy, technology selection, and geographic/scenario-based modeling. Beginning with a Gas Detection Philosophy development or review and update, we design a system that is fit for purpose, cost-effective, and has a defined basis that can be updated as the plant evolves.

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

Discover how aeSolutions delivers cutting-edge process safety and industrial automation solutions across process industries like oil & gas, chemicals, pharmaceuticals, batteries, and more. Explore our expertise today! Industries Served — Solutions For Critical Industries — Agrochemicals Battery Materials & Mineral Processing Chemical Manufacturing Energy & Power Generation Hydrogen Production & Processing Metals & Mining Processing Oil & Gas Production & Processing Petrochemicals & Hydrocarbon Processing Pharmaceutical & Life Sciences Manufacturing Renewable Fuels & Bioenergy Specialty Chemicals & Advanced Materials Utilities & Critical Infrastructure Agrochemicals aeSolutions provides deep expertise in the control and process safety management for the agrochemical industry, ensuring production stability and compliance with stringent environmental and safety regulations. We help clients manage the processes and hazards associated with fertilizers, pesticides, and other agricultural chemicals, including the safe handling of anhydrous ammonia and highly reactive substances. Battery Materials & Mineral Processing The production of battery materials requires safe handling of critical minerals, chemical processing, and fire/explosion risk management. aeSolutions delivers expertise in thermal runaway prevention, gas detection, and process hazard analysis to help clients mitigate risks and maintain regulatory compliance in lithium, nickel, and cobalt processing operations. Chemical Manufacturing Chemical production involves hazardous materials, stringent regulations, and high-risk processes. aeSolutions provides process automation, burner management, fire and gas detection, and process hazard analysis (PHA) to improve safety, efficiency, and regulatory compliance in bulk and specialty chemical production. Energy & Power Generation Energy production facilities, including traditional power plants, cogeneration units, and emerging alternative energy facilities, face complex control and safety challenges. aeSolutions provides fire and gas system design, combustion control and safety, and process hazard analysis to help clients maintain stable control, mitigate risks, enhance system reliability, and comply with industry standards. Hydrogen Production & Processing The hydrogen industry faces flammability risks, high-pressure storage challenges, and evolving regulatory requirements. aeSolutions specializes in the control, fire and gas detection, explosion protection, and quantitative risk analysis (QRA) to support the safety and efficiency of blue, green, and gray hydrogen production and processing facilities. Read More Metals & Mining Processing Heavy industrial operations in metals refining, mineral extraction, and processing require robust control and safety solutions to address risks like combustible dust, high-temperature reactions, and hazardous material handling. aeSolutions provides dust hazard analysis (DHA), fire and gas detection, and process risk assessment to ensure safe and stable operations. Oil & Gas Production & Processing From upstream extraction to downstream refining, the oil and gas industry must navigate complex safety and regulatory challenges, including high-pressure systems, flammable materials, and mechanical integrity risks. aeSolutions delivers expertise in layers of protection analysis (LOPA), safety instrumented systems (SIS), and emergency relief system evaluation to enhance operational integrity and regulatory compliance. Petrochemicals & Hydrocarbon Processing Petrochemical plants handle highly hazardous chemicals that require advanced control and safety measures to maintain process stability and to prevent fires, explosions, and toxic releases. aeSolutions provides process automation, consequence modeling, relief system evaluation, and process safety engineering to improve reliability, protect personnel, and ensure compliance with safety regulations. Pharmaceutical & Life Sciences Manufacturing The pharmaceutical industry must balance product purity, process safety, and regulatory compliance while handling flammable solvents, high-potency chemicals, and strict environmental controls. aeSolutions delivers ventilation system design, containment strategies, and process hazard analysis (PHA) to support safe and compliant manufacturing. Renewable Fuels & Bioenergy Renewable fuel production — including biofuels, synthetic fuels, and waste-to-energy processes — introduces safety challenges such as combustion risks, toxic gas emissions, and complex reaction chemistry. aeSolutions provides process control, hazard identification (HAZID), fire and gas detection, and safety instrumented systems (SIS) design to mitigate these risks and enhance operational efficiency. Specialty Chemicals & Advanced Materials Specialty chemicals require precision in process control and stringent safety management to prevent hazardous incidents. aeSolutions provides continuous and batch control, process hazard analysis (PHA), fire and gas system design, and SIS implementation to protect personnel, optimize operations, and maintain regulatory compliance. Utilities & Critical Infrastructure Utility providers — including power generation, water treatment, and industrial gas distribution—must manage safety risks related to combustion systems, hazardous gas handling, and emergency response. aeSolutions delivers expertise in burner management systems (BMS), alarm management, and process safety engineering to ensure reliable and secure operations. Why aeSolutions? Trusted Go-To Partner for Our Clients' Tough Challenges Innovative, Sustainable Solutions to Create Client Value Professional Project Management to Drive Client Business Results Consistent Performance and Delivery on Our Commitments Recognized Extensively Credentialed Professionals (PE, CFSE, PMP) Active in Leadership of Professional Organizations (ISA, AIChE, CSIA) Involved in Development of International Standards & Industry Best Practices Deep Technical Acumen, Thought Leadership

Control rooms, ergonomic multi-window stations Field panels, touch screen HMI Situational awareness Contextual data and trends Intuitive navigation Meaningful dynamics Single HMI for multiple control platforms and migrations Project specific HMI style guide Rockwell, Siemens PC7, Safety systems and critical controls, Triconex Human Machine Interfaces - SCADA Interacting with Intuitive Information aeSolutions designs and configures human machine interfaces for control and safety systems. HMI varieties range from DCS vendors' hefty client-server systems to small touch screens engineered with special purpose panels. To avoid incidents, an operator needs to quickly comprehend and react appropriately to changing conditions in the plant. Flashy graphics of the 1990's had too many distractions and made it hard to comprehend abnormal situations. Standards working groups like ASM, and ISA101-HMI are driving toward industry consensus. Control rooms, ergonomic multi-window stations Field panels, touch screen HMI Situational awareness Contextual data and trends Intuitive navigation Meaningful dynamics Single HMI for multiple control platforms and migrations Project specific HMI style guide Automation Servies

aeSolutions' aeRemoteConnect (aeRC) provides robust security controls that meet the high security bar set by today's IT professionals. aeRemoteConnect Simple, Secure, Responsible Remote Access Industrial clients, like all employers, are grappling with the significant loss of experienced staff, particularly in technical roles. The continually increasing complexity and specialization of today’s automation systems compound the challenge of replacing skilled automation personnel. This results in the inability to swiftly deploy qualified technical staff for troubleshooting and recovery from unforeseen system shutdowns which can lead to substantial downtime and costs. High-profile cyber attacks make companies cautious about permitting remote connections. Industrial manufacturers are faced with balancing the necessity and efficiency of using remote technicians with the security risks to their internal systems. aeRemoteConnect (aeRC™) allows engineers to remotely connect directly to on-site systems reducing response times when troubleshooting or modifications are urgently needed. A secure, end-to-end encrypted tunnel is established via cellular or existing on-site network and key-switch authorization from on-site staff. A wall-mounted panel houses all required components Modern security threats demand a Defense in Depth strategy to protect industrial operations aeSolutions provides a complete solution with all the necessary equipment, licenses, and services. Based on Siemens' SINEMA Remote Connect software and proven industrial networking equipment, this solution is ready for use with any control system platform. aeRC provides robust security controls that meet the high security bar set by today’s IT professionals. Certificate-based VPN tunnel Multi-Factor Authentication Role-based access control Account auditing System logging SOC 2 compliant data center Have More Questions About aeRemoteConnect? Recent Posts Case Study: Achieving a High-Risk Systems Overhaul on an Accelerated Schedule aeSolutions, a Siemens Solution Partner, delivered a critical CUP control system overhaul for TGES America on an accelerated schedule. Engineered Systems News: 6 Strategies for Boiler Fuel Conversion Projects: How to Maximize Efficiency and Strategic Alignment Boiler fuel conversions help industries meet regulations, boost efficiency, and reduce risks from aging equipment. Control System Migrations | Part 5 | Training Effective training is key to a smooth control system migration—plan early, tailor by role, and leverage simulation for hands-on learning.

Cost-effective, safe solution for integrated Burner Management Systems (BMS) and Combustion Control Systems (CCS) uses. aeSolutions has been suppling safe and standards compliant panels for over 20 years. Jump to a Specific panel: Siemens BMS/CCS 1151 Siemens BMS/CCS 1300 Rockwell CMS 5500 aeSolutions' Custom Fabricated Panels Cost-effective, safe solution for integrated Burner Management Systems (BMS) and Combustion Control Systems (CCS) uses aeSolutions Panel Fabrication Shop 1200 Woodruff Road, A-21 Greenville, SC 29607 See Our Shop: View on Youtube Panels: Developed around the Siemens SIMATIC ET200S IM151 Safety PLC, the 1151-Series Combustion Management Solution offers a cost-effective, safe solution for integrated Burner Management Systems (BMS) and Combustion Control Systems (CCS) uses. With pre-configured software and a simple touchscreen HMI, the system is easy to install and to use. Our clients enjoy a number of benefits from this totally integrated solution. Siemens BMS/CCS 1151 Features BMS is designed to meet FM 7605, IEC 61508, ISA/IEC 61511, ANSI/ISA 84.00.01, NFPA 85, NFPA 86, NFPA 87, API 556 and/or API 14C requirements for single-burner, dual-fuel combustion safeguard applications BMS is capable of meeting SIS requirements up to SIL 3 Advanced CCS firing logic is easily configured to implement a variety of fuel-saving optimization techniques that will reduce the cost of ownership while helping protect the safety of employees and the environment Interface capability to a wide variety of field sensors, analyzers, and valves Communication between combustion control systems or DCS via hardwired I/O, Profibus, Ethernet, or Modbus Designed to facilitate system functional testing HMI includes graphical display of unit operations including alarming, tuning, and diagnostic displays Master Fuel Trip (MFT) hand switch mounted on cabinet front with remote MFT option Touchscreen 10-inch HMI with automated local light-off (optional from a remote location) Preconfigured software, including customization for each application requirement Optional System Features Analog or discrete process instrumentation Free-standing or wall-mount cabinets Distributed I/O Classified area enclosure designs Local & remote alarm monitoring Fuel control valves Air damper controls Interfaces with remote I/O, VF drives, and motor controls using Profibus OPC server System Specifications CCS 1151 Processor: Siemens ET200S IM151-8 processors I/O: Siemens 131 DI Siemens 132 DO Siemens 134 AI Siemens 135 AO BMS 1151 Processor: Siemens ET200S IM151-8F processors I/O: Siemens 138-4FA DI Siemens 138-4FB DO GENERAL HMI: Siemens MP277 10” touchpad and/or Siemens distributed HMI solution. Larger screens available. Power Requirement: 120 Vac Cabinet: Painted 14 gauge steel; NEMA 12 is standard; size is application-dependent (NEMA 4 stainless steel or fiberglass optional) Area Classification: Class I, Division 2 Groups C, D Compliant With: NFPA 85, NFPA 86, NFPA 87, API 556, API 14C, ANSI/ISA 84.00.01-2004, IEC 61508, & ISA/IEC 61511 Siemens BMS/CCS 1300 Developed around the Siemens SIMATIC S7-300F Safety PLC, the 1300-Series Combustion Management Solution offers a cost-effective, safe solution for integrated Burner Management Systems (BMS) and Combustion Control Systems (CCS) uses. With pre-configured software and a simple touchscreen HMI, the system is easy to install and to use. Our customers enjoy a number of benefits from this totally integrated solution. Fe atures BMS is designed to meet FM 7605, IEC 61508, ISA/IEC 61511, ANSI/ISA 84.00.01, NFPA 85, NFPA 86, NFPA 87, API 556 and/or API 14C requirements for single-burner, dual-fuel combustion safeguard applications BMS is capable of meeting SIS requirements up to SIL 3 Advanced CCS firing logic is easily configured to implement a variety of fuel-saving optimization techniques that will reduce the cost of ownership while helping protect the safety of employees and the environment Interface capability to a wide variety of field sensors, analyzers, and valves Communication between combustion control systems or DCS via hardwired I/O, Profibus, Ethernet, or Modbus Designed to facilitate system functional testing HMI includes graphical display of unit operations including alarming, tuning, and diagnostic displays Master Fuel Trip (MFT) hand switch mounted on cabinet front with remote MFT option Touchscreen HMI with automated local light-off (optional from a remote location) Preconfigured software, including customization for each application requirement Optional System Features Analog or discrete process instrumentation Free-standing or wall mount cabinets Redundant and/or distributed I/O Classified area enclosure designs Local & remote alarm monitoring Fuel control valves Air damper controls Interfaces with remote I/O, VF drives, and motor controls using profibus System Specifications CCS 1300 Processor: Siemens S7-300 processors I/O: Siemens SM321 DI Siemens SM322 DO Siemens SM332 AI Siemens SM332 AO BMS 1300 Processor: Siemens S7-300F processors I/O: Siemens SM326F DI Siemens SM326F DO Siemens SM336F AI GENERAL HMI: Siemens MP377 12″ or 15″ touchpad and/or Siemens distributed HMI solution. Larger screens available. Power Requirement: 120 Vac Cabinet: Painted 14 gauge steel; NEMA 12 is standard; size is application-dependent (NEMA 4 stainless steel or fiberglass optional) Area Classification: Class I, Division 2 Groups C, D Compliant With: NFPA 85, NFPA 86, NFPA 87, API 556, API 14C, ANSI/ISA 84.00.01-2004, IEC 61508, & ISA/IEC 61511 Rockwell CMS 5500 Developed around the Rockwell ControlLogix platform, the Combustion Management Systems (CMS) 5500 offers a cost effective, safe solution for an integrated Burner Management Systems (BMS) and Combustion Control Systems (CCS) package. With pre-configured software and a simple touchscreen HMI, the system is easy to install and use. The system is easily adaptable to accommodate many different equipment configurations and options. Features BMS is designed to meet FM 7605, IEC 61508, ISA/IEC 61511, ANSI/ISA 84.00.01, NFPA 85, NFPA 86, NFPA 87, API 556 and/or API 14C requirements for single burner, dual-fuel combustion safeguard applications Standard BMS is capable of meeting SIS requirements up to SIL 2 (SIL 3 option is available with GuardLogix) Advanced CCS firing logic is easily configured to implement a variety of fuel-saving optimization techniques that will reduce the cost of ownership while helping protect the safety of employees and the environment Interface capability to a wide variety of field sensors, analyzers, and valves Communication between combustion control systems or DCS via hardwired I/O, Profibus, Ethernet, or Modbus Designed to facilitate system functional testing Touchscreen HMI includes graphical displays for unit operations, automated light-off, first-out alarming, tuning, and diagnostics screens Master Fuel Trip (MFT) hand switch mounted on cabinet front with remote MFT option Preconfigured software, including customization for each application requirement Optional System Features SI-BMS™ and CCS implemented as independent protection layers for added safety Remote burner light-off and alarm monitoring Multiple burner, multiple fuel applications Analog or discrete process instrumentation Redundant processors Redundant and/or distributed I/O Free-standing or wall-mounted cabinets Classified area enclosure designs Interfaces with remote I/O, VF drives, and motor controls using Ethernet, ControlNet, DeviceNet, HART or serial communications protocols Unit Operations aeSolutions has experience in applying advanced burner management and combustion controls to the following typical unit operations: Boilers TEG reboilers Glycol heaters Process heaters Furnaces and kilns Incinerators and thermal oxidizers Other process and utility fired heaters System Specifications Processor: Rockwell ControlLogix 1756-L6X series processors I/O: 120 VAC or 24 VDC digital I/O, 0-20 mA, 4-20 mA, 0-5 VDC, 0-10 VDC, +10 VDC analog I/O Diagnostic I/O cards (optional) HMI: PanelView Plus 6 series Power Req.: 120 VAC Cabinet: Painted 14 gauge steel; NEMA 12 is standard; enclosure size is application-dependent (NEMA 4 and NEMA 4X stainless steel or fiberglass optional) Area Class.: Class I, Division 2 Groups C, D Compliant With: NFPA 85, NFPA 86, NFPA 87, API 556, API 14C, ANSI/ISA 84.00.01-2004, IEC 61508, & ISA/IEC 61511 Certifications: FM-Approved SIL 2 SI-BMS BMW/CCS 1151 BMS/CCS 1300 CMS 5500 Looking for Fire and Gas panels? FGS 1400 MK II Industrial designed system, SIL 3-capable logic solver, scalable to large I/O count. Download datasheet FGS 1300 FM-approved for lower I/O count applications. Class I Division 2 area classification status. Download datasheet PS 1400 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 Division 2 areas. Rugged and reliable. Download datasheet

As a supplier of complete process safety systems and risk management solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety systems and backgrounds. Our specialists understand process safety. Planning "control systems" & "process controls", and process risk management. - Process Hazard Management HS4, HS5, HS- essential component of any facility. Learn about the importance of process safety management Process Safety Management As a supplier of complete process safety and risk management solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities. pro cess hazard management Services: PSM/RMP Process Hazard Analysis Quantitative Risk Assessment Human Reliability Auditing Facility Siting & Modeling Machinery Safety PSM/RMP Program Development & Implementation Risk Management Plan/Hazard Assessment Management of Change (MOC) Program Development & Implementation Incident Investigation Mechanical Integrity Program Operating Procedures & Training Training (PS Leadership, Auditor, PHA/LOPA) Electrical Area Classification Learn More Process Safety Management/Risk Management Plan (PSM/RMP) Hazard and Operability (HAZOP) What if What-If/Checklist Analysis Failure Modes and Effects Analysis (FMEA) Combustible Dust Hazard Assessment Control System Hazard and Operability (CHAZOP) Process Hazard Analysis (PHA) Learn More Risk Graphs Event Tree Analysis Bowtie Analysis Layers of Protection Analysis (LOPA) Independent Protection Layer (IPL) and Safety Integrity Level (SIL) Selection Learn More Implicit LOPA Safety Layer Matrix 3D Risk Matrix Quantitative/Semi-Quantitative Risk Assessment (QRA) Human Reliability Analysis (HRA) Human Error Analysis Human Reliability/Human Factors Learn More Compliance Auditing - PSM, RMP, and Risk Based Process Safety (RBPS) Independent Protection Layer (IPL) Verification Learn More Auditing Facility Siting Analysis Risk-based and Consequence-based Studies Gas Dispersion Modeling Failure Modes and Effects Analysis (FMEA) Gas Detector Placement Learn More Facility Siting & Dispersion Modeling Screening Robot Integration Risk Assessment Facility Compliance Evaluation State of Conformity Evaluation Safety Function Performance Level Verification & Validation Machine Guarding Assessment Machine Safety Risk Assessment Robotic Safety Light Curtain Positioning Interlock Design Circuit Design Safeguard Specification & Implementation Functional Safety Assessment Hazard Identification Training Learn More Machinery Safety PSM RMP PHA QRA LOPA Human Reliability Audit Siting & Modeling Machinery Safety Featured Stories Enhancing Process Safety: Five Tips to Build a Better System FSA Stage 2: Evaluating the Safety Instrumented System (SIS) Readiness for Field Installation Can Stage 3 FSA Confirm Your Safety Instrumented System Is Ready for Operational Use?

Ensure the safety and efficiency of your hydrogen production facility with aeSolutions' expert hydrogen gas detection system design and implementation services. Our comprehensive solutions address the unique challenges of hydrogen's flammability and detection, providing robust protection for both personnel and assets. Hydrogen Risk Management & Hazard Mitigation Ensuring Safety in Hydrogen Production & Storage As the global demand for hydrogen as a clean fuel source continues to rise, the need for robust safety protocols in hydrogen production facilities becomes increasingly critical. The industry experts at aeSolutions specialize in hydrogen facility siting and risk management services, addressing the unique challenges posed by hydrogen's properties. We provide comprehensive solutions that include advanced hydrogen gas detection systems, dispersion modeling, and ventilation system evaluation. By leveraging our expertise, you can assure the safety and efficiency of your hydrogen production processes, minimizing risks and maximizing operational uptime. Ready to discuss your facility's hydrogen safety? Click Here aeSolutions Capabilities 2,000+ Clients Served Capital Projects Regulatory Compliance Consultation Code Gap Assessment Operational Improvement Debottlenecking Expansions Upgrades Process Hazard Analysis (HAZID, PHA, LOPA, etc.) Facility Siting Dust Hazard Analysis Relief Device Sizing Electrical Area Classification PSM/RMP Auditing Mechanical Integrity Process Safety Functional Safety SIF & IPL Assessment, Selection, & Scoping SIF Design & Calculations SRS Development Alarm Management Philosophy Alarm Rationalization System Performance Analysis Conditional Alarming Asset Integrity Alarming Program Auditing Automation & Control DCS/PLC Migration & Upgrades I/O Cut-Over Planning Instrument & Electrical Conceptual Design FRS Development Fired Equipment Burner Management System Design Fuel Gas & Combustion Control System & Panel Design Equipment Upgrades Fire & Combustible/Toxic Gas Detection Plume Dispersion Modeling Detector Coverage Modeling NFPA & FM Approved PLC Panel Platforms Control System Conceptual Design Critical System Definition Project Estimation Long-Lead Procurement Front End Engineering & Design Detailed Engineering Design Periodic Testing, Auditing, Procedures, Training Procurement Fabrication, Installation Commissioning, Startup Our Hydrogen Service Areas aeSolutions is at the forefront of providing comprehensive hydrogen facility siting and risk management services. Our expertise assures that new and existing hydrogen production facilities operate safely and efficiently, while addressing the unique challenges posed by hydrogen's properties. Our hydrogen services include: Hydrogen Safety and Risk Management Hydrogen is a highly flammable, explosive, and reactive element. This makes safety a paramount concern in its production, storage, and transportation. aeSolutions' is experienced in applying the rigorous safety protocols tailored to the unique properties of hydrogen. Our comprehensive risk management strategies encompass detection, prevention, and mitigation measures to safeguard your facilities and personnel as well as meeting regulatory and compliance requirements. Facility Siting and Layout Optimization The siting of hydrogen facilities is crucial to minimizing risks and assuring operational efficiency. aeSolutions employs advanced modeling techniques and industry best practices to determine optimal facility layouts. We consider factors such as hydrogen's buoyancy, reactivity, and dispersion characteristics to design safe and effective plant layouts. Hydrogen Consequence Modeling aeSolutions leverages advanced consequence modeling tools, such as Computational Fluid Dynamics (CFD), to simulate hydrogen releases, dispersion patterns, and potential explosion scenarios. These models support the optimal placement of detection systems and the development of robust emergency response plans, ensuring the highest levels of safety and reliability. Advanced Gas and Flame Detection Systems Early detection of hydrogen leaks and fires is vital for preventing accidents. aeSolutions utilizes state-of-the-art gas and flame detection technologies, including catalytic bead detectors, ultrasonic detectors, and infrared flame detectors. Our expertise in placing these detectors strategically assures compliant, quick, and reliable hazard identification, enabling timely intervention and mitigation. Comprehensive Mitigation Measures In addition to detection and ventilation, aeSolutions implements a range of additional safety measures. These include grounding and bonding of equipment and maintaining safe distances from ignition sources. aeSolutions is continuously enhancing our safety protocols to meet or exceed regulatory and compliance requirements in the hydrogen industry. Ventilation System Evaluation Effective ventilation is essential to prevent the accumulation of flammable hydrogen gas. Proper venting along building eaves, strategic placement of inlet and exhaust openings, and ensuring adequate ventilation rates are key components of our approach. Our team of experts is experienced in assessing your facility's ventilation to enhance safety and assure compliance with industry standards and best practices. Expertise in Hydrogen Hazard Mitigation Hydrogen, with its small molecular size, high reactivity, and broad flammability range, presents unique safety challenges. The aeSolutions team understands these complexities and offers tailored risk management strategies to mitigate potential hazards. We employ state-of-the-art detection technologies and rigorous safety protocols to identify and address leaks and other risks promptly. Additionally, aeSolutions specializes in the process hazard analysis (PHA) techniques required to analyze and address the unique hazards presented by hydrogen. Our solutions are designed to meet NFPA standards and are customized to fit the specific needs of your facility, assuring a safer working environment for your personnel and assets. Comprehensive Risk Management Solutions At aeSolutions, we are committed to providing comprehensive and compliant risk management solutions for hydrogen facilities. From the initial siting and design to the implementation of advanced detection and mitigation measures, we cover all aspects of hydrogen safety. Our case studies demonstrate our ability to design and install effective fire and gas detection systems, optimize detector placements, and develop robust ventilation systems. By partnering with aeSolutions, your facility gains access to industry-leading expertise and innovative safety solutions that protect your operations and drive your success in the hydrogen industry. Dispersion Modeling Hydrogen Case Studies & Whitepapers Detection & Mitigation of Hydrogen Releases - Whitepaper Strategic Integration of SIS, BMS, & PSM in a Boiler Fuel Conversion Project - Case Study Designing and Implementing a Fire & Gas Detection System for a Hydrogen Production Plant

aeSolutions' has been a trusted provider of facility siting study and modeling needs for over 25 years. Let's discuss how we can positively impact your sustainable risk management program. Facility Siting Studies & Modeling Solutions Facility siting studies are advised as part of new projects (green or brown field) and modification of existing facilities (buildings, population and process changes, introduction of new chemicals or products). In cases where a facility has applicability to the OSHA PSM and/or EPA RMP standards, conducting baseline and revalidation facility siting studies are required by these regulatory authorities to assess the consequences of potential incidents such as fires, explosions, or toxic exposure on individuals both onsite and off. Evaluating the impact of these facility operational risks is vital when creating a comprehensive safety plan. aeSolutions' facility siting and consequence modeling experts work hand in hand with your team to identify potential process hazards, accounting for your operation's specific siting protocols and goals. aeSolutions is an industry-trusted provider of risk-based and consequence-based facility siting studies in addition to gas dispersion modeling, gas sensor mapping, and gas detector placement. Why Partner With Us? At aeSolutions, we believe one of the greatest influences on operational excellence is a comprehensive, sustainable risk management program that addresses both conformance and compliance. For over 25 years, aeSolutions has served as a multi-faceted safety solutions provider across a wide gamut of industries. When it comes to facility siting studies, we leave no stone unturned. aeSolutions' team of trained facilitators execute the hazard recognition and risk reduction process while our experienced modelers apply the appropriate methodology in line with API 752/753/756 in addition to industry best management practices. In short, we provide results that enable effective allocation of resources to minimize facility siting risks by your site leadership team. Trust Built On Experience Years of Combined Experience In Facility Siting Studies Facility Siting Studies Completed Years Serving the Industry Facility Siting Study & Analysis Our Facility Siting Capabilities Risk-Based & Consequence-Based Studies Gas Dispersion Modeling Fire Modeling Computational Fluid Dynamics (CFD) Modeling Gas Sensor Mapping Gas Detector Placement Explosion Modeling In accordance to API 752, 753, 756 recommended practices and the Center for Chemical Process Safety (CCPS) Guidance. The aeSolutions Six Step Approach Identify chemicals of concern Identify site-specific conditions Identify potential hazard event scenarios from review of site data Identify & classify occupied buildings Perform the hazard and consequence analysis Perform the risk management analysis aeSolutions utilizes DNV-GL's PHAST to provide quantitative fire and toxic effect data for pool fires, vapor cloud fires, vapor cloud explosions, jet fires, and toxic vapor clouds. Results are illustrated on a site plot plan with hazard endpoint circles for radiant heat, toxic concentrations, and pressure/impulse waves. Additionally, aeSolutions may perform computational fluid dynamics (CFD) models for highly hazardous scenarios upon request. Industries Served Chemical Metals & Mining Renewable Energy Hydrogen Agriculture Petrochemical Specialty Chemical Energy & Alternative Energy Oil & Gas Pharmaceutical Utilities LNG About Facility Siting Studies A Facility Siting Analysis is intended to evaluate the potential hazards and consequences of uncontrolled releases of flammable and toxic substances; to assess their potential for injuring the occupants of fixed and temporary structures on or offsite; to identify existing safeguards; and to determine measures to reduce the risk posed by these potential events. Within the United States, facility siting is required as an element of Process Hazard Analysis (PHA) for sites covered by the Occupational Safety and Health Administration's (OSHA) Process Safety Management (PSM) Standards under 29 CFR 1910.119 (e)(3)(v). aeSolutions' Facility Siting Studies are conducted in accordance with methods listed in the American Petroleum Institute's (API) Recommended Practices 752, 753, and 756, and published guidance from the Center for Chemical Process Safety (CCPS). Facility Siting is a multi-faceted analysis of potential fire, explosion, and toxic hazards to personnel from releases of hazardous chemicals. These chemicals of concern include those that vaporize quickly, are highly toxic to personnel or the environment, have low flash points and boiling points, are highly reactive, and/or are present at temperatures, pressures, and/or in quantities significant enough to pose a hazard of concern. Ready to Discuss Your Facility Siting Study? Recent Posts Understanding How Burner Management Systems Work Understanding how burner management systems (BMS) work and how they can benefit your facility's safety and regulatory compliance. Evolution of Fired Equipment Protective Systems in the Chemical Sector Several years ago, aeSolutions started our fired equipment business. This business is focused on safeguarding burners and furnaces,... Enhanced Reliability and Safety Through Standardization Fired equipment such as industrial boilers, incinerators, process furnaces, and fluid heaters are used everywhere. They are a crucial, compl

Periodic test performed to detect dangerous hidden failures in a system so that, if necessary, a repair can restore the system to an ""as good as new condition"", or as close as practical to this condition. The goal of a proof test of a SIF is to reveal previously undiagnosed dangerous hardware failures (those failures that would prevent the SIF from reacting to a hazard). Proof test coverage (the fraction of these failures a given proof can reveal) and the interval at which proof tests are conducted are important inputs into determining if a SIF meets its required SIL. Developing a proof test philosophy can provide for consistency in proof test procedures and how they are conducted. aeSolutions' experts have the field experience to discuss the testing requirements, site practices and available technologies to determine and document a comprehensive testing philosophy. We also have a library of proven proof test procedures to choose from when assembling a testing package, and we have the expertise to work with clients to implement effective testing, failure classification, and feedback mechanisms to validate reliability data claimed in Risk Analysis and SIL Verification. Acronyms & Terms Glossary <- More Definitions Proof Test Periodic test performed to detect dangerous hidden failures in a system so that, if necessary, a repair can restore the system to an ""as good as new condition"", or as close as practical to this condition. The goal of a proof test of a SIF is to reveal previously undiagnosed dangerous hardware failures (those failures that would prevent the SIF from reacting to a hazard). Proof test coverage (the fraction of these failures a given proof can reveal) and the interval at which proof tests are conducted are important inputs into determining if a SIF meets its required SIL. Developing a proof test philosophy can provide for consistency in proof test procedures and how they are conducted. aeSolutions' experts have the field experience to discuss the testing requirements, site practices and available technologies to determine and document a comprehensive testing philosophy. We also have a library of proven proof test procedures to choose from when assembling a testing package, and we have the expertise to work with clients to implement effective testing, failure classification, and feedback mechanisms to validate reliability data claimed in Risk Analysis and SIL Verification. Our Services Case Study: Achieving a High-Risk Systems Overhaul on an Accelerated Schedule aeSolutions, a Siemens Solution Partner, delivered a critical CUP control system overhaul for TGES America on an accelerated schedule. Engineered Systems News: 6 Strategies for Boiler Fuel Conversion Projects: How to Maximize Efficiency and Strategic Alignment Boiler fuel conversions help industries meet regulations, boost efficiency, and reduce risks from aging equipment. Control System Migrations | Part 5 | Training Effective training is key to a smooth control system migration—plan early, tailor by role, and leverage simulation for hands-on learning.

“At aeSolutions, we are humbled by our role as a trusted guide for our clients’ success,” said Ken O’Malley. “With our Project Development team, senior leadership is completely committed to the Client Success Model. We are excited to begin formally offering this unique service to our new and existing clients.” Celebrating client success, one challenge at a time. Case Study: Achieving a High-Risk Systems Overhaul on an Accelerated Schedule aeSolutions, a Siemens Solution Partner, delivered a critical CUP control system overhaul for TGES America on an accelerated schedule. Engineered Systems News: 6 Strategies for Boiler Fuel Conversion Projects: How to Maximize Efficiency and Strategic Alignment Boiler fuel conversions help industries meet regulations, boost efficiency, and reduce risks from aging equipment. Control System Migrations | Part 5 | Training Effective training is key to a smooth control system migration—plan early, tailor by role, and leverage simulation for hands-on learning. Making a Difference: Our 2024 Charitable Giving Initiative aeSolutions’ 2024 initiative supports hunger relief, health, education, & military causes, driving sustainable change with employee passion. Safety Culture: Examining Common Shortcomings | Industrial Equipment News Many organizations fall short in safety culture by overlooking mechanical integrity, change management, and incident investigations. Unplanned Shutdowns as Proof Test Credits: What to Know and Steps to Take | OH&S Learn how unplanned shutdowns can serve as partial proof tests for Safety Instrumented Functions (SIFs). Control System Migrations | Part 4 | Managing Scope, Schedule, Budget Control System Migrations Part 4 explores balancing scope, schedule, and budget for successful project outcomes. 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

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. 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 Case Study: Achieving a High-Risk Systems Overhaul on an Accelerated Schedule aeSolutions, a Siemens Solution Partner, delivered a critical CUP control system overhaul for TGES America on an accelerated schedule. Engineered Systems News: 6 Strategies for Boiler Fuel Conversion Projects: How to Maximize Efficiency and Strategic Alignment Boiler fuel conversions help industries meet regulations, boost efficiency, and reduce risks from aging equipment. Control System Migrations | Part 5 | Training Effective training is key to a smooth control system migration—plan early, tailor by role, and leverage simulation for hands-on learning.