AE Solutions was responsible for the replacement of an existing antiquated PLC with a new Safety Instrumented System (SIS) for two Ethylene Oxide / Polyethylene Oxide reactors. Project consisted of development of the SIS functional specification, safety system configuration and commissioning services for the Moore QUADLOG system. HMI consisted of Moore Safety Matrix Cause & Effect diagram.

AE Solutions completed Safety Integrity Level (SIL) calculations for a Batch Specialty Chemical facility. Calculations were performed and a summary report was produced that documented compliance with the project Safety Requirements Specification per ANSI/ISA S84.01 for each safety function associated with the facilities Safety Instrumented System (SIS).

AE Solutions developed a standardized Burner Management System (BMS) for dual burner fired equipment (boilers, furnaces, thermal oxidizers, etc.) utilizing Moore's QUADLOG Safety PLC system for Moore Process Automation Solutions submittal to Factory Mutual for system approval. Development of the pre-engineered product embodies the concepts of ISA's S84.01 (Designing and Applying Emergency Shutdown Systems) and compliance with IEC 61508, NFPA 8501, 8502, 86 & 86C standards, as well as, FM & IRI guidelines. Project focus was on minimizing Total Installed & Life Cycle Costs while maximizing functionality, availability and reducing risk. Responsibilities include complete system engineering, panel design, configuration, SIL evaluation and compliance with codes and standards.

AE Solutions replaced an antiquated Fire & Gas Detection system with a Moore QUADLOG Safety PLC. Responsibilities included software configuration, simulation and testing for the Fire & Gas Detection system. The Fire & Gas Detection system design included the complete replacement of the existing proprietary system with a modern safety PLC based system. Design included complete system instrumentation and electrical design in accordance with NFPA 72 requirements.

AE Solutions was responsible for the installation of a new Safety Instrumented System for the EO / PO reactor trains. Project consisted of development of the SIS functional specification, safety system configuration, complete field wiring design, Safety PLC installation design, and commissioning services for the Siemens-Moore QUADLOG system. Project architecture included a fully rack-to-rack redundant QUADLOG Safety PLC with a dedicated MODBUS interface to an existing Modicon PLC running Intellution as the HMI. Responsibilities included development of the SIS specification, QUADLOG configuration, complete field wiring design, Safety PLC installation design and commissioning.

AE Solutions was responsible for modification of a Liquefied Natural Gas (LNG) facility's Safety System. Plant includes gas purification, liquefaction, storage and vaporization processes. Project involved demolition of the existing Emergency Shutdown Relay Panel and incorporating the safety philosophy into a Moore QUADLOG Safety PLC with the addition of approximately 50 I/O. Responsibilities included wiring design, software configuration, simulation and testing for the QUADLOG Safety and APACS Process Systems. Design included complete system instrumentation and electrical design and was in accordance with ANSI/ISA S84.01 and NFPA 72 requirements.

AE Solutions was responsible for the Safety Instrumented System (SIS) replacement project for the EO / PO reactors. Project consisted of development of the SIS functional specification, safety system configuration and commissioning services for the Moore QUADLOG system. HMI consisted of Moore Safety Matrix Cause & Effect diagram. Responsibilities included development of the SIS specification and configuration.

AE Solutions was responsible for the completion of Safety Integrity Level (SIL) calculations for a Batch Specialty Chemical facility. Calculations were performed and a summary report was produced that documented compliance with the project Safety Requirements Specification per ANSI/ISA S84.01 for each safety function associated with the facilities Safety Instrumented System (SIS).

VAD AllWave Expansion Project

Principal Safety System Specialist for development of the Life Safety System (LSS) on the Vapor Axial Deposition process for the manufacturing of optical glass fiber. Project included Safety Life Cycle consulting services including HAZOP validation, Safety Instrumented Function (SIF) identification, Layer of Protection Analysis (LOPA) and SIL determination and evaluation per ANSI/ISA S 84.01 standard. LSS implementation included complete engineering, design, configuration and commissioning of the process Life Safety System (LSS) utilizing a Siemens QUADLOG safety PLC. LSS included process and area toxic gas detection, process shutdown and facility emergency response alarm systems. The LSS was integrated with the facility fire and security systems. Project work processes and deliverables were developed in such a way as to become the basis for standardization of future deployment of facility LSS. Responsibilities included technical lead for complete definition, engineering, detailed design, configuration and commissioning of the LSS.

AE Solutions was responsible for the development of an ANSI/ISA 84.01 & IEC 61508/61511 compliant Safety Instrumented System (SIS) for a PTA oxidation reactor line #2. The project included complete Safety Lifecycle consulting services to perform process risk assessment, Safety Instrumented Function (SIF) identification, Safety Integrity Level (SIL) selection, and SIL calculations to verify that the system conceptual design met requirements. This included the requirement for partial stroke testing within one SIF to meet SIL requirements. SIS implementation included development of the Safety Requirements Specification (SRS) and Conceptual Design Specification (CDS) (Including P&ID sketches, Safety PLC Architecture Diagrams and SIL calculations). AE Solutions also specified the Safety PLC and completed Technical analysis of vendor quotations. The Project implemented a TMR Triconex Tricon V9 with a dedicated SMM interface to an existing Honeywell TDC3000 for approximately 250 I/O.

AE Solutions developed Safety Instrumented System (SIS) Functional Test Plans per API 14C and project Safe Charts for an offshore oil platform.

AE Solutions provided complete Safety Lifecycle consulting services including process risk assessment, Safety Instrumented Function (SIF) identification, Safety Integrity Level (SIL) selection, Layer of Protection Analysis (LOPA), and SIL calculations to verify that the system conceptual design met requirements for a Life Safety System (LSS). In addition, AE Solutions provided complete LSS implementation including engineering, design, configuration and commissioning utilizing a Siemens QUADLOG safety PLC. The LSS included process and area toxic gas detection, process shutdown and facility emergency response alarm systems. In addition, it was integrated with the facility fire and security systems. Project work processes and deliverables were developed in such a way as to become the basis for standardization of future deployment of facility LSS.

AE Solutions implemented the new Safety Instrumented System (SIS) for two Ethylene Oxide / Polyethylene Oxide reactor trains. The project consisted of development of the SIS functional specification, safety system configuration and commissioning services for the Siemens / Moore Products QUADLOG system.

AE Solutions was responsible for the development of an ANSI/ISA 84.01 & IEC 61508/61511 compliant Safety Instrumented System (SIS) for a PTA oxidation reactor line #1. The project included complete Safety Lifecycle consulting services to perform process risk assessment, Safety Instrumented Function (SIF) identification, Safety Integrity Level (SIL) selection, and SIL calculations to verify that the system conceptual design met requirements. This included the requirement for partial stroke testing within one SIF to meet SIL requirements. SIS implementation included development of the Safety Requirements Specification (SRS) and Conceptual Design Specification (CDS) (Including P&ID sketches, Safety PLC Architecture Diagrams and SIL calculations). AE Solutions also specified the Safety PLC and completed Technical analysis of vendor quotations. The Project implemented a TMR Triconex Tricon V9 with a dedicated SMM interface to an existing Honeywell TDC3000 for approximately 350 I/O.

AE Solutions was responsible for the development of an ANSI/ISA 84.01 & IEC 61508/61511 compliant Safety Instrumented System (SIS) for a PIA oxidation reactor line. The project included complete Safety Lifecycle consulting services to perform process risk assessment, Safety Instrumented Function (SIF) identification, Safety Integrity Level (SIL) selection, and SIL calculations to verify that the system conceptual design met requirements. SIS implementation included development of the Safety Requirements Specification (SRS) and Conceptual Design Specification (CDS) (Including P&ID sketches, Safety PLC Architecture Diagrams and SIL calculations). AE Solutions also specified the Safety PLC and completed Technical analysis of vendor quotations. The Project implemented a Siemens / Moore Products QUADLOG PLC with a redundant Modbus interface to an existing Honeywell TDC3000 for approximately 150 I/O. AE Solutions also designed, fabricated and conducted Factory Acceptance Testing on the SIS panel.

AE Solutions was responsible for the development of an ANSI/ISA 84.01 & IEC 61508/61511 compliant Safety Instrumented System (SIS) for three (3) batch TMA oxidation reactor lines. The project included complete Safety Lifecycle consulting services to perform process risk assessment, Safety Instrumented Function (SIF) identification, Safety Integrity Level (SIL) selection, and SIL calculations to verify that the system conceptual design met requirements. SIS implementation included development of the Safety Requirements Specification (SRS) and Conceptual Design Specification (CDS) (Including P&ID sketches, Safety PLC Architecture Diagrams and SIL calculations). AE Solutions also specified the Safety PLC and completed Technical analysis of vendor quotations. The Project implemented a Siemens / Moore Products QUADLOG PLC with a redundant Modbus interface to an existing Honeywell TDC3000 for approximately 200 I/O.

AE Solutions was responsible for implementation of a cross-limited fuel/air combustion control system and Burner Management System (BMS) for two (2) multi-fuel (Natural Gas & Hydrogen) fired boilers with complex automatic sequence startup requirements. Control scheme included maximizing use of waste H2 fuel. Project included upgrade of existing panelboard system single loop controllers, pneumatics, and relay systems with new electrical & instrumentation design, logic design, configuration, simulation, commissioning and operator training on the Siemens APACS/ QUADLOG / ProcessSuite DCS. AE Solutions also designed, fabricated and conducted Factory Acceptance Testing on the BMS panels.

AE Solutions was responsible for implementation of a cross-limited fuel/air combustion control system for two (2) multi-fuel fired HCl furnaces with complex sequence startup requirements. Project included logic design, configuration, simulation, commissioning and operator training on a Siemens APACS / ProcessSuite DCS.

AE Solutions was responsible for conducting a study of eight (8) existing O2 analyzers that were to be utilized as sensors in a Safety Instrumented System (SIS) for a TMA reactor line. Study included field survey of existing analyzers, development of a conceptual design for a proposed new oxygen analyzer system, and preparation of a +/- 30% cost estimate for several options to assist client in determining the most cost effective design for their SIS.

AE Solutions was responsible for a process Safety Integrity Level (SIL) and equipment integrity/reliability level (IL) analysis (i.e. IL Study) on a Low Pressure Vent Gas Compressor (LPVGC). The study was used by the client as a tool to evaluate various architectures / technologies for Safety Instrumented Systems including recommendations as to the cost effectiveness of each options in an effort to improve the overall reliability and availability of the LPVG Gas Treatment System. The Study resulted in development of a design basis for a Safety Instrumented System (SIS) for the LPVGC, which included safety, environmental, and asset assessment.

AE Solutions was responsible for the upgrade of the combustion control Basic Process Control System (BPCS) and Burner Management System (BMS) for a utility steam boiler. The boiler was a single burner, dual fuel unit, having the ability to burn both natural gas and No. 6 fuel oil, but with only one fuel at a time. Both fuels were initiated by an intermittent, propane pilot with a spark igniter. The primary purpose of the upgrade was to improve each systems automatic capability, reliability, efficiency and safety. AE Solutions also designed, fabricated and conducted Factory Acceptance Testing on the BPCS / BMS panel.

AE Solutions was responsible for the replacement of a Syltherm oil heater Burner Management System (BMS) with a new system providing greater availability and reliability in heater operation. The new system re-used most of the existing field instrumentation and control devices. The new BMS logic solver employed the latest TUV and FM listed, microprocessor based Siemens QUADLOG safety PLC system. The system was designed to comply with the latest NFPA codes (85, 86C) and IEC standards (61508) governing the design and application of Safety Instrumented Systems (SIS) for BMS applications. The system was also designed to meet a minimum Safety Integrity Level (SIL) 2. AE Solutions also designed, fabricated and conducted Factory Acceptance Testing on the BMS panel.

AE Solutions was responsible for the Safety Integrity Level (SIL) selection for a Breathing Air System. The project included two (2) primary Safety Instrumented Functions (SIF), Loss of Breathing Air Compressor and Poor Air Quality. Process analysis and hazard review meetings were conducted to validate the primary functions.

AE Solutions was responsible for the assessment of the BMS systems for multi-fuel, multi-burner calciners to evaluatecompliance withcurrent codes and safety standards to include, as a minimum, NFPA 85, NFPA 86, ANSI / ISA 84.01 and IEC 61511. The Basic Process Control System (BPCS) was also evaluated for system maintainability, operability, and process performance improvements to evaluate potential reductions in both operating cost and lifecycle cost of ownership for the automation systems.

AE Solutions was responsible for analyzing the risk of an Upflow Anaerobic Sludge Blanket Reactor with the purpose of defining the required safety functions and selecting an appropriate SIL for each identified function. Deliverables included Risk Analysis Decision Support Calculations and SIL Selection Decision Support Report. In addition, AE Solutions designed, fabricated and conducted Factory Acceptance Testing on a relay based logic solver which utilized Moore Industries SPA's. The SIS was designed and SIL calculations performed to verify that the system was capable of meeting SIL 1 requirements.