Case Studies
The following case studies are compiled from our real projects. In accordance with client confidentiality, company names are not disclosed; each case is presented focusing on the needs encountered, the engineering approach we applied, the standards we used, and the results obtained.
Our more than 100 completed projects span a wide range of sectors, from mining and metallurgy to automotive, energy, public infrastructure, insurance, and data centers. Selected examples are shown below.
Case 1 — Multi-Year Integrated Audit in a Mining & Chemical Company
Sector & Scope: A large-scale mining and chemical plant with multiple locations and continuous production.
Need: Periodic inspections, energy isolation (LOTO), and fire safety processes were being handled by scattered subcontractors; the company wanted to consolidate these into a single accredited business partner, without interrupting production and in a way that was ready for inspection.
AES Approach: An annual periodic inspection schedule was created for all sites; electrical, grounding, pressure vessel, and lifting equipment were inspected according to regulations. LOTO procedures and energy isolation points were defined for critical equipment, and fire extinguishing systems and cylinder inventory were checked.
- Work Equipment Regulations Annex III
- TS EN ISO/IEC 17020 accredited inspection
- BYKHY (fire) and LOTO/EKED principles
Outcome & Achievement: The company gained a repeatable audit schedule that continuously maintains its legal compliance, standardized reporting across all areas, and a single, documentable infrastructure for insurance/audit processes.
Case 2 — Arc Flash Analysis and Labeling in a Heavy Industry Facility
Sector & Scope: An automotive/heavy industry production facility with a dense electrical infrastructure.
Need: The arc flash energy to which maintenance crews working on energized equipment were exposed was unknown; this left the selection of PPE and safe working decisions uncertain.
AES Approach: The facility's power system was modeled; short-circuit and protection data were used to calculate incident energy. Arc flash labels were designed for each panel, and the required arc-rated PPE categories were determined.
- IEEE 1584 event energy calculation
- NFPA 70E safe working limits
- Panel-based arc flash labeling
Outcome & Achievement: Field crews began working with labels clearly indicating the energy they would be exposed to and the required PPE on each panel. The facility made the risks of working with energy measurable and manageable.
Case 3 — Grounding and Electrical Safety in the International Arena
Sector & Scope: An industrial infrastructure site abroad (Africa/Middle East).
Need: Grounding performance and electrical safety, suitable for local soil and climate conditions, needed to be verified according to international standards.
AES Approach: Field grounding measurements were conducted; soil resistivity, grounding impedance, and step/touch voltage risks were assessed. Necessary improvements were recommended in an engineering report, and an electrical safety analysis was performed.
- Grounding resistivity and impedance measurements.
- Step/touch tension assessment
- Reporting in accordance with international standards.
Outcome & Achievement: The project demonstrated AES's engineering capabilities to manage measurement, analysis, and reporting end-to-end in cross-border sites, and supported the site's transition to safe operation.
Case 4 — Generator and Lightning Rod Inspection in a Construction and Infrastructure Project
Sector & Scope: A large-scale construction/transportation infrastructure project (construction site and facility buildings).
Need: The legal requirement for periodic inspections and documentation ready for audit was necessary for generator and lightning protection (lightning rod) systems in the electrical infrastructure of the construction site and buildings.
AES Approach: Generator periodic inspections and lightning rod and grounding measurements were carried out using accredited methodology; deficiencies were prioritized with non-conformity reports.
- Generator periodic inspection
- Lightning rod/lightning protection measurement (TS EN 62305)
- Grounding continuity and resistance measurements
Outcome & Achievement: The project has obtained legally compliant electrical safety documentation, ready for audits and payment claims, and this has been ensured through repeated checks throughout the process.
Case 5 — Electrical Control and Feasibility in a Solar Power Plant (SPP)
Sector & Scope: An investment in a grid-connected solar power plant.
Need: The investor wanted to verify the electrical safety, grounding adequacy, and performance/feasibility parameters of the power plant through an independent engineering assessment.
AES Approach: The field inspection examined the string and inverter connections, DC/AC side grounding, and protection systems; connectivity and performance parameters were evaluated as part of the feasibility study.
- DC/AC grounding and protection control
- String/inverter field inspection
- Feasibility and performance evaluation
Outcome & Achievement: The investor received an independent technical assessment of the power plant in terms of safety and performance, as well as an improvement roadmap, and supported its investment decision with solid data.
Case 6 — Cathodic Protection (ICCP) Assessment in Pipeline/Tank Yard
Sector & Scope: An industrial facility with underground pipelines and storage tanks.
Need: It was unclear whether the cathodic protection (ICCP) system, which is critical for protection against corrosion, actually provided adequate protection.
AES Approach: Structure/electrolyte potentials were evaluated using reference electrode measurements; areas that did not meet the protection criteria (inadequately protected) were identified, and corrective recommendations were reported.
- Structure-soil potential (reference electrode) measurements
- Protection criteria suitability analysis
- Identifying and prioritizing unprotected areas.
Outcome & Achievement: The facility revealed the true performance of the cathodic protection system, prioritizing areas with a high risk of corrosion and developing an action plan to protect asset lifespan and safety.
Case 7 — Energy Audit and Efficiency in an Industrial Facility
Sector & Scope: An industrial production facility with high energy consumption.
Need: The facility aimed to reduce energy costs and prioritize efficiency opportunities in a data-driven manner.
AES Approach: Energy flow was determined through field measurements and consumption analyses; efficiency and savings opportunities were identified by evaluating power quality, load profile, and tariff structure, and prioritized according to payback periods.
- Energy measurement and consumption analysis
- Power quality and load profile assessment
- Tariff optimization and efficiency opportunities.
Outcome & Achievement: The company gained a concrete, prioritized list of improvements to reduce energy costs and an energy roadmap to support investment decisions.
Case 8 — ATEX/Ex-Proof Equipment Inspection at a Petrochemical/Gas Plant
Sector & Scope: A petrochemical/process plant containing an explosive atmosphere (gas/dust).
Need: The suitability of explosive atmosphere equipment, compliance with zone classification, and periodic Ex inspection requirements had to be ensured.
AES Approach: The zone classification was reviewed; the protection type, marking, and installation suitability of the Ex equipment were examined. The equipment underwent periodic Ex inspections according to the TS EN 60079 series, and any non-conformities were reported.
- TS EN 60079 series Ex inspection
- Zone 0/1/2 and 20/21/22 compliance check.
- Ex marking and protection type verification.
Outcome & Achievement: The facility has documented the suitability of explosive atmosphere equipment, identified risky points, and strengthened both legal compliance and explosion protection safety.
Case 9 — Technical Risk Audit (Due Diligence) for Insurance/Finance
Sector & Scope: Requesting an independent technical assessment prior to insuring/financing a facility.
Need: The insurance and finance parties wanted to see an objective, independent technical report on the electrical and fire safety risks of the facility.
AES Approach: The facility's electrical, grounding, and fire safety systems underwent a field inspection; risks were classified according to their severity, and a technical due diligence report was prepared regarding insurability.
- Electrical and fire safety field inspection
- Prioritization and classification of risks.
- Insurability / due diligence reporting
Outcome & Achievement: The insurance and finance parties received the independent and objective technical opinion they needed for the decision; the facility, in turn, obtained a concrete list of actions to mitigate the risks.
Case 10 — UPS and Uninterruptible Power Security in a Healthcare/Data Center
Sector & Scope: A healthcare facility/data center environment where uninterrupted operation is critical.
Need: The safety and continuity of the uninterruptible power supply (UPS) and distribution infrastructure supplying vital and critical loads had to be verified.
AES Approach: UPS systems, battery banks, bypass and distribution panels were inspected; grounding and protection coordination was evaluated, and single-point failure risks and maintenance deficiencies were reported.
- UPS and battery pack check
- Bypass and distribution panel security
- Grounding and protection coordination
Outcome & Achievement: The critical facility identified vulnerabilities threatening power continuity in advance and received a maintenance and improvement plan to reduce the risk of outages and data/service loss.
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