Combustible Dust Testing

Laboratory testing to quantify dust explosion & reactivity hazards

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Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Chemical Reactivity Testing

Laboratory testing to quantify reactive chemical hazards, including the possibility of material incompatibility, instability, and runaway chemical reactions

DIERS Methodology

Design emergency pressure relief systems to mitigate the consequences of unwanted chemical reactivity and account for two-phase flow using the right tools and methods

Deflagrations (Dust/Vapor/Gas)

Properly size pressure relief vents to protect your processes from dust, vapor, and gas explosions

Effluent Handling

Pressure relief sizing is just the first step and it is critical to safety handle the effluent discharge from an overpressure event

Thermal Stability

Safe storage or processing requires an understanding of the possible hazards associated with sensitivity to variations in temperature

UN-DOT

Classification of hazardous materials subject to shipping and storage regulations

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Biological

Model transport of airborne virus aerosols to guide safe operations and ventilation upgrades

Radioactive

Model transport of contamination for source term and leak path factor analysis

Fire Analysis

Model transport of heat and smoke for fire analysis

Flammable or Toxic Gas

transport of flammable or toxic gas during a process upset

OSS consulting, adiabatic & reaction calorimetry and consulting

Onsite safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up

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Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid flow, electric power systems

Battery Safety

Testing to support safe design of batteries and electrical power backup facilities particularly to satisfy UL9540a ed.4

Hydrogen Safety

Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen

Spent Fuel

Safety analysis for packaging, transport, and storage of spent nuclear fuel

Decommissioning, Decontamination and Remediation (DD&R)

Safety analysis to underpin decommissioning process at facilities which have produced or used radioactive nuclear materials

Laboratory Testing & Software Capabilities

Bespoke testing and modeling services to validate analysis of DD&R processes

Nuclear Overview

Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant.

Severe Accident Analysis and Risk Assessment

Expert analysis of possible risk and consequences from nuclear plant accidents

Thermal Hydraulics

Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions

Environmental Qualification (EQ) and Equipment Survivability (ES)

Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions

Laboratory Testing & Software Capabilities

Testing and modeling services to support resolution of emergent safety issues at a power plant

Adiabatic safety calorimeters (ARSST and VSP2)

Low thermal inertial adiabatic calorimeters specially designed to provide directly scalable data that are critical to safe process design

Other Lab Equipment (DSC/ARC supplies, CPA, C80, Super Stirrer)

Products and equipment for the process safety or process development laboratory

FERST

Software for emergency relief system design to ensure safe processing of reactive chemicals, including consideration of two-phase flow and runaway chemical reactions

FATE

Facility modeling software mechanistically tracks transport of heat, gasses, vapors, and aerosols for safety analysis of multi-room facilities

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Recent Posts

Chemical Process Safety Testing - Key to Best Practice PLM?

Posted by The Fauske Team on 01.29.15

 

At the risk of showing my age, I have to admit the Pointer Sisters' 80's hit "Automatic" is going through my chemical-reaction-beaker-1head as I ponder the idea of Product Life Cycle Management (PLM) and its growing use in the chemical process or chemical manufacturing industries.  Are we relying so much on automated systems that, well,

"No way to control it, I'm totally automatic, whenever you're around.  I'm walking blindfolded, completely automatic, all of my systems are down, down, down, down. Autoooomatic, autooooomatic, autoooomatic, autoooomatic..." ? 

Now, that I've got you groovin' (and you know you are), let's discuss.  

Generically defined by Wikipedia: "The core of product life cycle management is in the creations and central management of all product data and the technology used to access this information and knowledge. PLM as a discipline emerged from tools such as CAD, CAM and PDM, but can be viewed as the integration of these tools with methods, people and the processes through all stages of a product's life.

Per CIMdata: "Product life cycle management is a strategic business approach that applies a consistent set of business solutions in support of the collaborative creation, management, dissemination, and use of product definition information across the extended enterprise, and spanning from product concept to end of life-integrating people, processes, business systems, and information. It forms the product information backbone for a company and its extended enterprise." 

In this month's issue of Processing magazine, is an insightful article by Tony Christian, director of Combashi, "How PLM is Relevant to Process Industries". In it, Christian outlines, "Product life cycle management is today a $3 billion market served by some of the most successful software companies on the planet.  Indeed, the market is larger if services and support eco-system is included.  However, adoption of PLM in the chemicals industries has been tentative - and perhaps with good reason."

Most definitions point to comprehensive software that collects, sorts and relays data. 

Simply said, from where Fauske & Associates, LLC (FAI) sits, how can a computer software adapt to and remain vigilant in the delicate arena of safely mixing chemicals together?  

Sure, there are "recipes".  There are approved lists of certain compounds from list A that can be mixed with list B.  But, what about under condition X? And, in which environment?  How to transport or store, once mixed, if even possible?  Without adiabatic and reactive chemical system testing, how do you truly know your safety risks?  

Meeting ever changing regulatory requirements is another plus and minus with product life cycle management capabilities. While broad stroke information can be automated and supplied to meet standards by organizations such as ASTM, OSHA, REACH  (Registration, Evaluation, Authorization and Registration of Chemicals), letting these requirements be the driving force may devalue the integrity of your unique safety program needs. 

As Christian aptly points out, evolving cloud-based capabilities make a PLM an increasingly great tool, but nothing can replace the actual process safety lab for testing scenarios unique to your systems.  "Automatic" was/is a great song though intended to describe one's unconditioned romantic response to another.  Let's hope it has no application in our workings with chemical safety.  Thoughts?

For more information on adiabatic tests, adiabatic calorimetry, reactive hazards and other chemical reaction system testing, dust combustibility, gas and vapor flammability, relief vent sizing and numerous other chemical process engineering and lab safety testing, please contact Jeff Griffin at griffin@fauske.com, 630-887-5278

Managing Chemical Reactivity - Minimum Best Practice

 

 

 

 

Topics: process safety, process hazards analysis, relief venting, process hazards, chemical engineering safety, nuclear engineering, severe accident, relief sizing, nuclear safety, chemical engineering, chemical process, chemical process safety

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