Hazards Analysis, Code Compliance & Procedure Development

Services to identify process safety hazards and facilitate compliance with established standards and codes.

Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Flammable Gas & Vapor Testing

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

ISO Accreditation and Scope
Fauske & Associates fulfills the requirements of ISO/IEC 17025:2017 in the field of Testing
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


Classification of hazardous materials subject to shipping and storage regulations

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents


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


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

Mechanical, Piping, and Electrical

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 and Parts for the DSC/ARC/ARSST/VSP2 Calorimeters

Products and equipment for the process safety or process development laboratory


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


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


Our highly experienced team keeps you up-to-date on the latest process safety developments.

Process Safety Newsletter

Stay informed with our quarterly Process Safety Newsletters sharing topical articles and practical advice.


With over 40 years of industry expertise, we have a wealth of process safety knowledge to share.

Recent Posts

Component Analysis Case Study: Auxiliary Relay Refurbishment

Posted by The Fauske Team on 09.19.17

By Bill Berger, Sr. Vice President, Fauske & Associates, LLC


Component Testing at FAIPerformance issues began to arise for an ABB auxiliary relay used in several non-safety related control schemes. As is typical in the industry, the component is no longer manufactured raising an issue of obsolescence. Other relays are available which would serve as an adequate replacement, but refurbishment is preferred since the characteristics and foot print match the application and minimize replacement work.


The issue with the relay was sticking on pick-up. The first step was to take temperature measurements at a variety of locations within the relay to determine if there were any signs of a localized heating effect. A check was also made of the DC coil resistance and pick up voltage. This was followed by a systematic disassembly and a check of the air gap dimension. Contacts were evaluated for pitting or other signs of degradation. As the coil ages, the magnet wire insulation becomes more glassy and shorting between turns begins. This essentially leads to a reduction in the number of turns, therefore effecting coil operation. Often this process begins toward the middle to start of the coil winding, since this area has a greater strain on the turn. The key checks were air gap dimension, coil integrity, contact status and signs of heating.


The coil was unwound and the turns counted. The magnet wire gauge and insulation class were determined and the coil rewound. The contacts were cleaned and resurfaced. The DC resistance and the pickup voltage were measured and found to be within specification. Finally, the coil temperature rise was measured by resistance. The DC coil resistance, pickup voltage and temperature rise were all indicators that the refurbishment was successful in establishing like for like relay meeting form, fit and function.

Case Study-Coil Heat Rise at FAI

Please join us with questions or discussion.  For more information on component, obsolescence, cable and other nuclear and industrial plant safety testing, please contact us at info@fauske.com, or 630-323-8750, www.fauske.com


 #nuclear safety #component analysis

Topics: nuclear safety, plant safety, obsolescence, nuclear plant safety, nuclear, auxiliary relay


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