Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Gas and Vapor

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Classification of hazardous materials subject to shipping and storage regulations
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Thermal Stability

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

Adiabatic Calorimetry
Data demonstrate the consequences of process upsets, such as failed equipment or improper procedures, and guide mitigation strategies including Emergency Relief System (ERS) design
Reaction Calorimetry
Data yield heat and gas removal requirements to control the desired process chemistry
Battery Safety

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

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Cable Testing
Evaluate electrical cables to demonstrate reliability and identify defects or degradation
Equipment Qualification (EQ)
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Water Hammer
Analysis and testing to identify and prevent unwanted hydraulic pressure transients in process piping
Acoustic Vibration
Identify and eliminate potential sources of unwanted vibration in piping and structural systems
Gas & Air Intrusion
Analysis and testing to identify and prevent intrusion of gas or air in piping systems
ISO/IEC 17025:2017

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

ISO 9001:2015
Fauske & Associates fulfills the requirements of ISO 9001:2015
Dust Hazards Analysis
Evaluate your process to identify combustible dust hazards and perform dust explosion testing
On-Site Risk Management
On-site safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up
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 safely handle the effluent discharge from an overpressure event

FATE™ & Facility Modeling

FATE (Facility Flow, Aerosol, Thermal, and Explosion) is a flexible, fast-running code developed and maintained by Fauske and Associates under an ASME NQA-1 compliant QA program.

Mechanical, Piping, and Electrical
Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid, flow, and electric power systems
Hydrogen Safety
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Thermal Hydraulics
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Nuclear Safety
Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant
Radioactive Waste
Safety analysis to underpin decomissioning process at facilities which have produced or used radioactive nuclear materials
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 Fauske & Associates 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, or 630-323-8750,


 #nuclear safety #component analysis

Topics: Nuclear


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