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

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


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

Recent Posts


Posted by Elizabeth Raines on 05.04.21

With a combined 75 years of being leaders in process simulation and process safety, FAI and Chemstations release a brand new software to revolutionize relief system design.

March 29, 2021, Burr Ridge, IL – FAI, world leaders in chemical, nuclear, and industrial process safety, and Chemstations, expert first principle process simulation software developers and creators of CHEMCAD, announced today the collaborative release of FERST, a new easy-to-use software to set the new standard for safety and relief system calculations. FERST combines the seamless user experience and robust simulation capabilities developed for CHEMCAD with the relief system design expertise and experience gained from FAI’s 40+ years with leadership positions in DIERS (Design Institute of Emergency Relief System) to create a premier emergency relief sizing software. FERST contains extensive built-in material property options and a rigorous thermodynamic package as well as incorporates the latest methodology and applicable standards.

“After extensive research, development, and testing, we are extremely excited to reveal FERST,” says FAI President Zach Hachmeister. “We know that this new tool will be a great addition for our VSP2TM and ARSSTTM users to help them efficiently ensure the safe scale-up of their processes.” FAI has 40 years of experience globally serving the chemical industry to help identify, evaluate, and provide guidance to mitigate hazards to develop and maintain safe processes. FERST encapsulated this experience into a single tool that brings this knowledge to user’s fingertips.

The foundation of FERST is the knowledge and equations for relief calculations that FAI has developed and utilized across four decades. These capabilities are combined with the software design and delivery expertise collected by Chemstations throughout 30+ years deploying CHEMCAD to engineers. CHEMCAD is an integrated suite of intuitive chemical process simulating software that fits into the chemical engineering workflow and amplifies an engineer’s efficiency to save time and money. FERST incorporates the positive CHEMCAD user-experience to provide a tool to evaluate relief systems that is unparalleled to other tools on the market.

“Chemstations is excited to work with FAI on FERST, as the product promises to be uniquely powerful in the safety and hazard mitigation space. Never before has the storied experience of a company like FAI been combined with the rigorous, first-principles based simulation software like CHEMCAD, and we are proud of our contribution to the product and the industry,” says Steve Brown, President of Chemstations.

Together FAI and Chemstations are releasing FERST, software that combines both companies’ expertise to bring powerful calculation, ease of use, and a wealth of domain expertise to users’ fingertips.

FAI is a world leader in nuclear, industrial, and chemical process safety. Founded in 1980 by Dr. Hans Fauske, Dr. Michael Grolmes, and Dr. Robert Henry, FAI became a wholly owned subsidiary of Westinghouse Electric Company, LLC, in 1986. FAI assumed early leadership in the acclaimed DIERS program for AIChE and the IDCOR program for the nuclear power industry. These efforts led to the development of state-of-the-art methodologies and laboratory tools for characterizing reactive chemical systems and computer models for analyzing severe accidents in commercial nuclear power plants. FAI is recognized worldwide for phenomenological modeling and testing services related to the prevention and mitigation of chemical and nuclear power accidents. FAI offers a wide range of process safety and thermal hazards analyses, laboratory testing services, advanced training, and offers onsite safety assessments. Visit www.fauske.com, or call 877-FAUSKE1 (877-328-7531) for more information.

Chemstations, Inc. is a worldwide leader in process simulation software, supplying the process industries and associated fields. Chemstations offers the CHEMCAD suite, several individually licensed and tightly integrated technologies, to increase the productivity and profitability of the chemical engineer's tasks. CHEMCAD is actively used by more than 800 organizations around the world. For more information, see our web site, www.chemstations.com, or call 800‑CHEMCAD (243-6223).

Name of Press Contact: Elizabeth Raines
Phone: 312-914-9562
Email: ERaines@fauske.com

Topics: FATE


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