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


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

Process Hazards Analysis (PHA) Process Safety Management (PSM) Tackled

Posted by The Fauske Team on 03.18.15

Most companies adapt and grow over time, adjusting to the market and needs of customers.  process-safetyNothing new. Some companies, however, get to experience the thrill of growing by partnerships and collaborations which allow like-minded, science soul mates to greater serve customers. That's magic.  Anticipating customer need and knowing where to absorb knowledge and talent to better serve them makes everyone grow.  

That said, serving folks in the elusive world of Process Safety Management (PSM) and ALL of its 14 elements can be a challenging endeavor for even the most comprehensive engineering and testing labs.  In its continuous effort to accommodate customer requests, Fauske & Associates, LLC (FAI) partners with Industrial Psychologists, Inc. (IPi).  In a nutshell, IPi's forte is their methodology of material reviews, work process analyses and involvement in customer’s personnel at all levels to facilitate the culture changes needed to enhance an organization’s effectiveness and compliance with various regulations such as those associated with PSM.  IPi provides services in all of PSM’s elements. One example of IPi’s services is conducting in-depth job and task analysis to identify the tasks that classify job positions within an organization.  Job analyses information is then used as the following activities are performed:

1.     Creation of or upgrades to job descriptions

2.     Evaluating job environments through job safety analyses

3.     Identification of the procedures needed to safely and efficiently perform job tasks

4.     Design of training programs that are job-related, valid and reliable

5.     Knowledge and performance evaluation instruments that are legally defensible and objectively fair

IPi consultants review customer programs, upgrade elements where needed and facilitate the culture change required for consistent implementation They do this by providing organizational development, effective communication and program development support.  IPi also provides a wide selection of workshops ranging from professional and leadership training for supervisors to Train-The-Trainer and documentation development for facility trainers.

According to IPi CEO V. Earl Brown, Jr., "We perform program audits such as gap analyses, training and procedure audits and support all elements of an effective safety program.  Since effective communication is so critical, many of our activities improve policies, procedures and training.  IPi employs the Instructional System Design (ISD) Methodology for our training and procedure activities.  This time proven approach ensures that training activities are relevant and valid."  

This, together with FAI's state of the art engineering and testing lab facilities allows us to go beyond auditing programs and identify deficiencies.  We help customers mitigate deficiencies that are identified.  For example, if the gap analysis identifies a deficiency in a facility's operating procedures, we can assign a team of consultants and technical specialists to upgrade procedures. 


Both FAI and IPi assist customers worldwide.  Like FAI, IPi serves the broad spectrum of industries with experience including crude oil and gas exploration and production (both on and off shore), oil and natural gas pipelines, chemical/ petrochemical, refining, computer chip, pulp and paper, pharmaceutical, health care (both medical equipment manufacturing and actual hospital services), airline, general manufacturing, food and beverage, brewery/distillery, and fossil, hydro, and nuclear power generation.                      

V. Earl Brown, Jr., CEO, IPi

FAI reviews and IPi develops process safety programs to support manufacturing facilities or development programs.  This can be performed for facilities including a kilo lab, pilot plant, medium scale and commercial scale plants.  Services include:

    • Auditing, reporting and presenting
    • Gap assessment to identify and prioritize needs
    • Process validation
    • Safe scale-up guidance
    • Development report documentation
    • Consulting on process safety issues for change control management of change (MOC)

IPi adds expertise in the important labor component of comprehensive PSM and PHA programs - bringing it all together.  We are ready to support you with any PSM need. afauske@fauske.com, 630-887-5213

Process Safety Management (PSM) Overview

Subscribe to FAI's Quarterly "Process Safety News"

Topics: process safety management, process hazards


Is My Dust Combustible?

A Flowchart To Help You Decide
Download Now