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

NFPA 652 And What It Means For You – Clearing The FUD Around DHAs

Posted by The Fauske Team on 08.09.16

By: Mark Yukich, S&B Development, Fauske & Associates, LLC (FAI)

By now, most of us have heard that NFPA 652 has been released, so what does that mean? The highlights are that you will be required to evaluate combustible dust hazards that may exist at your facilities by conducting a Dust Hazard Analysis or DHA within 3 years ofCombustible_Dust_1.jpg NFPA 652’s release date of October 2015. That means that NFPA 652 asks operators of facilities to identify combustion hazards involving dusts and powders and then implement needed protective measures and safeguards by October 2018. Please note that dusts, powders, flock, flyings and fibers are categorized into one general group as “dust.” According to Susan Bershad, the NFPA staff liaison for the combustible dust technical committee, there are the following 3 fundamental principles in the standard: containing the fuel, controlling the ignition sources and limiting the spread of any combustion event. Those elements can be found by conducting a DHA, which will need to be revalidated at least every 5 years.

In NFPA 652, the term “Dust Hazard Analysis” or DHA is introduced. This is designed to differentiate from the more complex Process Hazard Analysis or PHA required by the OSHA Process Safety Management (PSM) program for the chemical process industry. Many print and electronic publications are spreading Fear, Uncertainty and Doubt (FUD) by mixing up the requirements for an OSHA PSM PHA with the less arduous DHA approach mentioned in NFPA 652. Industrial and academic experts in the area of combustible dust, fire and explosion safety guided the formation of 652. Its purpose is to give personnel a single source for information on the fundamentals of safe handling combustible dust and powders in and industrial setting. The standard also directs users to commodity specific standards such as the following which offer material and production specific guidance:

• NFPA 61 – Prevention of Fires and Dust Explosions in Agricultural and Food Processing Facilities
• NFPA 484 – Standard Combustible Metals
• NFPA 654 – Prevention of Fire and Dust Explosions from the Manufacturing, Processing and Handling of Combustible Particulate Solids
• NFPA 664 – Wood Processing and Woodworking Facilities

The reason for an implementation deadline for the DHA is to encourage that proactive actions are taken in completing the assessment. According to Guy Colonna, NFPA division manager of industrial and chemical engineering, “The concern is if there’s no timetable, it would never get done.” Colonna went on to say, “The committee is not proposing a shutdown and redesign of every industrial facility where solids are handling and dust could be present. They’re starting with saying: ‘Do the DHA. See what it tells you.’”

Chemical Safety Board (CSB) Chairman, Vanessa Sutherland said, “Their internal practices are focused on minimizing the amount of accumulated dust, making sure it’s less of a hazard, and also workers are kept up to date on new practices and consensus standards through NFPA.” According to Sutherland, employers can take three actions to protect against explosible dust hazards:

• Review CSB Materials, including a safety video and investigation reports
• Review and adopt NFPA standards
• Pay greater attention to worker training and facility housekeeping

OSHA offers other combustible dust and ignition source control recommendations, as well as guidance on injury and damage control methods. The following are some key recommendations, presented in no particular order:

  • Enforce a program that includes dust inspections, testing, housekeeping and control
  • Use appropriate dust collection systems and filters
  • Limit escape of dust from equipment or ventilation systems
  • Use surfaces that limit dust accumulation and ease cleaning
  • Regularly check for dust residue in all areas, including hidden locations
  • Clean without creating dust clouds around ignition sources
  • Operate vacuum cleaners certified for dust collection
  • Use appropriate electrical equipment
  • Keep heated surfaces and systems away from dust
  • Create an emergency plan

The recently published OSHA fact sheet is provided here your reference:OSHA_Page_1.jpg



For more information, please contact Mark Yukich at yuckich@fauske.com, 630-887-5788

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