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

Paper vs. Practice, How's Your Hot Work Combustible Dust Safety?

Posted by The Fauske Team on 10.22.14

By Tim Cullina, Senior Consulting Engineer, Fauske & Associates, LLC

I recently visited a facility that had a nicely written hot work program.  They had a fewGrinding Image (3) completed permits, and even had training and auditing records.   They had nice paper.   A couple of hours later out in the plant, I observed a worker preparing to weld a crack.  Lots of combustible dust (starch) was on the equipment, the floor and even near the crack.  I expected to see the clean-up starting any minute.  Instead, he prepared to weld...

How good was their Hot Work program? Not Very! How good is yours?

The danger of working with fire near flammable or combustible materials seems obvious. Fire doesn't play nice with materials that can easily ignite.  Why then, do we continue to hear about fires or explosions ignited by hot work? 

By the way, does your hot work program address combustible dust?

Year after year, hot work is a leading cause of industrial fires and has been responsible for many injuries, fatalities, and significant loss of property.  We readily think of hot work as welding or oxy-acetylene torch cutting, but it's a whole lot more.  Hot work is any work with the potential to produce enough heat to ignite a fire or explosion.  Did you know that hot work includes high speed metal grinding and cutting?  Hot work also includes any task with an open flame such as open-flame soldering, open-flame torch heating, burning, and brazing.

Between 1990 and 2010, the U.S. Chemical Safety and Hazard Investigation Board (CSB) identified over 60 fatalities resulting from “hot work.” These specifically related to welding, cutting, and other activities using high heat around confined spaces.

By the way again, does your confined space program address combustible dust?

Even when workers know that there are flammable materials in the area, they can be unaware where these materials may accumulate to reach dangerous levels – levels that might lead to a flash fire or an explosion. 

If you have combustible dust, does your hazard communication program identify the physical hazard of your combustible dust?

Hot work accidents are preventable.  This incident became a near miss as we stopped the welding operation before things got "hot". 

There is a lot unsaid here. I hope that the same cannot be said about your training and execution of tasks involving hot work, confined spaces, and flammable materials, including combustible dusts.

For more information regarding combustible dust, flammable hazards, process safety management (PSM), risk management safety (RMS), OSHA and NEP compliance or related testing, programs and services, please contact us (or, someone you trust).  dust@fauske.com, 630-323-8750. www.fauske.com



Topics: Combustible Dust, process safety management, process safety, flammable substance, process hazards, hazards analysis, Probabilistic Safety Assessment


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