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

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

How Does Human Behavior Affect Process Hazards Analyses?

Posted by The Fauske Team on 01.11.18

By AnnMarie Fauske, Fauske & Associates, LLC

Chemical Processing's December 2017 issue included a salient piece "Make Hazard Analyses Better" by GC Shah. When discussing Process Hazards Analyses (PHA) with customers, we often refer to the pure PROCESS. The human factor is a huge though often assumed component of this, however.

Process_Hazard_Analysis.jpgA PHA is a systematic evaluation of the hazards involved in the process. PHAs are required for initiation of a process and at least once every five years after that. It is important to address normal operating conditions as well as start-up, normal shut down and emergency shutdown procedures during the PHA. The PHA team should be multi-disciplinary, including operations, engineering and maintenance.

To properly conduct a PHA, the process safety information (PSI) must be as complete as possible. Performed for compliance to OSHA PSM requirements as well as National Fire Protection Association (NFPA), PHA's can use a variety of techniques including, hazard and operability (HAZOP) analysis, what-if, checklists, failure modes and effects analysis (FMEA), combustible or hazardous dust as well as quantitative risk assessments such as layer of protection analysis (LOPA).

But, what about the people?

Combustible Dust Hazard 20L Chamber Go No-Go Test, Explosion Severity Test, LOC, MEC, Pmax, MIE Tests...-1.jpgAccording to Shah:

"Human error is a culprit in many industrial incidents, including some catastrophic events."

Some safety experts suggest that human errors contribute to 60% to 70% or more of these incidents. However, some process hazard analyses (PHAs) pay scant attention to human factors — i.e., how workers interact with various aspects of running and managing operations. Equally troubling, human factors get barely any consideration during the design stage."

Per Shah, while some companies arrange multiple sessions during design and PHAs to discuss human factors, many other companies do not. "Although the U.S. Occupational Safety and Health Administration’s process safety management regulation requires human factors as a part of risk analysis (29 CFR 1910.119 (e) (3) (vi)), it lacks specificity. As a result, some companies regard human factors in a very narrow sense, states Shah. In addition, many operating companies have laid off or otherwise lost experienced workers at plants. This robs new or relatively inexperienced operators of mentors. In addition, many plants have curtailed or eliminated training departments. Operating instructions aren’t always written clearly. Thus, human errors can occur because of poor instructions or poor understanding by operators or both. Increasing language and cultural barriers also contribute to human errors.

Shah further states: "Safety managers and plant managers have the formidable task of ensuring that all operators and contractors have a clear unambiguous understanding of procedures. Many plants rely on legacy control systems that didn’t consider human factors adequately. As a result, the human/machine interface (HMI) displays aren’t easy to grasp quickly. In the event of an emergency, the legacy systems could delay effective response by an operator. (New control and information systems do consider human factors in design, e.g., for the HMI.)"

After outlining 8 key factors to reviewing human risk factors in PHA management programs, the article reminds us that  "operator/equipment interactions; operator interactions with instruments/controls and networks; contractor interactions; and tasks" must be vital part of review. It also notes specific factors that can impact safety in the event of an error. "The bottom-line during design is to match systems with average human capabilities."

Regional, cultural, experience, ability to be part of review and training are key aspects of conquering human error factors in process hazards.  It has to be ingrained in the organization's culture from the top down. Pervasive. Persuasive. Natural.

For more information or discussion on PHA's or other risk assesments to your processes, please contact Kris Fauske at kfauske@fauske.com, 630-251-8647, www.fauske.com

FAI Process Safety Newsletter

Topics: process safety, plant safety, PHA, process hazard


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