Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Gas and Vapor

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Classification of hazardous materials subject to shipping and storage regulations
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Thermal Stability

Safe storage or processing requires an understanding of the possible hazards associated with sensitivity to variations in temperature

Adiabatic Calorimetry
Data demonstrate the consequences of process upsets, such as failed equipment or improper procedures, and guide mitigation strategies including Emergency Relief System (ERS) design
Reaction Calorimetry
Data yield heat and gas removal requirements to control the desired process chemistry
Battery Safety

Testing to support safe design of batteries and electrical power backup facilities particularly to satisfy UL9540a ed.4

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Cable Testing
Evaluate electrical cables to demonstrate reliability and identify defects or degradation
Equipment Qualification (EQ)
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Water Hammer
Analysis and testing to identify and prevent unwanted hydraulic pressure transients in process piping
Acoustic Vibration
Identify and eliminate potential sources of unwanted vibration in piping and structural systems
Gas & Air Intrusion
Analysis and testing to identify and prevent intrusion of gas or air in piping systems
ISO/IEC 17025:2017

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

ISO 9001:2015
Fauske & Associates fulfills the requirements of ISO 9001:2015
Dust Hazards Analysis
Evaluate your process to identify combustible dust hazards and perform dust explosion testing
On-Site Risk Management
On-site safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up
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 safely handle the effluent discharge from an overpressure event

FATE™ & Facility Modeling

FATE (Facility Flow, Aerosol, Thermal, and Explosion) is a flexible, fast-running code developed and maintained by Fauske and Associates under an ASME NQA-1 compliant QA program.

Mechanical, Piping, and Electrical
Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid, flow, and electric power systems
Hydrogen Safety
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Thermal Hydraulics
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Nuclear Safety
Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant
Radioactive Waste
Safety analysis to underpin decomissioning process at facilities which have produced or used radioactive nuclear materials
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 Safety Tools of the Trade

Posted by Fauske & Associates on 08.13.14

By Chuck Kozlowski, Manager, Thermal Hazards Testing & Consulting, Fauske & Associates, LLC 

Just like different repairs around the house require different tools, process safety requires specific tools for specific applications. Engineering safety labs like ours work with our clients to determine the best and most cost effective way of meeting their process safety needs. Many of the jobs that we see involve vague chemistries with very few known physical properties. For these types of chemistries the VSP2TM or ARSSTTM teamed with one of the simplified analytical relief sizing methods (Fauske vapor/gas or Omega methods) is typically the preferred choice for obtaining a viable, cost effective relief system design.

However, in cases where well defined chemistries/physical properties are considered, simulation programs can be a very useful tool. Runaway reaction simulators are particularly useful for projects where a large number of vessels with similar chemistries/reactants are being studied. An example of one such application would be a runaway reaction assessment/inhibitor effectiveness and relief system design for a complete unit. Simulation tools such as RRERSP simulation program (developed by Harold Fisher, Chair of the AIChE, DIERS group and Principal Consultant to FAI) can provide the necessary information to size relief systems and produce a variety of time dependant data for each runway scenario including temperature, pressure, venting rate and venting composition. Simulation can be used to explore a variety of mitigation strategies when necessary, including lowering set pressure, installation of insulation of various types and thickness, water spray, or other means of overpressure protection. The RRERSP simulation program can also be used to calculate heat losses due to radiation during a cooling period after a fire or inadvertent heating scenario to confirm continued stability of the material. An example of a design case using the RRERSP simulation program for a fire exposure scenario is outlined below.

Vessel Volume

  880 Gallons


  3.5 barg


  5000 lb Styrene inhibited with 1800 TBC

Upset Scenario

  Fire exposure (2 hr duration)

Existing Relief Device

  3K4 Relief Valve Orifice area = 2.138 in2

Using the RRERSP simulation program, the fire exposure scenario was explored for the existing relief system and is shown in Figure 1. Simulation shows that the vessel exceeds the maximum allowable accumulated pressure (MAAP) for a reactive system of 1.1*MAWP. As a result, different mitigation strategies were considered and are summarized below:

  •  Lower set pressure to see if existing valve can be used with a 1 barg set  pressure (see Figure 2)
  •  Rupture disk (4 inch) to fit on vessel nozzle (see Figure 3)
  •  Insulate vessel with 1 inch of cellular foam glass insulation (see Figure 4)

Using this methodology, mitigation strategies can be easily explored for large numbers of vessels with similar chemistries. It was determined that for this specific application, simply lowering the set pressure to 1 barg would not suffice, however utilizing a 4 inch rupture disk would provide adequate protection for the vessel. It was also determined that a relief scenario could be avoided by applying at least 1 inch of fire resistant foam glass insulation.

pic 1

Figure 1                                    Simulation output for existing relief installation

 Pic 2

Figure 2                                    Simulation output for 3K4 SRV with 1 barg Set Pressure

Pic 3

 Figure 3                                    Simulation output for 4 inch Rupture Disk 3.5 barg Set Pressure

Pic 4 

Figure 4                                    Simulation for vessel with 1 inch foam glass insulation (does not vent)

Providing a comprehensive package of tools and design alternatives allows our customers to make better, more cost effective decisions when designing or verifying relief systems. To discuss a full list of our testing and simulation capabilities and which methodology is best for your application, please contact Mr. Chuck Kozlowski at (630) 887-5216 or,


Topics: Process Safety, Process Hazards Analysis, Reactive Chemicals


Is My Dust Combustible?

A Flowchart To Help You Decide
Download Now