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


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With over 40 years of industry expertise, we have a wealth of process safety knowledge to share.

Recent Posts

The Potential Hazards of Hydrogen

Posted by Fauske & Associates on 02.13.24

Growing interest in hydrogen builds on the recognition that clean hydrogen can play a crucial role in global decarbonization. Currently 40% of all carbon dioxide emissions come from power plants burning fossil fuels to generate energy. Other relatively high pollution sectors include transportation and industrial factories. Consumption of hydrogen for energy produces only water, and hydrogen has a high energy density by mass, which makes it an interesting low carbon alternative. The demand for hydrogen has increased threefold since 1975 and is expected to continue this trajectory, with the demand for clean hydrogen anticipated to be a crucial component of Net Zero Emissions by 2050 Scenario (NZE) and with a potential demand of 150 to 500 million metric tonnes of hydrogen a year. To try and meet this demand, there is a global push for financial investment in clean hydrogen at scale in both commercial and industrial applications.


Where Does Hydrogen Come From?

Not all hydrogen is considered “clean” as its production can sometimes be carbon intensive.  Thus, while hydrogen is a colorless gas, it is typically described by color to represent its source. Green hydrogen is of particular interest to combat global warming, because it is produced in a “climate-neutral manner.” Table 1 provides a comparison of the commonly discussed hydrogen production methods.

The different types of hydrogen


Hydrogen Properties & Potential Hazards

Hydrogen has many properties that make it attractive as a source of energy, and many of which are inherently safe features, however there are potential hazards associated with any fuel source. Here are some of hydrogen’s properties, and how they might relate to potential hazards that must be considered depending on the application:

  • Hydrogen is a colorless, odorless, and tasteless non-toxic gas typically in the form of a diatomic molecule (H2). While rare, hydrogen is a potential asphyxiation hazard in confined spaces. In addition to the gaseous form, hydrogen flames are also nearly colorless, and the low radiant heat and low emissivity of the flame can make early identification difficult.

  • Hydrogen is non-corrosive; however, it can cause embrittlement leading to unexpected mechanical failures or leaks. Properly selected materials and system layout, periodic visual checks, adequate passive or active ventilation systems, and safety systems (e.g., leak or hydrogen detection sensors) are important aspects of a safe design.

  • Hydrogen has excellent energy density; however, its vapor density is very low (around 1/15th of air). This is great for the buoyant dissipation of a vapor cloud following a leak but can make it difficult to store large quantities of hydrogen. High pressure vessels can be used to store gaseous hydrogen; alternatively, hydrogen can be compressed, and stored under cryogenic conditions. Both options should be evaluated for potential overpressure hazards and unignited releases (e.g., loss of temperature control in cryogenic storage or fire exposure in gaseous storage, both of which can lead to rapid pressurization and a loss of containment).
    Expansion of Initially Choked Jet and Entrainment after Depressurization

  • Hydrogen has a very large flammable range (typically considered 4% to 75% by volume in air) and a very high burning velocity when compared to other typical fuel types. This increases the likelihood and potential consequences of combustion (via fire or explosion). Despite hydrogen's propensity to diffuse quickly in air, high-pressure leaks can lead to unconfined jet fires or explosions, and the low minimum ignition energy of hydrogen makes it difficult to eliminate all potential ignition sources. Confined vapor cloud explosions (i.e., deflagrations or deflagrations that undergo transition to detonations, or DDT) are a hazard that must be considered and that can have potentially severe consequences. Proper siting and barriers can help to protect against this hazard and reduce the risk of a catastrophic event.


Hydrogen Safety

Developing a safe process to harvest or utilize hydrogen is much like developing any other safe process involving chemical hazards:

1. Identify Potential Hazards (via HAZOP, FMEA, or other tools)

2. Evaluate the Hazard Risk Level in Terms of Likelihood and Severity

3. Identify Preventative, Mitigative, or Elimination Techniques

4. Document the Findings, Employ the Techniques, and Train Personnel

5. Ensure Safety Systems and Facility Meet Relevant Regulations, Codes, and Standards

6. Periodically Review System and Monitor for Changes, and Repeat Process if Change Occurs




Topics: Flammability


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