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

The Process Safety Benefit of a Robust Thermal Hazards/Stability Tool

Posted by The Fauske Team on 02.24.15

By Sara Peters, Fauske & Associates, LLC (FAI)

Often, material safety data sheets refer to the thermal stability of a chemical or its stability at higher TAM2_phototemperatures, as an intrinsic property of the chemical or mixture.  In fact, this is an oversimplification of a concept that must be defined in a more comprehensive way. 

Understanding the thermal stability of a chemical or mixture is critical to ensuring its safe handling in any setting. The more stable a material is at higher temperatures, the more resistant it is to breaking down or decomposing . This understanding is accomplished through thermal stability testing aimed at collecting reaction rate data and applying that data to assess whether a specified quantity of material can be used in a way such that runaway reactions are avoided.  This is important when considering processing, long-term storage, or shipping of a material.

Unique testing and consulting requests make it advantageous for a reliable testing organization to have a variety of instruments and tools available to characterize the thermal stability of a material. For example, if the purpose is to characterize reactive chemical systems and consequences that could occur due to process upset conditions, then use of a low thermal inertia adiabatic calorimeters: the Vent Sizing Package 2 (VSP2TM) and the Advanced Reactive Systems Screening Tool (ARSSTTM)  might be most appropriate. However, if the goal is to help quantify the heat released during intended chemical reactions– preparing for the expected, then you may look to reaction calorimetry instruments such as the Mettler-Toledo RC1, ChemiSens CPA 202, or  THT μRC. Or, if the desired outcome is to formulate an accurate determination of safety parameters and plan for mitigating a potential reaction, then you may look to an instrument such as the VSP2TM, ARSSTTM, Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA), Thermal Activity Monitor (TAM)  or Accelerating Rate Calorimetry (ARC). 

All of these instruments are or should be part of a well equipped thermal hazards laboratory, to ensure that each customer’s unique system and problem is properly addressed with the correct tools. At Fauske & Associates, LLC (FAI), we have all of these instruments in our thermal hazards lab but recently saw a need to enhance our toolkit even further  with the addition of the C80 Calorimeter manufactured by Setaram.

Some of the key benefits the C80 offers include:

  • The C80 is a reaction, thermal and scanning calorimeter that operates like a larger version of a DSC which accommodates a larger sample size and bigger test cells  -  10 ml test cells, as opposed to 20-50 µl test cells. This is especially advantageous when dealing with heterogeneous or multi-component samples that come in and are not uniformly mixed and cannot be uniformly mixed (think different colored M&Ms) as the larger size allows a more representative sample to be tested. 
  • It has a wide range of vessels that can be used with it which makes it flexible
  • A lot of the other instruments primarily use metal cells, but the C80 can use glass-lined cells which is beneficial when dealing with peroxides or other chemicals that are highly sensitive/reactive to metals
  • The C80 offers a unique level of sensitivity to thermal events and also the ability to design cells and vessels to simulate almost any potential condition
  • Temperature ramp measures heat flow as a function of time and temperature 
  • Temperature range is from ambient to 300mC


As you can see, the C80 is a fantastic addition to our toolkit here at FAI as it nicely complements other instruments in our lab and enhances the ability of our engineers to offer practical and customized solutions to unique process safety issues dealing with thermal hazards and thermal stability. When you are considering a provider for your own process safety needs in this area make sure that they too have a robust toolkit with which to effectively address your concerns.

For more information regarding our thermal hazards, adiabatic calorimetry/relief system design or reactive calorimetry testing services at FAI, contact Gabe Wood, wood@fauske.com, at 630-887-5270.


The Versatile VSP2 – Still Cooking After 26 Years



Topics: process hazards, thermal stability, reaction calorimetry, adiabatic calorimetry


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