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

What's Missing in Your Process Safety Toolkit?

Posted by The Fauske Team on 11.17.15

By Amy Theis, Director of Risk Management Services and AnnMarie Fauske, Customer Outreach and Digital Media Manager, Fauske & Associates, LLC (FAI)

Process safety focuses on preventing fires, explosions and accidental chemical releases in chemical process facilities or other facilities dealing with hazardous materials such as refineries, and oil and gas facilities. Traditionally, process safety has been implemented through OSHA's Process Safety Management (PSM) of potentially hazardous chemicals. The purpose of PSM is to prevent or minimize catastrophic loss of primary containment events such as the release toxic, reactive, flammable, or explosive chemicals that could result in The ChemiSens* is a heat flux calorimeter that provides a true heat flow signal without requiring any calibration.toxic exposure, fire or explosion hazards. An effective PSM program requires a systematic approach to evaluating the chemical process. Using this approach, the process design, process technology, process changes, operational and maintenance activities and procedures, non-routine activities and procedures, emergency preparedness plans and procedures, training programs and other elements that affect the process are all considered in the evaluation.

The key component to implementing an effective PSM program is appropriate hazard identification which utilizes the process safety information (PSI) piece of PSM. The process should be reviewed to identify hazards associated with the following:

  • Chemicals
  • Technology The RC1 is a heat flow calorimeter.
  • Equipment

Chemicals should be evaluated to identify: 

Toxicity information –

  • Permissible exposure limits
  • Physical data
  • Flammability data
  • Reactivity data
  • Corrosivity data
  • Thermal and Chemical Stability data
  • Chemical Incompatibility data for Inadvertent Mixing
  • Material Safety Data Sheets (MSDS’s)
  • Process Chemistry information
  • Runaway Reaction characterization
  • If applicable, Material Incompatibilites, unwanted reactions and potential decomposition reactions

Process technology should be evaluated to identify:

  • Block flow diagram or simplified process flow diagram
  • Process chemistry for desired reaction
  • Maximum intended inventories
  • Safe upper and lower limits for operating parameters
  • Qualitative evaluation of the consequences of deviations

Process equipment should be evaluated to identify:

  • Piping & Instrumentation Diagrams (P&IDs)
  • Design Codes & Standards Materials of Construction Data from RSST/ARSST can be used directly to assess prevention (safe storage and transportation of self-reactive substances and organic peroxides) and accommodation (runaway reactions in terms of adequate pressure protection) of uncontrolled chemical activity
  • Electrical Classification
  • Relief System Design & Design Basis Ventilation System Design
  • Material & Energy balances for processes built after 5/26/92
  • Safety Systems (interlocks, detection or suppression systems)

This information is all used together to support the Process Hazards Analysis (PHA) effort and make the study as effective as possible to identify hazards associated with the process.

If there are gaps in the information needed in order to characterize material for flammability parameters, desired reactive chemistry, potential unwanted reactions, decomposition reactions or combustible dust characeristics, extensive laboratories such as Fauske & Associates (FAI) have capabilities to meet those needs. A full service lab also has subject matter experts in flammability, combustible dust and reactive chemicals in order to be able to guide the discussion and/or facilitate the PHA study.

For more information regarding Process Safety, Process Hazards Analysis and other reactive chemical safety topics, please contact Amy Theis, Director of Risk Management Services, Fauske & Associates, LLC (FAI), 630-887-5211, theis@fauske.com

Process Safety Management (PSM) Overview

Subscribe to FAI's Quarterly "Process Safety News"

Topics: process safety


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