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

UN-DOT

Classification of hazardous materials subject to shipping and storage regulations

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Biological

Model transport of airborne virus aerosols to guide safe operations and ventilation upgrades

Radioactive

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

FERST

Software for emergency relief system design to ensure safe processing of reactive chemicals, including consideration of two-phase flow and runaway chemical reactions

FATE

Facility modeling software mechanistically tracks transport of heat, gasses, vapors, and aerosols for safety analysis of multi-room facilities

Blog

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.

Resources

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

Celebrating 40+ years of success

Fauske & Associates has been at the forefront of process safety innovation since the early 1980's, building a reputation as technical leaders who solve the toughest safety problems in the chemical and nuclear industries.  Our people have always been our strongest asset and we are proud to celebrate a few of our accomplishments.

1980

Fauske & Associates, Inc. (FAI) is founded by Dr. Hans K. Fauske, Dr. Robert E. Henry, and Dr. Michael A. Grolmes, and assumes technical leadership for the DIERS research project

Drs. Hans K. Fauske, Robert E. Henry, and Michael A. Grolmes found Fauske & Associates, Inc. (FAI) after transitioning from the Argonne National Laboratory. The company name is later modified to Fauske & Associates, LLC.

diers-logo

FAI is selected as the technical leader and principal research contractor for the DIERS (Design Institute of Emergency Relief Systems) project. The mission included development of methods and tools for sizing a safe but not overly conservative emergency relief system (ERS) to accommodate two-phase flow and runaway chemical reactions.

1981

FAI starts development of the MAAP code

FAI is selected by IDCOR (Industry Degraded Core Rulemaking Program) to provide technical leadership to resolve severe accident issues associated with the operation of a commercial light water reactor (LWR) nuclear power plants. This initiative was an integrated industry response to the degraded core accident at Three Mile Island (TMI) on March 28, 1979.

1981 report cover

FAI starts developing the Modular Accident Analysis Program (MAAP) for modeling the severe accident response of a commercial light water reactor.

1983

Large scale DIERS blowdown tests are done at FAI

Large-scale DIERS blowdown tests performed at FAI were used to confirm vapor disengagement and flow regime methodologies.

  • “Without data, all you have is an opinion” – phrase locally attributed to HK Fauske, emphasizing the importance of data in any process safety assessment

1984

Large scale DIERS runaway chemical reaction tests are done at FAI

Large-scale DIERS chemical runaway reaction testing performed at FAI validated pressure relief and effluent handling models.

 

MAAP1 and MAAP2B software versions released.

1985

The DIERS Bench Scale Apparatus is commercialized as the VSPTM

The original DIERS Bench-Scale Apparatus, a significant achievement of the FAI-led DIERS research program, is commercialized as the Vent Sizing Package (VSPTM).

Marty - PhD student 1980s

 

1986

 MAAP3 released

Westinghouse Electric Company acquires FAI.

MAAP3 released.

FAI staff around 1986

 

1987

Two-Phase Venting ERS Design Software (VSSP) released

Two-Phase Venting ERS Design Software (VSSP) released.

Direct Containment Heating (severe accident simulation) experiments conducted.

MARS (Modular Accident Response System) is first introduced to monitor and predict nuclear power plant response to abnormal or accident conditions.

1988

Reactor Pressure Vessel (RPV) External Cooling Experiments performed at FAI.

Reactor Pressure Vessel (RPV) External Cooling Experiments performed at FAI

RPV external cooling

 

1989

FAI introduces the Reactive System Screening Tool (RSSTTM)

FAI introduces the Reactive System Screening Tool (RSSTTM) to more easily generate directly scalable data on runaway chemical reactions and thermal decompositions.

ARSST old

 

1990

MAAP 3B-CANDU released

MAAP 3B-CANDU released.

Individual Plant Examinations (IPEs) to assess nuclear plants for severe accident vulnerabilities

Drs. Hans K. Fauske, Robert E. Henry, and Michael A. Grolmes found Fauske & Associates, Inc. (FAI) after transitioning from the Argonne National Laboratory. The company name is later modified to Fauske & Associates, LLC.

diers-logo

FAI is selected as the technical leader and principal research contractor for the DIERS (Design Institute of Emergency Relief Systems) project. The mission included development of methods and tools for sizing a safe but not overly conservative emergency relief system (ERS) to accommodate two-phase flow and runaway chemical reactions.

FAI is selected by IDCOR (Industry Degraded Core Rulemaking Program) to provide technical leadership to resolve severe accident issues associated with the operation of a commercial light water reactor (LWR) nuclear power plants. This initiative was an integrated industry response to the degraded core accident at Three Mile Island (TMI) on March 28, 1979.

1981 report cover

FAI starts developing the Modular Accident Analysis Program (MAAP) for modeling the severe accident response of a commercial light water reactor.

Large-scale DIERS blowdown tests performed at FAI were used to confirm vapor disengagement and flow regime methodologies.

  • “Without data, all you have is an opinion” – phrase locally attributed to HK Fauske, emphasizing the importance of data in any process safety assessment

Large-scale DIERS chemical runaway reaction testing performed at FAI validated pressure relief and effluent handling models.

 

MAAP1 and MAAP2B software versions released.

The original DIERS Bench-Scale Apparatus, a significant achievement of the FAI-led DIERS research program, is commercialized as the Vent Sizing Package (VSPTM).

Marty - PhD student 1980s

 

Westinghouse Electric Company acquires FAI.

MAAP3 released.

FAI staff around 1986

 

Two-Phase Venting ERS Design Software (VSSP) released.

Direct Containment Heating (severe accident simulation) experiments conducted.

MARS (Modular Accident Response System) is first introduced to monitor and predict nuclear power plant response to abnormal or accident conditions.

Reactor Pressure Vessel (RPV) External Cooling Experiments performed at FAI

RPV external cooling

 

FAI introduces the Reactive System Screening Tool (RSSTTM) to more easily generate directly scalable data on runaway chemical reactions and thermal decompositions.

ARSST old

 

MAAP 3B-CANDU released.

Individual Plant Examinations (IPEs) to assess nuclear plants for severe accident vulnerabilities

1980-1990

1991

 FAI presents DIERS Multi-phase flow methodology.

FAI presents DIERS Multi-phase flow methodology.

1992

Severe Accident Management Guidelines - Technical Basis.

Severe Accident Management Guidelines - Technical Basis.

plant waldown after shot about 1991

 

1993

FAI introduces Polystyrene Vent Sizing Simulation software.

FAI introduces Polystyrene Vent Sizing Simulation software.

1994

MAAP4 and MAAP4-VVER released

MAAP4 and MAAP4-VVER released.

Hanford (DOE) Spent Nuclear Fuel Program (SNFP) initiated; FAI was on the review board.

FAI receives ISO 9001 certification.

Inaugural issue of FAI Process Safety Newsletter features an article by Jim Burelbach on pool fire experiments, an article by Joe Leung on sizing SRVs for flashing liquids, and new RSST software version 1.9

1995

FAI introduces the VSP2TM

VSP2TM adiabatic calorimeter is introduced.

1996

Polypropylene and Polyvinyl Chloride Simulation Software

Polypropylene and Polyvinyl Chloride Simulation Software.

FAI offers Waterhammer Testing to address the requirements of the nuclear regulatory commission (NRC) generic letter GL 96-06.

Waterhammer in FAI Flume Lab

 

1998

MAAP4-CANDU released

MAAP4-CANDU released for use on the Canada Deuterium Uranium pressurized heavy water reactor design.

1999

ARSSTTM is introduced

Advanced Reactive System Screening Tool (ARSST) is introduced.

Hanford Spent Nuclear Fuel Project moves first fuel – FAI key contributor.

Super Magnetic Stirrer

2000

Simplified screening methods for vapor, gassy, and hybrid system vent sizing is introduced.

Simplified screening methods for vapor, gassy, and hybrid system vent sizing is introduced.

Timeline - Fauske Screening Equation

 

FAI presents DIERS Multi-phase flow methodology.

Severe Accident Management Guidelines - Technical Basis.

plant waldown after shot about 1991

 

FAI introduces Polystyrene Vent Sizing Simulation software.

MAAP4 and MAAP4-VVER released.

Hanford (DOE) Spent Nuclear Fuel Program (SNFP) initiated; FAI was on the review board.

FAI receives ISO 9001 certification.

Inaugural issue of FAI Process Safety Newsletter features an article by Jim Burelbach on pool fire experiments, an article by Joe Leung on sizing SRVs for flashing liquids, and new RSST software version 1.9

VSP2TM adiabatic calorimeter is introduced.

Polypropylene and Polyvinyl Chloride Simulation Software.

FAI offers Waterhammer Testing to address the requirements of the nuclear regulatory commission (NRC) generic letter GL 96-06.

Waterhammer in FAI Flume Lab

 

MAAP4-CANDU released for use on the Canada Deuterium Uranium pressurized heavy water reactor design.

Advanced Reactive System Screening Tool (ARSST) is introduced.

Hanford Spent Nuclear Fuel Project moves first fuel – FAI key contributor.

Super Magnetic Stirrer

Simplified screening methods for vapor, gassy, and hybrid system vent sizing is introduced.

Timeline - Fauske Screening Equation

 

1991-2000

2001

 Deflagration Venting Methodology is released

Deflagration Venting Methodology is released.

DOEWORKSHOPforsocialmedai

The HANSF safety software earns a Department of Energy (DOE) Technology Innovation Award for Hanford applications related to the Spent Nuclear Fuels Project.

2003

First MAAP installation in a nuclear power plant simulator to model severe accidents.

First MAAP installation in a nuclear power plant simulator to model severe accidents.

2004

FATETM 2.0 facility modeling software released

FATETM 2.0 facility modeling software released (previously HANSF), developed, and maintained under our NQA-1 compliant quality program.

Air Intrusion experiments completed to address commercial nuclear plant concerns.

2005

FATE software used for Savannah River MOX plant

FATE software used for fire analysis for Savannah River MOX plant

2006

VSP2 Software Version 4.3

VSP2 Software Version 4.3

FAI offers closed cell ARSST option for fast screening tests with pressure generation.

2007

CE certification granted for ARSST and VSP2 adiabatic safety calorimeters

Dedication of a comprehensive Dust Explosion and Department of Transportation Testing Laboratory.

CE certification granted for ARSST and VSP2 adiabatic safety calorimeters. This certification recognizes these instruments meet the EU standards for health, safety, and environmental protection.

2008

MAAP 5.0 release

MAAP 5.0 release.

FATE software used for fire analysis of Oskarshamn-1.

 

2009

Dedication of new and comprehensive Flammability Testing Laboratory.

Dedication of new and comprehensive Flammability Testing Laboratory.

2010

FAI receives ISO 17025 accreditation

FAI receives ISO 17025 accreditation to indicate that ISO and IEC's laboratory management system standard has been met.

Practical Emergency Vent Sizing Software (PrEVent) is released.

Timeline - PrEVent

 

Deflagration Venting Methodology is released.

DOEWORKSHOPforsocialmedai

The HANSF safety software earns a Department of Energy (DOE) Technology Innovation Award for Hanford applications related to the Spent Nuclear Fuels Project.

First MAAP installation in a nuclear power plant simulator to model severe accidents.

FATETM 2.0 facility modeling software released (previously HANSF), developed, and maintained under our NQA-1 compliant quality program.

Air Intrusion experiments completed to address commercial nuclear plant concerns.

FATE software used for fire analysis for Savannah River MOX plant

VSP2 Software Version 4.3

FAI offers closed cell ARSST option for fast screening tests with pressure generation.

Dedication of a comprehensive Dust Explosion and Department of Transportation Testing Laboratory.

CE certification granted for ARSST and VSP2 adiabatic safety calorimeters. This certification recognizes these instruments meet the EU standards for health, safety, and environmental protection.

MAAP 5.0 release.

FATE software used for fire analysis of Oskarshamn-1.

 

Dedication of new and comprehensive Flammability Testing Laboratory.

FAI receives ISO 17025 accreditation to indicate that ISO and IEC's laboratory management system standard has been met.

Practical Emergency Vent Sizing Software (PrEVent) is released.

Timeline - PrEVent

 

2001-2010

2011

The Onsite Safety Services (OSS) Group is formed

The Onsite Safety Services (OSS) Group is formed to provide clients with expertise for dust hazard analysis and process safety assessments, including consulting to address a wide variety of safety and compliance issues.

First Commercial loss-of-coolant accident (LOCA) test conducted at FAI for DBA (Design Basis Accident) Test Facility in support of commercial nuclear plant equipment qualification (EQ).

Toshiba's Fukushima "War Room" response includes FAI staff who provide technical leadership in designing a new ion exchange system to clean up contaminated water.

2012

Secure Level B Laboratory Facility opened

Secure Level B Laboratory Facility opened.

FATE software used for design and safety analysis to remediate Hanford fuel particulate.

2013

Dedication of the new Thermal Hydraulics Testing Facility

Dedication of the new Thermal Hydraulics Testing Facility.

Dedication of new state-of-the-art Combustible Dust Hazards Testing Lab and Education Center opened.

Combustible Dust Hazard 20L Chamber Go-No-Go Test, Explosion Severity Test, LOC, MEC, Pmax, MIE Test-thumb

2014

New Reaction Calorimetry and Thermal Hazards Testing Laboratory

 

Dedication of new Reaction Calorimetry and Thermal Hazards Testing Laboratory to develop data for the desired and the adverse reactions to support fire-sizing and emergency relief system calculations.

MAAP 5.03 release includes post-Fukushima modifications.

Innovative Dual-bore Hydrogen Vent Design invented and proven by experiments to maintain safe hydrogen levels in Self Shielded Boxes (SSBs) of hazardous waste at the UK Sellafield site.

Timeline - Dual Bore Vent

 

2015

Long-term cable aging experiment is conducted

Long-term cable aging experiment is conducted to improve electrical safety.

MAAP-CANDU Graphical Animation Package Extension (GRAPE) is released, providing an interactive visualization tool for severe accident management.

2016

Named as a recipient of a prestigious NDA Supply Chain Award

NDA Supply Chain Award Certificate 2016

 

Named as a recipient of a prestigious NDA (Nuclear Decommissioning Authority) Supply Chain Award for technical work underpinning an estimated $1.3 billion in savings at the UK Sellafield site.

 

2017

Testing and analysis to support accelerated removal of nuclear waste at Sellafield

Timeline  - Sellafield Support Team with Filter Testing Apparatus

 

Testing and analysis to support accelerated removal of nuclear waste at Sellafield.

2019

Radioactive source term transport and release calculations

Provided radioactive source term transport and release calculations (Leak Path Factors) supporting the Safety Analysis Report (SAR) for a new medical isotope facility.

2020

FERST is released

Flammability testing confirmed expanded metal mesh device technology could prevent deflagration to detonation transitions (DDT).

Fauske Emergency Relief System Tool (FERST powered by CHEMCAD) is released.

Published a groundbreaking journal article illustrating the use of the FAI FATETM safety software to predict airborne virus transport within a facility.

Timeline - FATE - predict airborne virus transport

 

The Onsite Safety Services (OSS) Group is formed to provide clients with expertise for dust hazard analysis and process safety assessments, including consulting to address a wide variety of safety and compliance issues.

First Commercial loss-of-coolant accident (LOCA) test conducted at FAI for DBA (Design Basis Accident) Test Facility in support of commercial nuclear plant equipment qualification (EQ).

Toshiba's Fukushima "War Room" response includes FAI staff who provide technical leadership in designing a new ion exchange system to clean up contaminated water.
Secure Level B Laboratory Facility opened.

FATE software used for design and safety analysis to remediate Hanford fuel particulate.

Dedication of the new Thermal Hydraulics Testing Facility.

Dedication of new state-of-the-art Combustible Dust Hazards Testing Lab and Education Center opened.

Combustible Dust Hazard 20L Chamber Go-No-Go Test, Explosion Severity Test, LOC, MEC, Pmax, MIE Test-thumb

Dedication of new Reaction Calorimetry and Thermal Hazards Testing Laboratory to develop data for the desired and the adverse reactions to support fire-sizing and emergency relief system calculations.

MAAP 5.03 release includes post-Fukushima modifications.

Innovative Dual-bore Hydrogen Vent Design invented and proven by experiments to maintain safe hydrogen levels in Self Shielded Boxes (SSBs) of hazardous waste at the UK Sellafield site.

Timeline - Dual Bore Vent

 

Long-term cable aging experiment is conducted to improve electrical safety.

MAAP-CANDU Graphical Animation Package Extension (GRAPE) is released, providing an interactive visualization tool for severe accident management.

Named as a recipient of a prestigious NDA (Nuclear Decommissioning Authority) Supply Chain Award for technical work underpinning an estimated $1.3 billion in savings at the UK Sellafield site.

 

Testing and analysis to support accelerated removal of nuclear waste at Sellafield.
Provided radioactive source term transport and release calculations (Leak Path Factors) supporting the Safety Analysis Report (SAR) for a new medical isotope facility.

Flammability testing confirmed expanded metal mesh device technology could prevent deflagration to detonation transitions (DDT).

Fauske Emergency Relief System Tool (FERST powered by CHEMCAD) is released.

Published a groundbreaking journal article illustrating the use of the FAI FATETM safety software to predict airborne virus transport within a facility.

Timeline - FATE - predict airborne virus transport

 

2011-2020

2022

FAI receives Westinghouse award

FAI receives Westinghouse award for innovative hydrogen venting design in support of Fukushima decommissioning

TEPCO TEAM

 

FAI receives Westinghouse award for innovative hydrogen venting design in support of Fukushima decommissioning

TEPCO TEAM

 

2021 - Present