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.


We have a wealth of information pertaining to reactive chemical hazards, nuclear and chemical process safety engineering and testing. With over 40 years of industry expertise, we have developed numerous content pieces, from white papers to videos, to help answer your safety-related questions. We hope you find this information useful!

Blast Analysis and Design Capabilities


Emergency preparedness experts recognize the importance of structural protection against ...

FAI Ion Exchange Model Introduction

By Jim Burelbach, PhD, Chief Commercial Officer, Fauske & Associates, LLC

and Marty Plys, DSc...

dust screening

FAI Dust Collection Kit and Common Sampling Questions

A common question that comes into our dust testing lab is, “How should I ship my sample?”

As a res...

Dust Hazard Analysis dust cloud

dust hazard analysis

NFPA Extends Dust Hazards Analysis (DHA) for 2020 | Fauske

Written by Ashok Dastidar, PhD, Fellow Engineer, VP Dust & Flammability Testing & Consulting, Fauske...

Combustible Dust

Process Safety News - Spring 2020

Please enjoy this latest issue of Process Safety News! FAI is proud to be celebrating our 40th ann...

Flammability Testing as Fauske


FAI Flammability Testing

Ask Us About Testing

process safety

Process Safety News - Winter 2020

Please enjoy this latest issue of Process Safety News! FAI is proud to be celebrating our 40th anniv...

Combustible Dust

Summer 2018 Process Safety News

Read up on the latest in chemical, thermal hazards and relief system design as well as combustible...

Combustible Dust

Winter 2019 Process Safety News


  • Recommendations on the Maximum Operating Pressure of ARC Test Cells
  • I Have A...

Combustible Dust

Fall 2018 Process Safety News

Read up on the latest in risk based inspection, chemical process, thermal hazards and relief syst...

Combustible Dust

Fall 2017 Process Safety News Released
Stay on top of the latest in process safety hazards procedures, testing and industry news each qu...

Combustible Dust

Summer 2015 Process Safety Newsletter

A SIMPLE REAL TWO-PHASE FLOW CORRELATIONBy: Hans K. Fauske, D.Sc., Regent Advisor, Fauske & Assoc...

OSS - 08192

Combustible Dust

Are Your On-Site Safety (OSS) Services Up to Snuff?

Do you work with an objective, outside process safety engineering firm offering a complete range o...


shock hazard

Electrical Arc Flash Risk and Shock Hazards

Do you have the electrical engineering expertise to help you understand and address electrical arc...


Combustible Dust

New Approach to DHAs: 7 Steps to Tackling Combustible Dust

You've been tasked with overseeing potential dust hazards at your plant and/or you need to be read...


process safety

How Proper Chemical Hazard Characterization Impacts Process Safety

By Sara Peters, Customer Outreach & Digital Media Specialist, Fauske & Associates, LLC 

FAI -video-thing


Importance of Analytical Modeling AND Experimental Data in Complex Fluids

Ryan Vanston, Manager, Technology Development Group II System & Risk Applications, Westinghouse El...

advanced reactive system screening tool

runaway reactions

Safe Packaging of Chemically Reactive Radioactive Waste

James P. Burelbach, PhD, Elizabeth J. Raines and Martin G. Plys, ScD, Fauske & Associates, LLC


Combustible Dust

Combustible Dust Control Needs Video

Dust explosion is never something you think you need to worry about - but have you had your dust tes...

BWR reactor similar to Fukushima Daiichi Unit 1 (Aerial view of Fukushima Daiichi nuclear site in the background).

severe accident

Severe Accident Post Fukushima Engineering /MAAP5 Advanced Capabilities


BWR reactor similar to Fukushima Daiichi Unit 1 (Aerial view of Fukushima Daiichi nuclear site i...

Fear Appeal illustration courtesy of www.larkin.biz and aiche.org/cep

process safety

Process Safety Management and 5 Reasons to Use Scare Tactics

"Communication that stimulates emotion will bring about more behavior change than communication th...

Metallic spent nuclear fuel vacuum drying model


What Should Your Nuclear Waste Management Technology (D&D) Include?

Does your nuclear engineering, testing and consulting firm provide technical expertise and program g...

1 Cubic Meter Chamber at Fauske & Associates, LLC- one of the few in the United States

Combustible Dust

Is your DHA Laboratory State of the Art?

 1 Cubic Meter Chamber at Fauske & Associates, LLC             - 1 of very few in the Unite...


process safety

Avoiding Hazardous Runaway Reactions in Cold/Freezing Temperatures

By Ken Kurko, Process Safety Services Director, Fauske & Associates, LLC

Colder temperatures mean ...



Combustible Dust Hazard 20L Chamber Go/No Go Test, Explosion Severity Test
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MIT, LIT, MIE - Characterizing for Dust Hazard Analysis DHA
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UN 4.1 Burn Rate Test - Is My Dust Combustible, Flammable or a Fire Hazard?
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How to Test for Combustible Dust: BAM Fallhammer Drop Impact Test


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Hartman Tube Combustible Dust Explosion
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10 Tips for Setting up an ARSST Test to Yield Good Thermal Data
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Sustained Burning Test on a Condensed Aerosol Sample

ASTM D92 Cleveland Open Cup Flash Point and Sustained Burning. The sample was a condensed aerosol. A...



Sound Structural Design Demonstrated: Slug Flow

This video shows a field test we recently performed.  In this test, liquid is being vented which res...



Combustible Dust Hazard Analysis (DHA) Sample Prep and Screening


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relief system design

Non/Equilibrium Flashing Flows in Safety Relief Valves (SRVs)

Further Clarification of Non-Equilibrium and Equilibrium Flashing Flows Through Top Located Safety...

severe accident

Fauske & Henry: On Vapor/Steam Explosion Analysis

As seen in the August 2017 issue of Nuclear News, Copyright © 2017 by the American Nuclear Society


Verification of GOTHIC Room Heatup Analysis by Alternate FATE Calculation

By: Matthew Kennedy, Nuclear Engineer & Dr. Sung Jin Lee, Sr. Consulting Engineer, Fauske & Associ...


risk management

How to Collect a (Potentially) Combustible Dust Sample

Wondering if your facility may have combustible dust? In some cases, less than 1/4 inch layer of dus...


Combustible Dust

Chemical Testing Services That Will Save You Money

Adiabatic Calorimetry & Relief System Design Combustible Dust Hazards Analysis (DHA) AnalysisFailure...

Combustible Dust

Three Critical Oversights That Precede Combustible Dust Incidents

By: Tim Cullina, MS. PE, Senior Safety and Environmental Consulting Engineer, Fauske & Associates, L...

nuclear plant

Revisiting Chernobyl - 30 Years Later

By: AnnMarie Fauske, Customer Outreach & Digital Media Manager, Fauske & Associates, LLC

Combustible Dust

The Economics of Fugitive Dust (Combustible Dust Hazards)

By: Ursula Malczewski, Chemical Engineer – Onsite Safety Services, Fauske & Associates, LLC

Combustible Dust

OSHA Combustible Dust Citations - Who Are They Writing Up?

A quick look at Occupational Safety & Health Administration (OSHA)'s website can tell you this:  in...

Combustible Dust

Combustible Dust Management Made Easy

Customer inquiry inspired us to develop the Combustible Dust Flowchart to help guide the decision-m...

Combustible Dust

Developing Good Engineering Practice in Biomass Industry

Biomass Background - Forest, Sawmill and Agricultural Perspective

Biomass energy is a suggested rep...

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