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.

Published July 23, 2015

Value of Near Miss Incidents - Process, Plant and Facility Safety

by Mark Yukich, Sales & Business Development, Fauske & Associates, LLC

Sometimes a near-miss is seen as no big-deal, when really, it should be an opportunity to start taking Lincolnthe necessary steps to ensure a safe working environment.   When it comes to process safety, a continual effort is needed to keep your employees and facility safe because factors in the process are continually changing.  As a company that focuses on safety, we often see who chooses to ignore near-miss events.  Ideally, companies should be more proactive rather than reactive, so that a near miss is not needed to start the conversation. 

Why are Near-Misses Important?

According to the National Safety Council (NSC), history has shown that most major loss producing events were preceded by warnings or near miss incidents.  We have seen this through our work with many clients over the years.  Oftentimes, operators are accustomed to small fires occurring as part of a process.  This desensitizes them to potential risks.  Then, when there is an equipment change or an outside contractor, there is an opportunity for a catastrophic event.  With this in mind – the question becomes: 

What are the best practices for managing Near Misses?

The NSC goes on to say, “Recognizing and reporting near miss incidents can significantly improve worker safety and enhance an organization’s safety culture.”  Some of the best practices that the NSC suggests are the following:

• Leadership must establish a reporting culture reinforcing that every opportunity to identify and control hazards, reduce risk and prevent harmful incidents must be acted on.

• The reporting system needs to be non-punitive and, if desired by the person reporting, anonymous.

• Investigate near miss incidents to identify the root cause and the weaknesses in the system that resulted in the circumstances that led to the near miss.

Safety2One of the core components suggested in the area of near miss reporting is that the employees feel empowered to report any issues they see as a hazard somewhere in the process.  As stated earlier, a near miss is an opportunity to discover workplace hazards and establish focused interventions that will prevent similar accidents from happening again. 

Is Near-Miss reporting required?

An article from April of 2013 in “Safety Smart Compliance” mentions that near miss reporting is not a requirement by OSHA.  The article went on to say, “In some ways, OSHA actually discourages near miss reporting by using reports of near miss incidents as evidence of an employer’s knowledge of a particular problem.  Thus, having a near incident report about a hazard in your files increases your risks of being cited for the hazard.”  Just because reporting a near miss is not required by OSHA, don’t let that stop your company from taking the proactive approach.

Conclusion:  Be Proactive!

Ultimately, the safety of your personnel and facility is a continual process and should include multiple levels and members of your team.  If your company has a clear plan that allows open communication of any potential hazards, you are taking the necessary steps to ensure plant safety.  Leadership should stress the importance of taking proactive measures before any catastrophic event takes place.  If there is ever any question about your plant’s safety process, reach out to Fauske & Associates, LLC to assist you with a proper review of Process Safety Management.  Abraham Lincoln once said, “You cannot escape the responsibility of tomorrow by evading it today.” Safety3


NSC.org “Near Miss Reporting Systems”

Safety Smart Compliance, April 2013, “8 steps for effective near miss management.”

Lifehack Quotes

For more information, please contact Mark Yukich at yukich@fauske.com, 630-321-4788,

Guide to Process Scale Up


Understanding Recently Issued OSHA PSM NEP:  Process Safety Management of Highly Hazardous Chemicals


Subscribe to FAI's Quarterly "Process Safety News"

Sign up for our newsletter to Get all the latest information

Share this article

Find more resources articles