Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Gas and Vapor

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Classification of hazardous materials subject to shipping and storage regulations
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Thermal Stability

Safe storage or processing requires an understanding of the possible hazards associated with sensitivity to variations in temperature

Adiabatic Calorimetry
Data demonstrate the consequences of process upsets, such as failed equipment or improper procedures, and guide mitigation strategies including Emergency Relief System (ERS) design
Reaction Calorimetry
Data yield heat and gas removal requirements to control the desired process chemistry
Battery Safety

Testing to support safe design of batteries and electrical power backup facilities particularly to satisfy UL9540a ed.4

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Cable Testing
Evaluate electrical cables to demonstrate reliability and identify defects or degradation
Equipment Qualification (EQ)
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Water Hammer
Analysis and testing to identify and prevent unwanted hydraulic pressure transients in process piping
Acoustic Vibration
Identify and eliminate potential sources of unwanted vibration in piping and structural systems
Gas & Air Intrusion
Analysis and testing to identify and prevent intrusion of gas or air in piping systems
ISO Accreditation and Scope

Fauske & Associates fulfills the requirements of ISO/IEC 17025:2017 in the field of Testing

Dust Hazards Analysis
Evaluate your process to identify combustible dust hazards and perform dust explosion testing
On-Site Risk Management
On-site safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up
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 safely handle the effluent discharge from an overpressure event


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

Model transport of flammable or toxic gas during a process upset

Mechanical, Piping, and Electrical
Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid, flow, and electric power systems
Hydrogen Safety
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Thermal Hydraulics
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Nuclear Safety
Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant
Radioactive Waste
Safety analysis to underpin decomissioning process at facilities which have produced or used radioactive nuclear materials
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.

Chemical Reaction Hazards

Hazards Arise from Pressure

The greatest hazard that threatens process vessels is pressure. It is rare that temperature alone will cause a vessel to fail. Therefore it is critical to identify, and then mitigate or prevent the potential for overpressurization of your vessels.

There are many potential sources of pressure:

Desired Process

Raw Material Desired Reaction Product (Heat / Vapor / Gas)

Undesired Process

Raw Material Desired Reaction Product + Heat Undesired Reaction Undesired Product (Heat / Vapor / Gas)


Raw Material Upset Scenario Undesired Product (Heat / Vapor / Gas)
  • Heat from the desired reaction leading to a secondary reaction or decomposition reaction at elevated temperatures (generating non-condensable gas and/or vapor)
  • Upset conditions (e.g. loss of cooling, excess catalyst, incorrect raw material added etc.) lead to greater or uncontrollable rates of reaction or alternative reactions (generating non-condensable gas and/or vapor)
  • Self-heating or self-reactive substances during shipping or storage that over time can accumulate heat (generating non-condensable gas and/or vapor)
Identifying and Assessing Sources of Overpressure

There are three key steps to take to avoid or appropriately protect against an overpressure situation:

What aspects of my process should I focus my evaluation on?
  • Thermal Screening: quantify heat associated with process chemistry and the thermochemistry of materials involved with the process

How do I run my process safely?
  • Reaction Calorimetry: determine heat and gas removal requirements to control the desired process chemistry

How do I avoid or mitigate the effects of a runaway reaction?
  • Adiabatic Calorimetry: determine the consequences of potential upset scenarios such as failed equipment or improper procedures, and mitigate the consequences by determining appropriate control or safety systems (SIS, SIL, pressure relief, etc.)

Chemical Reaction Hazards

Understanding chemical safety instruments gives an introduction to some of our calorimeters as well as practical uses.

Thermal Screening

In addition to the evaluation of literature data and performing theoretical calculations, small-scale instruments such as the Differential Scanning Calorimeter (DSC) or Advanced Reactive System Screening Tool (ARSST) can be used to quickly thermally screen starting materials, process streams, and products to identify the existence of hazards.

  • Thermal ScreeningIs there thermal decomposition of raw materials, intermediates, products, etc.?
  • Are there exothermic reactions that should be studied more closely?
  • How should this material be stored or shipped?

Reaction Calorimetry

Reaction calorimetry is a tool that is used to understand the equipment or process requirements to perform a chemical process safely. Typical instruments are the RC1 (Mettler Toledo) and the CPA202 (ChemiSens).

  • How much heat does my cooling system need to remove?
  • How large of a scrubber do I need, and what rate of gas generation does it need to handle?
  • What are the temperature dependent kinetics of my reaction?
  • What is my heat of reaction or instantaneous heat flow for a step in my process?
Reaction Calorimetry

Adiabatic Calorimetry

Adiabatic calorimetry is a tool that can simulate large-scale vessels to determine the consequences of a runaway reaction. This can be performed in instruments such as the Vent Sizing Package 2 (VSP2), ARSST, or Accelerating Rate Calorimeter (ARC).

  • Are there secondary or decomposition reactions that begin within the maximum temperature of synthetic reaction (MTSR)?
  • How much non-condensable gas would be generated if I had a runaway reaction?
  • How do I protect my vessel if an upset scenario occurs?
Adiabatic Calorimetry

Relief System Sizing gives introductory guidance to chemically reactive vent sizing using either VSP2 or ARSST data.

FAI is a world leader in chemical process safety.