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/IEC 17025:2017

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

ISO 9001:2015
Fauske & Associates fulfills the requirements of ISO 9001:2015
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

FATE™ & Facility Modeling

FATE (Facility Flow, Aerosol, Thermal, and Explosion) is a flexible, fast-running code developed and maintained by Fauske and Associates under an ASME NQA-1 compliant QA program.

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.

Reactive Chemicals Testing

Understanding Chemical Reactions and Testing Strategies

Reactive chemical hazards must be assessed in order to minimize risk to a chemical process. Pressure is the greatest threat to process vessel integrity, as it is rare that temperature alone will cause a vessel to fail. Therefore, it is critical to identify, characterize (by testing), and then mitigate or prevent the hazardous potential for overpressurization of your vessels.


  • 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)

Request a Quote

Testing Services

Flash Point

      • 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.
          • Is 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 the process?
  • 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?

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

Identifying and Assessing Sources of Overpressure

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

Screen Shot 2023-03-02 at 5.59.48 PM

Related Services:

FAI is a world leader in chemical process safety.

Understanding Chemical Reactivity - Resources