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.

On-Site Process Safety and Risk Management

BackgroundRisk Management Companies

In response to continued rapid growth in safety needs for the chemical and nuclear industries, Fauske & Associates, LLC (FAI) offers a complete range of On-Site Safety Services including Combustible Dust Hazard Analysis (DHA) Explosion and Fire Hazard Evaluation, Process Hazard Analysis (PHA), Hazard Identification Risk Analysis, Consequence AnalysisSafer Process Scale-up, Process Safety Management (PSM) Program Development, and Relief System Design Review.



  • Understand and address hazards that pose the highest level of risk to your process facility
  • Ensure compliance with relevant national, local and industry standards
  • Implement best engineering practices
  • Reduce overall level of risk
  • Increase productivity and employee morale
  • Make organization more competitive
  • Decrease insurance premiums


Pre constructionIncreasingly, savvy customers come to us to get a jump on construction projects.  With our team’s preliminary review, we are able to make recommendations to meet required standards while anticipating facility safety needs.  We also provide desktop reviews (in addition to walk downs) and assist in the development of safety management plans. We can develop Combustible Dust Management Programs or processes to help in personnel shifts/changes as well as comprehensive Process Safety Management (PSM) plans.  Bring us any of your safeguard, risk reduction, risk mitigation and explosion protection requests.  We will help your team get and stay on top of it.

Desktop Review


Chemical Risk ManagementFAI experts provide onsite Combustible Dust Hazard Assessments (DHAs), Process Hazard Analyses (PHAs), OSHA Combustible Dust NEP compliance support, training and other services related to characterizing, preventing and mitigating combustible dust explosion and fire hazards.  An onsite assessment provides an experienced engineer to visit a facility, evaluate its compliance with relevant national, local and industry standards and provide recommendations for risk reduction.  Additional services include deflagration vent sizing calculations, desktop reviews, equipment selection guidance, training of personnel on combustible dust hazards as well as development of process safety programs to address these issues.  Click here for more on Combustible Dust



AnalysisA PHA is a systematic evaluation of the hazards involved in the process.  PHAs are required for initiation of a process and at least once every five years after that.  It is important to address normal operating conditions as well as start-up, normal shut down and emergency shutdown procedures during the PHA.  The PHA team should be multi-disciplinary, including operations, engineering and maintenance.  To properly conduct a PHA, the process safety information (PSI) must be as complete as possible.  FAI can provide PHA services including PHA auditing / review, revalidating PHAs and facilitating. 

FAI has performed PHAs for compliance to OSHA PSM requirements as well as combustible dust related PHAs for compliance per national National Fire Protection Association (NFPA) guidelines: NFPA 654, NFPA 664 and NFPA 484. 

FAI provides a full range of PHA services, using a variety of techniques including, hazard and operability (HAZOP) analysis, what-if, checklists, failure modes and effects analysis (FMEA) as well as quantitative risk assessments such as layer of protection analysis (LOPA). 

Process Hazard Analysis


FAI offers consulting services to identify hazards related to the handling or storage of flammable and combustible liquids and gases, combustible dust and reactive chemicals.  Extensive testing experience allows our team to identify potentailly hazardous conditions that may not be readily discernable.  


FAI experts can evaluate the effect of various process upset scenarios including fire and explosions, vessel overpressure scenarios, chemical reactivity concerns, vapor cloud dispersions and chemical releases.  Computer models are used in conjunction with appropriate data to determine the effects.  The benefit or risk reduction of safeguards or mitigation strategies can also be evaluated.  


Provides life safety and fire protection consulting, engineering, and design services to architects, owners and developers, construction teams and facility operators. Helps clients to understand and achieve essential life safety goals like complying with codes, meeting egress requirements, choosing sustainable fire protection systems, analyzing hazards, and preparing for and responding to emergencies. Risk mitigation; help to lower design, construction, and operating budgets; and ensure enhanced safety for end users. 

  • Building and fire code consulting
  • Means of egress evaluation
  • Plan review
  • Commissioning and construction management services
  • Fire modeling
  • Explosion modeling
  • Dispersion modeling
  • Quantitative risk analysis


Process Safety and Risk ManagementFAI offers services for safer scale-up of batch, semi-batch and continuous processes.  Consultation is available for process development groups involved in the scale-up of chemical processes throughout the development cycle.  Areas of expertise include the following topics. 

  • Onsite or desktop review
  • Determine critical process parameters to avoid or mitigate unwanted reactivity
  • Development of customized scale-up program designed for safer operation at various stages
  • Perform calorimetry testing to characterize desired and undesired reactions
  • Identify safe operating limits for temperature, pressure and other safety-critical parameters
  • Emergency relief design calculations for pilot plant, kilo lab and commercial scale equipment
  • Independent safety assessment


Male Plant ManagerFAI can review or develop process safety programs to support chemical manufacturing facilities or development programs.  This can be performed for facilities including a kilo lab, pilot plant, medium scale and commercial scale plants.  Services include:

  • Auditing, reporting and presenting
  • Gap assessment to identify and prioritize needs
  • Process validation
  • Safe scale-up guidance
  • Development report documentation
  • Consulting on process safety issues for change control (management of change)


Dr. Hans K. Fauske served as the principal investigator and leader of the Design Institute of Emergency Relief Systems (DIERS) research project team.  The team of subject matter experts at FAI continues to participate in the DIERS users group and contribute to developments in relief system design technology.  Years of testing experience provides FAI the unique capability to consult on this topic with proficiency.

  • Third party review of existing relief system design
  • Provide cost-effective solutions if existing relief system design is not adequate
  • Ensure current design basis is appropriate and credible
  • Develop / review pressure relief guidelines
  • Specialists in effluent control for two-phase flow systems


Our team is happy to help train your staff in the understanding of technical issues, process safety programs or audits, regulations and more.  We perform process safety audits as part of a comprehensive hazards analysis and can work with you to make sure your staff is supplied with skills training needs in many ways including: 

Level I - Gap Analysis
Level II - training & consulting
Level III - Program Development and Implementation

Partial List of Services Offered:
• Reviews and upgrades of all your safety process systems and regulatory requirements
• VPP Consulting
• Audits, reviews, and upgrades of all your Operating, Safety, and Maintenance Procedures
• Training program evaluations for both completeness and effectiveness (from technical skills to professional development) and upgrades where
• Reviews and upgrades of your program elements such as Employee Participation and Process Safety Information for effectiveness and completeness
• Work process effectiveness evaluations and upgrades
• Overall organizational development (e.g., motivation, work processes)
• Stress reduction
• Evaluations of the effectiveness of communication

We design, custom develop and deliver any site specific training materials needed by your organization. Our Consultants, Engineers and Technical Specialists are available to deliver the classroom, lab or on-the-job training your staff needs. In addition, we will assist with the identification and procurement of commercially available training materials where available.


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