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Spark Detection & Suppression Systems

INTRODUCTION


Spark detection and suppression systems are a key risk mitigation measure in many industrial processes where finely divided combustible materials are handled. The definitive reference for these systems is RISCAuthority RC28 – Recommendations for Spark Detection and Suppression Systems on Pneumatic Conveying Installations, available on ATLAS. All Risk Engineers and Consultants are expected to be familiar with RC28 and its detailed technical and procedural guidance.

 

APPLICATION


Spark detection and suppression systems have been on the market for many years and have grown in number as manufacturing plants have become larger, more sophisticated and more valuable, both in terms of asset value and business dependency. Any process or manufacturing industry in which ducts, hoppers, filters, silos, dryers and other vessels contain finely divided combustible materials will have a potential application for a spark detection and suppression system.


Typical examples include:

  • Textile Industry – brushing and raising machines

  • Food Industry – bakeries, cereal production, spice and rice milling

  • Rubber and Plastics – regrinding and granulating machines

  • Metalworking – flue gas filtration in foundries, metal polishing

  • Timber Panel Industry – presses, dryers, cyclones, screens and mills

  • Woodworking – dust and waste extraction systems

  • Printing Industry – dust and waste extraction systems

  • Recycling Industry – crushers, shredders and screening lines


Leading UK-based and international suppliers of spark detection and suppression systems include:


Principal Suppliers:

  • GreCon Ltd – Full-service offering: surveys, design, installation, maintenance.

    Website: www.fagus-grecon.com 


  • Minimax Viking Group – Broad fire protection product suite.

    Website: www.minimax-viking.com/en/ 


  • Orthos Ltd – UK distributor for Firefly spark detection and suppression equipment.

    Website: www.orthos.uk.com


  • Firefly AB – Swedish-based specialist in spark detection and flame suppression technologies.

    Website: www.firefly.se


Most systems utilise high-speed water mist as the extinguishing medium, though CO₂ or other gaseous agents may be employed in specialist or sensitive environments.


It is important to recognize that spark detection and suppression systems are intended to be installed to complement and not to replace conventional protection methods such as screening and explosion relief.


Costs for the supply and installation of spark detection systems will vary considerably depending on the extent of the protection requirements. As a rough guide, the average cost for a single application system is circa £15,000.

Typical duct installed spark detector and suppression

                                                          

STANDARDS AND APPROVALS


There are no recognised British or European Standards specifically covering spark detection and suppression systems, although FM, NFPA and VdS operate system approvals schemes.


Each of the GreCon, Minimax and Firefly systems has achieved approval to at least one of these schemes. A CEA approvals scheme was introduced some years ago, but this appears to have been little utilised.

 

SYSTEM MAINTENANCE


As with all fixed fire protection systems, maintenance and testing of the installation is essential and reference should be made to the guidance in Section 6 of RC28. In addition to routine maintenance “in house”, full inspection and maintenance the system(s) should be carried-out by the installer annually or more frequently as advised.


Maintenance routines should include:

  • Sensor function checks,

  • Suppression nozzle integrity and flow testing,

  • Control panel diagnostics,

  • Data log reviews (if available).

  

RISK IMPROVEMENTS


Requirements/Recommendations for spark detection and suppression systems are to be risk based in which due regard should be taken of the potential exposure (EML) in respect of MD & BI. As a general rule, these would normally come into play where exposures are in excess of £10m. Consideration for such protection below this figure may be necessary when dealing with a particularly hazardous risk and/or where there is adverse loss experience. Except for extreme situations, risk improvements for spark detection systems would normally be submitted as Recommendations.


SUMMARY


Spark detection and suppression systems are a vital part of modern fire risk management in high-value, dust-generating manufacturing environments. While not a substitute for fundamental safety engineering, these systems provide rapid response to ignition sources and help mitigate large-scale fire and explosion events.


Consultants are encouraged to:


  • Refer to RC28 for in-depth technical guidance.

  • Assess installations based on hazard type, asset value, and BI exposure.

  • Engage with reputable, certified system providers for detailed risk-specific solutions.

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