Spark extinguishing systems

Spark Detection and Extinguishing System
Donat Czapski

Donat Czapski – I am at your disposal

+48 695 244 220

info@grupa-wolff.com

Design
Delivery
Installation
Service

We know the requirements of insurers

From ATEX AUDIT to protection implementation

We provide 24/7 service

Spark extinguishing systems

We design and manufacture spark detection and extinguishing systems for dust collectors, cyclones, central vacuum cleaners and silos. We are familiar with the specifics of the wood, food, textile, waste processing and disposal and automotive industries. The security work we carry out is in accordance with Polish standards, as well as the requirements of insurers. We carry out work on the site in a way that minimises the impact on production continuity and takes into account in-house health, safety and fire regulations.

Key benefits

sparks detection systems - benefit 1

Up to 50% fewer sensors = lower costs

sparks detection systems - benefit 2

4 to 7 times fewer cables = lower costs

sparks detection systems - benefit 3

In compliance with the requirements of the insurance company

sparks detection systems - benefit 4

We reduce the impact of assembly on production

sparks detection systems - benefit 5

Swap water for gas, gate or diverter

sparks detection systems - benefit 6

Large service department and a 24/7 emergency number

Typical applications

Principle of operation

Spark Extinguishing System for Dust Collection System

Project examples

See what makes our spark detection and extinguishing system stand out

As many as 50% fewer detectors = lower cost

Traditional spark detectors cannot see the full cross-section of the channel. As a result, their manufacturers require between 2 and even 4 spark detectors. This dramatically increases the cost of purchasing the system, installation and use. The patented V300EX series sensor sees the entire cross-section of the duct so that in 90% of cases we are able to use 50% to even 75% fewer sensors. In addition, our detector has a daylight filter and, most importantly, detects not only glowing sparks but also hot particles. Remember also that we can adjust its sensitivity at any time to perfectly suit your process.

IMPORTANT FEATURES OF SPARK SENSORS

  • Whole duct cross-section in FOV
  • up to 50% fewer spark detectors.
  • Insensitive to daylight
  • Capable of detecting hot objects
  • heat-resistant version
  • AISI 316L stainless steel grade housing
  • Easy and safe installation with no welding required
  • ATEX-certified zones 20, 21 and 22
  • High wear resistance

Up to tens of thousands of savings on cables alone

With competing systems, each sensor and extinguishing nozzle requires a separate cable to connect to a control panel, which is often hundreds of metres away. In practice, this means four to seven cables per extinguishing line. Thanks to intelligent solutions, our system requires only one cable to operate the same extinguishing line, which is only separated in the immediate vicinity of the sensors and nozzles. This difference saves from several to several thousand pounds per extinguishing line. When protecting several devices, the amount increases to tens of thousands of zlotys.

Amount of cable our spark extinguishing system
  • only one cable from the control unit to the installation (regardless of the number of sensors and nozzles)
  • 4 to 7 times shorter cables
  • From 8,550 to 17,550 PLN in savings per extinguishing line (value for distance between control panel and device = 200 m)
Amount of cable used other spark extinguishing systems
  • each sensor and nozzle requires a separate cable to the control unit
  • the lack of a signal router extends the cables by up to 7 times for each extinguishing line
  • depending on the distance between the control panel and the device and the number of protected devices, the cost of the cables alone can be tens of thousands higher

How much you can save - an example

Let’s assume that the extinguishing installation is 200 metres from the control unit and requires two spark detectors and two extinguishing nozzles. In this case, our system requires approximately 230 metres of cable, which we run from the control unit to the router, which in installed near the protected device. From the router, there are 4 short cables to operate 2 sensors (NOTE: our system requires only 1 sensor 90% of the time, whereas other systems need to use 2 to 4 sensors) and two nozzles. Other solutions require 4 separate cables with a total length of 800 metres.

The price of a 4-wire cable for this type of installation is between 13 and 17 zlotys net. Assuming an average price of 15 zlotys for such a cable, the savings on the cable alone for our system would be 8,550 zlotys.

If several pieces of equipment, e.g. several dust collectors, are protected in a given plant, this amount will be multiplied.

Versatile and easy-to-use control panel

The VR18Z is one of the most comprehensive spark detection and extinguishing systems on the market. With its user-friendly interface, large LCD display and Ethernet-based remote control system, it is simple and easy to use. The system is equipped with a memory capable of storing the last 10,000 events. The decentralised bus structure reduces cabling and installation costs. The possibility of connecting additional heat or flame detectors to the control unit further increases the level of safety.

Spark detection and extinguishing system control panel
  • lower cost of purchase and installation due to reduced cabling
  • ease of use thanks to a user-friendly interface that requires no programming
  • increased level of security due to the redundancy of each protected zone
  • a decentralised system based on the BUS protocol
  • lower expansion costs thanks to the 18-zone control panel, which does not require .replacement or future expansion
  • remote control via Ethernet
  • additional heat or flame sensors can be plugged in

Intelligent extinguishing nozzles that do not disappoint

The only nozzle on the market that measures water temperature, water flow during extinguishing or testing and recognises the position of the water shut-off valve. What is this all for? Measuring the water temperature gives us confidence that the system has not frozen. Measuring the flow of water through the extinguishing nozzle allows periodic tests to be carried out and confirms that this particular nozzle was working correctly when sparks were detected. A valve position sensor, on the other hand, avoids accidental water shut-off, which has happened with competing solutions.

Intelligent extinguishing nozzles for spark extinguishing systems

IMPORTANT FEATURES OF THE EXTINGUISHING NOZZLE

  • high speed
  • accidental water cut-off sensor
  • sensor that eliminates the risk of freezing
  • sensor for correct nozzle operation
  • frost protection sleeve
  • possibility of gas extinguishing
  • can be replaced with a slider
  • can be replaced with a diverter
  • various types of nozzles

Can’t put out with water? Use the following option:

Spark extinguishing with CO2 gas

Extinguish with gas instead of water

  • Swap water for gas to completely eliminate the impact of the extinguishing system on your process.
Spark detection system with gate valve instead of extinguishing nozzle

Replace the water with a gate

  • Temporary closure of the duct allows the fire to cool to a safe level.
Spark detection system with diverter instead of extinguishing nozzle

Swap water for diverter

  • A duct-mounted diverter will catch and guide the fire out of the system.

Fan temperature measurement and more

The ease with which additional sensors can be plugged into the system makes it customisable. This option is most commonly used to measure the temperature of fans and equipment that, by their nature, often overheat which increases the risk of fire or explosion (bearings, drives other electrical equipment). This solution is extremely important for the timber industry, where one in two fires is caused by an overheated appliance.

  • various additional sensors can be connected to the system
  • temperature sensor in the form of special adhesive tape for easy installation
  • typical applications include temperature measurement of fans, bearings, drives
  • in the wood industry, one in two fires is caused by an overheated appliance
  • a simple solution that does not require additional drivers

Expand your spark extinguishing system with additional options

Thermal sleeve for extinguishing nozzles

Thermal sleeve for extinguishing nozzles

If the nozzles are installed outdoors, there is a risk of the water freezing. We insulate the water pipe permanently with foam and bind it with sheet metal. However, the nozzles require easy access, so instead of enclosing them with classic insulation, we propose a special insulation sleeve.

Heating cable to protect pipes from freezing

Heating cable

If the installation requires heating due to operation in sub-zero temperatures, a heating cable can be used. Its integration into the system is problem-free, which makes it a low-cost solution.

Flame detector to increase the efficiency of the spark detection and extinguishing system

Flame detector

Some equipment generates sparks during normal operation. This is the case, for example, with various types of shredders. To reduce the frequency of activation of the spark detection and extinguishing system, we use flame detectors.

The industries we protect with spark extinguishing systems

extinguishing sparks wood dust

Woodworking industry

spark detection and extinguishing installation for a sugar silo

Food industry

textile industry spark detection and extinguishing system

Textile industry

extinguishing sparks in the automotive industry

Automotive

Waste sorting and incineration plants

Waste sorting and incineration plants

Power plants and combined heat

Power and heating

Spark detection and extinguishing system for paper mills

Paper and pulp industry

Fire protection in metal processing plants

Metalworking plants

“Do you not see your industry? Check if we can help you.”

Components of the Spark Detection and Extinguishing System

Spark Detection
  1. Spark detectors – sees the full cross-section of the duct so we can halve the number of detectors.
  2. High-efficiency extinguishing nozzle to minimise the amount of water used.
  3. The signal router which manages and monitors the spark extinguishing system.
  4. 18-zone control panel monitoring the entire system as standard.
  5. A light and sound alarm which warns of the detected hazard with a sound signal and flashing light.
  6. The trip controller which stops the fans if overheated or a rain of sparks is detected.
  7. The cable to detect overheating of the fan, its bearings or the rain of sparks.
  8. Controller to supervise the operation of the water pump and heat-conducting cables.
  9. The compressor system which removes air bubbles from the fire water and delivers it at the correct pressure.

Operating principle of the Spark Detection and Extinguishing System coupled to a dust separating filter

The Spark Detection and Extinguishing System is intended to detect hot, glowing, or flaming debris entrained by air inside of the duct. The detection is to be processed in milliseconds, and the debris is to be suppressed by injection of a small volume of pressurized water to the inside of the duct. A spark sensor and a water jet nozzle are installed in the duct to enable this operation. Both units are installed in a certain calculated distance to enable the Spark Detection and Extinguishing System to respond to the fire/explosion hazard in time. A key feature is the patented design of the spark sensors which makes the System extremely effective.

Work that is safe for equipment and infrastructure

The safety of the owner’s infrastructure, machinery or individual equipment is our top priority. We are aware that in the case of a fire protection system upgrade at an active facility, any damage to the technology could have a critical impact on production continuity.

BEFORE INSTALLATION

production site before installation of the fire protection system
production site before installation of the fire protection system

We define the scope of work with the owner

Read the safety guidelines carefully

We secure the workplace before starting work

Covering machinery and equipment

DURING AND AFTER INSTALLATION

installation of fire protection in an active production site
installation of fire protection in an active production site

We take extreme caution when moving on the premises

We take care not to damage anything

Thoroughly clean the site after installation

We ensure rapid restoration of production

Why do customers choose us?

We take care of the details.


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How else does a fire system upgrade on an active plant differ from an investment in new buildings? These are, first and foremost, any requirements related to the owner’s internal procedures within the production building or the plant as a whole. Our site managers and fitters are used to meticulous safety procedures, weighing cars at the entrance and exit of the plant, the need to have all the necessary passes and regular contact with the client’s representatives, hygiene requirements especially in food production, or having a valid SANEPID (in Poland: health department) booklet also in the food industry.

Advice on how to prepare a plant for the start of work


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We realise that for you such a fire installation upgrade is also a challenge. It is highly likely that no changes have been made to fire protection since the construction of the production halls or the warehouse. Due to that we also provide advice, based on our previous implementations, on how to prepare the production facility and crew for such work. We are at your disposal at all times, so that you always have the feeling that everything is running according to schedule, with no impact on production and storage processes

We will advise you on how to prepare your plant for fire protection investments

We operate to all standards and norms.


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In our experience, the majority of investments in upgrading fire protection systems and installations start after the insurer’s audit. The requirements of an insurance company which apply to fire protection investments usually explicitly state the standards and/or norms to which the required solutions are to be designed and constructed. These could be requirements listed in the EN standard, or VdS, FM Global or NFPA standards. Whatever the requirements your insurer has outlined for you, we will meet them all.

fire safety standards and norms

Fire protection of production buildings in continuous operation – frequently asked questions

The most important thing for you to know is that this is a typical situation and our engineers often implement spark detection and extinguishing systems to meet the requirements of the various insurers and insurance brokers that operate in the Polish market. At the same time, contact us to discuss the initial assumptions made by the insurer and to discuss what such a project might look like from the supply and installation side of the systems. Don’t worry if you don’t know what to ask your insurance company – we’ll give you a hint of what’s relevant or take over the contact if you wish.

Keep calm We have experience in this type of projects. The key to success is proper coordination of our work with maintenance and production planning. Our managers and fitters are like Himalayan climbers – they wait for the ‘weather window’, i.e. permission to enter a specific zone, to carry out the work, so that they can proceed to the summit attack, i.e. the ultimate success of the project. Sometimes it happens during the day, sometimes at night. Sometimes we can work for the whole day, other times only for 2 hours on a given day. We are used to this variability and know how to plan our work with this type of specificity of carrying out the works.

Large equipment resources could be worth many millions of zlotys. It is not without reason that experience becomes crucial to maintaining safety on such projects. Once a specific work zone has been made available to us, we first secure all the machinery and equipment operating there. Our staff are sensitive to ensuring that, when moving, no activities are carried out that could lead to damage to your property. When the work is finished, we clean thoroughly and restore the work zone to its original state. However, that is not all, we and you are protected by our insurance. It is said that the man who does not do things makes no mistakes, and better safe than sorry.

Fire retrofit activities are not common. It may be that no such works had ever taken place at your site since the plant was built. Hence you may not have developed any procedures for such situations. Based on our experience from previous projects, we will advise you on what activities are worthwhile in terms of organisation to make our cooperation run smoothly.

Of course. We have carried out quite a few projects in the food industry, so we have really extensive experience in this area. We are aware of the need to maintain hygiene standards, to have valid SANEPID tests. We understand the stringent requirements that may be imposed by the owner to protect the manufactured products from contamination. We follow all the requirements defined by the owner.

Spark extinguishing systems

SCOPE OF WORK – spark detection and extinguishing system

We design and implement spark detection systems and integrate them with existing security systems, including in particular the fire protection system and explosion-proof plant. The basic scope of our work includes the following steps:

  • development of the concept and necessary designs
  • selection and delivery of key elements of the spark extinguishing system
  • development and implementation of the control system
  • integration of the spark extinguishing system with existing fire protection and explosion safety systems
  • fitting up, commissioning and service of the fire protection plants

SCOPE OF WORK – complete fire-fighting systems. In addition to spark extinguishing systems, we also design and implement complete fire and explosion protection systems. These systems integrate all or selected solutions from the list below. We also integrate our solutions with existing security systems in a given facility. Thus, we carry out tasks at different levels of complexity and at various stages of a given facility’s life.

  1.  Explosion-proof system as required by the ATEX directive
  2. Fire signalling systems (FAS, FSS) – wired and wireless
  3. Fire detection system
  4. Ventilation and smoke removal systems
  5. CCTV monitoring system
  6. Burglary and assault alarm systems (B&AAS)
  7. Sound warning system (SWS)
  8. Access control and time recording systems
  9. Emergency and evacuation lighting
  10. Fixed fire-fighting equipment

SPARK DETECTION AND EXTINGUISHING SYSTEM – description

When the detector detects a spark, it sends a signal to the control panel and activates the extinguishing process, the duration of which depends on the number of sparks detected. After detecting from 1 to 3 sparks, the control panel will activate the extinguishing process for 5 seconds. When there are 4 or more sparks, the extinguishing time will be extended to 15 seconds. In the event of system activation, light and sound signalling will be activated. Thanks to relays in the control panel it is possible to switch off the device or send a signal with sparks to any point of the plant.

Due to the high power of infra-red radiation penetration, the sensors are characterized by high sensitivity also in systems with high dustiness.

In dust systems, the extinguishing agent is usually water from the sprinkler system or hydrant system of the plant. The condition is that the minimum extinguishing water pressure is 5 bar and the delivery – 150 l/min. If this condition cannot be met, a hydrophore must be used to generate the necessary water pressure for the proper operation of the extinguishing nozzles.

To verify the current state of the system and any events, pressure and water flow sensors will be used which also have the function to control the pump operation and check whether the extinguishing process runs properly.

It should be added that the system is programmed in such a way that in case of sparks the extinguishing process is automatically activated without interrupting the production process.

SYSTEM WYKRYWANIA I GASZENIA ISKIER – elementy układu

  • highly sensitive optical-electronic spark detectors,
  • control cabinet,
  • automatic fire extinguishing units,
  • water pressure boosting kit

SPARK DETECTION AND EXTINGUISHING SYSTEM – application

  • dust extraction, drying and storage installations
  • wood industry plants
  • textile industry plants
  • food processing plants
  • chemical industry plants

Fire protection systems – offer

Fire protection systems – offer

Sprinkler
systems

They are an automatic fire extinguishing system that detects the onset of a fire, sends information to the control system, and automatically starts the selective water extinguishing process – only where there is a fire.

Fire protection systems – offer

Deluge
systems

They are equipped with open fire sprinklers and can be divided into several extinguishing zones. When a fire is detected, the appropriate valves for a given area are opened. Water is released throughout the protected area.

Fire protection systems – offer

Foam
systems

We use them especially for high fire risk facilities, such as: fuel tanks, solvents, and other flammable liquids; warehouses of plastics; flammable products and/or those creating explosive atmospheres.

Strobe light sirens EX ATEX

Fire detection
and signaling

We design and implement complete fire detection and signaling systems. Depending on the needs, we use one of the four available systems or a hybrid of two or three of them, optimizing the investment in terms of technical and cost aspects.

Fire protection systems – offer

Spark detection
and extinguishing

These systems are designed for installation on industrial installation channels. Their task is to prevent a potential ignition source in the form of a spark, cigarette butt, or heated particle from reaching the device.

Secure your industrial plant

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DONAT CZAPSKI - I am at your disposal

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