BS 7

Spark Detection and Extinguishment Systems

Offer Safety for Your Production

G ®
Spark Detection/Extinguishment Systems Safety for Your Production

Spark detection and extinguishment systems detect and Within the framework of its special technology and its
automatically extinguish sparks. The risk of dust fires and distinct design, the GreCon system was developed to
explosions can thus be reduced. detect and extinguish these ignition sources in pneumatic
exhaust systems before they reach filters and silos and
Dust fires and explosions often occur in filters, silos and cause a fire or explosion in these areas!
dryers. They endanger human lives, cause severe property
damage and interrupt production operations. The reason
can be sparks or burning embers caused when working
with or drying combustible material and reaching plant
areas at risk through the pneumatic and mechanical con-
veying systems.

Protection of Dust Filters and Silos

Spark sensors are flush-mounted on the walls of the

exhaust ducts to detect the infrared radiation emitted by
sparks in the transport air stream.

Immediately upon spark detection, a water mist spray is

released into the duct and the sparks are extinguished.
The extinguishing device consists of a special high-speed
solenoid valve with one or more spray nozzles. These are
flush-mounted to the duct wall about 4 to 6 meters (12 to
18 feet) downstream of the sensors, depending on the
conveying velocity.

Extinguishment is accomplished with water at high flow

pressure. Special extinguishing nozzles spray a water mist,
which covers the entire cross section of the duct. With a
properly planned installation, the ignition sources enter
the water mist and are effectively extinguished. The valve
closes after a preset and adjustable time frame, normally
5 seconds.

The GreCon system effectively detects and extinguishes

ignition sources without machinery shut-down or inter-
ruption of the production process. The amount of water
released is sufficient to extinguish the sparks, but generally
does not adversely affect the filter media.

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Protection of Dryers Protection of Milling Equipment

Sparks and burning embers can occur any time combus- With high speed milling equipment, heavy showers of
tible materials are dried. Sources of spark danger can be sparks may be generated, when metal or stones enter
uncontrolled machinery shut-down, overdried material the mill, or, when mechanical parts are damaged. GreCon
within the dryer or overheated material build-up in the sensors detect these showers of sparks and activate the
ducting. Overheated glowing particles leave the dryer, extinguishing devices.
come in contact with oxygen in the air, and may cause a
fire or explosion. All plant areas connected by the pneu- The GreCon system counts each spark as it is detected.
matic conveyor system and even the dryer itself can be The system can be pre-programmed to extinguish indi-
affected. Because temperatures in this area exceed the vidual sparks without interrupting production and addition-
operating temperature of standard sensors, sensors with ally shut down machinery upon counting a preset number
fibre optic cables are utilised. or shower of sparks. This feature protects machinery from
further damage due to mechanical failure or foreign mate-
GreCon sensors can detect sparks in pneumatic transport rial in the mill.
ducts of dryers or in discharge chutes and mechanical
conveyors.

Upon detection of sparks, pre-programmed counter-

measures are automatically triggered; i.e., release of
extinguishing spray, closing or aborting pneumatic pipes,
or, in extremely critical cases, shut-down of and deluging
the dryer or filters.

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Spark Detection

Spark Detection
Preferably in Dark Areas

Preferable location for a GreCon Spark Detection and

Extinguishment System is within a pneumatic conveying
duct or other areas where ambient light is not present.
This ensures the high sensitivity of the sensors, so that
the detection of ignition sources can be optimised even in
dense material flow. The optics of the sensors are normally
kept clean by the air and material flow which makes the
system easier to maintain.

Spark Detection
in High Temperature Areas

Sensors with fibre optic cables are used where process-

ing or drying temperatures exceed 65° C (149° F). Three
separate stainless steel covered glass fibre cables transmit
the infrared radiation to the sensor, with each cable ending
on a separate photo optic diode. Solid glass adapters are
added to the cable end for extremely high temperatures.
Detection reliability is achieved by using three detection
elements per sensor. The fibre optic cables are available
in different lengths for different duct diameters.

Sensor with fibre optic cables

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Spark Detection
under Daylight Conditions

GreCon can detect sparks on conveyor belts, production

lines, or at transfer points between conveyor systems. A
special sensor is used where ambient light is present.

Interference-Free Installation

Sensors and spray nozzles are flush-mounted in the duct

Mounted Mounted
walls and do not obstruct the material flow. spark sensor extinguishing nozzle

1 Extinguishing nozzle* · 2 Spark sensor* · 3 Daylight spark sensor* · 4 Glass fibre spark sensor*
* with mounting adpater

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Spark Extinguishment

Water Extinguishment

A fine water mist spray emerges from the extinguishing

nozzles and is used for extinguishment. They are made
of high-quality stainless steel, which increases the resist-
ance to wear. After extinguishment, the shutter cone
of the nozzle automatically seals it and keeps it free of
contamination.

Pressure Increasing Units

If the available water flow pressure is inadequate, a pres-

sure increasing unit is installed to create the required water
Shut-Down
pressure. If the water flow rate to the pressure increasing
of Material Flow
pump is too low, or, if the unit is connected to a drinking
water supply, a storage tank must also be installed.
Different traps, valves and gates are available to interrupt
or divert the hazardous material flow. They can counteract
Anti-Freeze Protection the risk of transmission of ignition sources to endangered
plant areas.

Heat tape and insulating material can be used to protect

water pipes and extinguishing devices from freezing in
areas exposed to frost. We offer special insulating bags
for the extinguishing devices.

1 2

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 Electrically Air purge
monitored extinguishing device adapters

Additional Measures
against Heavy Dirt Accumulation

If dirt accumulation or other build-up on the sensor optics

is expected, special air purge adapters increase the detec-
tion reliability. Cleaning intervals are thus extended.

3 4 5

1 Fire Trap · 2 Shut-off gate · 3 Diversion gate

4 Pressure increasing unit with 5 storage tank and pressure vessel

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GreCon Control Console

The control console is the core of a spark extinguishing

system. It records, analyses and stores all events. In case
of alarms or trouble messages, suitable counter-measures
can be automatically initiated. Robust, dust-proof hous-
ings make the use in industrial conditions possible. The
operation and connection elements are ergonomically
arranged and allow quick and precise system operation.
Thanks to maintenance-free batteries, uninterrupted pro-
tection is ensured.

Ease of Operation

Personnel can easily operate the system. Comfortable user

guidance is done via a full-graphic LC display. Up to four
operation languages are pre-installed via the firmware and
can be changed at any time.

Self-Monitoring

An automatic system testing function checks sensors and

extinguishing valves at regular intervals. This substantially
reduces manual checks by operating personnel.

Remote operation panel

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Alarm Concepts

A variable alarm concept allows for adequate response

to individual events, i.e., extinguishment of a single spark
and automatic deviation of the material flow or shut-down
of machinery during abnormal spark activity.

Repeated spark detection within short intervals can give a

clue to a faulty production process. To be notified of this
condition or to avoid long extinguishments, an additional
alarm can be activated or the individual production proc-
ess can be shut down automatically.

Recording of Events

The GreCon console stores up to 2,500 events, which

can be shown in a full-graphic LC display at any time. All
recorded events can be transferred to a PC for detailed
analysis and evaluation under Windows to determine
potentially hazardous areas or malfunctioning processes
or equipment.

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GreCon Control Console

Central Visualisation on a PC Modular Design

Events recorded by several consoles, which are installed The control console consists of modular components so
in different areas of the plant, can be stored on an OPC that there is no size limit. The capacity of the console can
server. Using a standard visualisation system, an overview be adapted to the required application.
of the current condition is ensured at any time. If a suitable
visualisation system is not available on site, GreCon can Extensions are possible at any later time, also by adding
offer project-specific visualisation. further housings.

A further advantage is the possibility to install several

consoles locally and operate them via a remote operation
Evaluation of Events panel centrally, in a control station, for example.
and Defence against Danger

The GreCon console displays and records information from

each individual occurrence of sparks; i.e., time of occur-
rence, exact number of sparks, duration of the event, and
location of the spark occurrence. Chronological record-
ing of alarms is accomplished for each monitoring zone
exactly to the millisecond. Alarms in connected zones can
be evaluated in chronological order according to cause,
propagation and effect.

Protection against Damage

Caused by Water

The GreCon system automatically monitors the extinguish-

ing assemblies and immediately triggers an alarm in case
of no water flow or water system leakage, considerably
reducing the risk of water damage.

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 3

1·2·3 Control consoles with different capacities

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Maintenance

High-quality materials with very long wear resistance are

used for all components that come in contact with the
material flow. This greatly reduces the wear of sensor
optics and extinguishing nozzles.

Rapid connections and a modular design make the

replacement of components easy. The stand-by batteries
of the console are maintenance-free.

Experimental station - permanent development

After-Sales Service and Maintenance State-of-the-Art Technology

The GreCon after-sales service is available at any time. GreCon Spark Detection and Extinguishment Systems
Complete training and instruction of the operating per- are fully warranted and are approved by Factory Mutual
sonnel is part of this service. During the maintenance of (FM) and the German Association of Property Insurers
the system, which is usually carried out once or twice a (VdS). These institutions require stringent manufacturing
year, technical improvements or software updates can be standards and technical reliability. These standards also
implemented. The GreCon after-sales service can give apply to planning and after-sales service.
online support via a remote control function.
GreCon has their own experimental station to test new
applications. GreCon spark detection and extinguishment
components can be generally installed in ex zones 20, 21
and 22 in consideration of the valid ex regulations.

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Extraction system with spark detectors Mounted spark detector

Anti-freeze protection of extinguishing devices with insulating bags

Application Recommendations References

A GreCon Spark Detection and Extinguishment System GreCon protects more than 100 different industries with
can easily be installed in existing production plants. How- over 100.000 applications of the GreCon Spark Detection
ever, it is advantageous to take the installation of a spark and Extinguishment System worldwide. Reliable after-
detection and extinguishment system into account when sales service is available 24 hours a day to assist you and
planning a new plant. ensure your plant’s safety.

The mounting of sensors and nozzles is very easy. Stand-

ard non-shielded wiring may be used for the electrical
installation. The installation of the extinguishing system is
made with standard water pipes.

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Applications

Application Example
Particleboard Industry

Fine dust Supply of

chips

Cyclone
Dryer Combustion chamber

Bucket wheel

Screen sifter

Air separator

Silo surface layer Silo core layer

Mill
Scale

Glue blending
Filter

Forming station Press Trimming saws Sander

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Application Example
Furniture Industry

Filter

Application Example
Mills

Application Example
Metal Recycling

Filter

Spark Detector
Smoke Detector
Shredder Cyclone Thermo Detector
Extinguishing Device

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G

Fagus Factory, constructed by Walter Gropius in 1911

Subject to technical and country-specific modifications. | © 2005 GreCon | EN »ENGLISH« | 01.2005 | M. Reiss

GreCon
P.O.BOX 1243
D-31042 ALFELD/HANNOVER
GERMANY

TEL.: +49 (0) 5181-790

FAX: +49 (0) 5181-79229
EMAIL: [email protected]
WEB: www.grecon.de