Spark Detection Installation Checklist

A practical, field-ready checklist for placing spark detectors and extinguishing nozzles in ductwork and conveying lines, so ignition sources get stopped before they reach a dust collector or filter.

What this page is

This is the installation and commissioning checklist that prevents the most common spark detection failures, bad placement, missing water details, poor access, and no plan for testing and service.

For product overview, see: Spark Detection and Spark Detection Systems.

Real-world use case

A hot ember rides the airstream from a saw, grinder, pelletizer, dryer, or transfer point, then lands in a dust collector where fuel is concentrated. Spark detection is the early interception layer.

The goal is simple, detect early, extinguish reliably, and prove it works during commissioning.

Spark detection sensor in industrial ductwork
Detector placement matters.
Proper orientation, access, and line-of-sight are common failure points when systems are installed late or without a duct survey.
Spark detector mounted on ducting near a process line
Designed for harsh environments.
Install details decide whether detection stays dependable under vibration, dust loading, washdowns, and normal process upsets.

Quick Checklist, What Fails Most Often

If you only check five things, check these.

  1. Detector location is selected from a duct survey, not guessed from drawings.
  2. Extinguishing nozzles and detector spacing follow manufacturer requirements for your duct size and velocity.
  3. Water supply has verified pressure, flow, filtration, freeze protection, and drainage plan.
  4. Controls are wired, supervised, and tied into the right shutdown actions.
  5. Commissioning includes a documented functional test and a service plan that keeps optics clean and valves reliable.

Step 1, Do a Duct Survey Before You Place Anything

Spark detection works best when it is treated like a system, not a sensor purchase. The duct survey is where you prevent rework and missed hazards.

Survey checklist

  • Duct diameters, materials, and access points
  • Air velocity range and direction, including startup and upset conditions
  • Branch lines, merges, bends, transitions, and long straight runs
  • Ignition source locations, saws, grinders, dryers, cyclones, transfer points
  • Distance from ignition sources to collector or filter receiver
  • Ambient light sources or windows that could affect optical sensors
  • Vibration hot spots and areas with dust buildup
  • Washdown zones, chemicals, temperature swings, and condensation risk
  • Water supply location, routing, and ability to drain after discharge
  • Cold weather exposure, freeze protection and heat tracing needs

Map what you are protecting

Spark detection typically protects the path into high fuel concentration equipment such as dust collectors and filter receivers.

If your facility also has combustible dust explosion hazards, spark detection is a prevention layer, not a replacement for explosion protection.

Start with the system view: Industrial Explosion Protection and Dust Hazard Analysis (DHA).

Step 2, Detector Placement That Holds Up in the Real Plant

Detector placement is where projects either become reliable or become noisy. The goal is clean line-of-sight detection with access for inspection and cleaning.

Placement rules that prevent headaches

  • Choose locations with stable flow, avoid turbulent zones near sharp transitions when possible.
  • Protect before the collector, place detection upstream of dust collectors, baghouses, and filter receivers where ignition sources commonly travel.
  • Plan access, if the optics cannot be inspected and cleaned, the system will degrade.
  • Avoid false triggers, manage bright ambient light sources and reflections at the sensor location.
  • Follow tested constraints, spacing, duct diameter, and mounting orientation must match manufacturer requirements for your geometry.
  • Confirm power and supervision, reliable signaling and fault indication prevents silent failure.

Step 3, Nozzles and Water Details That Actually Work

Extinguishing is only as good as the water delivery. Many systems are installed with vague water assumptions, then fail a functional test or create unintended mess and downtime.

Water supply checklist

  • Verified water pressure and flow at the system connection, not assumed.
  • Filtration and strainer plan that prevents nozzle clogging.
  • Freeze protection plan for exposed piping and valves.
  • Drainage and cleanup plan after discharge, including floor and equipment impacts.
  • Water quality concerns if the system is in food or sensitive manufacturing areas.

Nozzle planning checklist

  • Nozzle type and spray pattern are matched to duct size and velocity.
  • Nozzle location provides full coverage of the duct cross section during discharge.
  • Discharge duration and valve response meet the performance intent.
  • Mounting is accessible and protected from impact and vibration.
  • Install spacing and distances match manufacturer requirements for your geometry.

Step 4, Controls and Interlocks That Prevent Repeat Events

Detection and extinguishing can stop a spark, but you still need the right plant response. Interlocks reduce the chance that the same ignition source repeats five minutes later.

Common, high value interlocks

  • Fan shutdown or airflow control logic when the system activates.
  • Process stop signals to upstream equipment that may be generating the ignition source.
  • Alarm annunciation at the plant HMI or control panel.
  • Fault supervision so blocked optics, valve faults, and power issues are not hidden.
  • Event logging so you can identify patterns and root cause, not just reset and hope.

Step 5, Commissioning and Proof, What Done Looks Like

A system is not complete when it is installed. It is complete when it is tested, documented, and maintainable.

Commissioning checklist

  1. Verify each detector location matches the duct survey and the final as-built layout.
  2. Confirm wiring, supervision, alarms, and fault indication are functional.
  3. Prove water valve operation, pressure, and flow at the discharge point.
  4. Confirm nozzle direction, coverage, and physical security.
  5. Test interlocks and shutdown actions with operations present.
  6. Document final settings, device IDs, and maintenance access notes.

Acceptance documentation

  • As-built detector and nozzle locations, with photos.
  • Water supply verification record, pressure and flow confirmation.
  • Interlock and alarm verification results.
  • Operator quick reference, how to respond to an activation.
  • Service schedule, who cleans optics, who tests valves, what spares are required.

Step 6, Maintenance and False Alarm Prevention

Spark detection lives in dirty ductwork, vibration, and changing process conditions. If maintenance is vague, reliability will be vague.

Service checklist

  • Regular optic inspection and cleaning, with a documented interval based on dust loading.
  • Verify detector alignment and mounting integrity after maintenance or vibration events.
  • Confirm water valve operation and strainer condition, especially after long idle periods.
  • Review activation logs to locate repeated ignition sources and correct the upstream cause.
  • Keep a reset and response procedure that operations can execute safely.

Quote Request Checklist, Send This and Move Faster

If you want accurate scope, correct placement, and fewer design loops, provide these details up front.

  • Process description: ignition source equipment, operating schedule, and typical upsets.
  • Duct map: diameters, lengths, branches, bends, and access points.
  • Airflow: velocity range and normal direction of flow.
  • Collector details: make, model, location, indoor or outdoor, and return air conditions if applicable.
  • Utilities: available water pressure and routing, electrical supply, control interface needs.
  • Constraints: washdown, sanitation, cold exposure, access restrictions, downtime windows.
  • Goals: fire prevention priority, insurance requirements, and any prior ignition events.

Frequently Asked Questions

Does spark detection replace explosion protection?

No. Spark detection is an ignition source control layer. If combustible dust explosion hazards exist, you still need the engineered explosion protection strategy for vessels and interconnections.

Where is spark detection most commonly used?

Most commonly in ductwork and pneumatic conveying lines feeding dust collectors, baghouses, and filter receivers, especially where upstream processes can generate hot embers.

Why do some systems create false alarms?

False triggers often come from poor placement, ambient light interference, dirty optics, and vibration issues. A duct survey and a maintenance plan usually fix the root causes.

What is the fastest way to get a correct design?

Start with a duct survey and a hazard discussion, then align detector placement, water delivery, interlocks, and commissioning testing as one engineered scope.

Next Step, Get a Layout Review From SSI

Stop ignition sources before they reach high fuel concentration equipment.

SSI can review your duct layout, identify high risk ignition paths, and recommend a spark detection and extinguishing design that is installable, testable, and serviceable.

Request a consultation or call 1-800-360-0687 .