Can your plant switch to safety mode on its own? If not, it’s time for a change – learn about fail-safe systems.
In industrial plants, where the presence of flammable gases, dust, and vapors is an everyday occurrence, a spark that is invisible at first glance can cost millions—or human lives. That is why more and more companies are turning to fail-safe systems that do not wait for a failure to occur, but react before the threat develops. In this article, we show how these solutions work, what benefits they bring, where they work well, and what to look for when implementing them. If you care about real safety, ATEX compliance, and operational efficiency, this is a must-read.
Fail-safe from scratch – how does a system that switches to safety mode before a spark appears work?
The principle of fail-safe systems in explosion-hazardous environments is one of those things that sounds simple – but in practice saves lives and millions in investments. It is thanks to the fact that the system itself can “predict” a potential threat and immediately switch to a safe state that the continuity of operation can be maintained without endangering people and infrastructure. When an irregularity is detected, such as a change in the current characteristics of a circuit, the power supply is automatically cut off before a spark can occur. This happens literally in microseconds. And the sooner the ignition of an explosive atmosphere can be prevented, the greater the chance of avoiding tragedy.
In practice, the entire system is based on continuous monitoring. Current, voltage, changes in their values – all of this is analyzed in real time. If the system detects an anomaly, it reacts instantly and, independently of the operator, switches to safe mode. This means that you do not need an immediate human response, which is crucial in industrial conditions where fractions of a second count. Fail-safe is not just a system that responds to failure – it is a way of thinking about safety design. It assumes that failures will happen. The question is: are your installations ready for them?
From intrinsically safe to DART – which type of fail-safe system is right for your installation?
The type of fail-safe system you choose has a real impact on the level of safety, but also on the convenience of everyday work. The most basic and still extremely effective form of protection are intrinsically safe systems, marked as Ex i. There are three levels – Ex ia, Ex ib, and Ex ic, where the first one ensures safety even in the event of two simultaneous failures. Sounds solid? Because it is – and that is why they are used in the most demanding hazard zones – 0 and 20.
Provide your company with a risk assessment that genuinely improves security.
But that’s not all. If you need higher power in your circuit without compromising on intrinsic safety, take a look at DART technology – Dynamic Arc Recognition and Termination. This solution enables energy transfer of up to 50W while maintaining all fail-safe properties. How does it work? The system recognizes characteristic changes in di/dt current and cuts off the power supply before an electric arc occurs. Not a second later – microseconds. It is this precision that makes DART a technological breakthrough today.
In addition to electrical systems, there are also mechanical slam-shut valves that automatically block the flow of gas when the pressure exceeds the safe range. In addition, there are active explosion suppression systems (HRD), which introduce a suppressant into the system in a few milliseconds before the explosion pressure reaches a critical level. There is a wide range to choose from, but the decision should depend on the specifics of the plant, the type of explosive atmosphere, and the required power output.
It is worth remembering that fail-safe is not only good practice, but also a response to specific legal requirements. If you want to know what regulations and standards define the obligations of an investor or employer, take a look at the practical guide to regulations on explosion risk assessment on our blog.
Not just technology – what do you really gain from fail-safe systems? (people, equipment, ATEX compliance)
In all the discussion about fail-safe systems, it is easy to forget that behind every standard, sensor, and circuit there are people. Employees who work in potentially explosive atmospheres every day have the right to expect that the plant will ensure their safety. And it is in this context that fail-safe is more than just technology – it is real protection for health and life. A system that works preventively, eliminates ignition sources and does not require human intervention ensures that even in the event of a failure, a disaster will not occur.
The protection of property and infrastructure should also be considered. According to NFPA data from 2017, property damage alone from explosions in industrial plants amounted to $1 billion. This does not include reputational damage, downtime costs, or legal consequences. Fail-safe is an investment that can protect against the dramatic consequences of unforeseen events while meeting formal requirements, including the obligations under the ATEX 137 directive. It is worth emphasizing that these are not recommendations – they are a legal obligation, and failure to comply with them may result in serious sanctions.
So if you are wondering what you gain by investing in this type of system, the answer is: everything you cannot afford to lose. People, equipment, reputation, and peace of mind that you have done everything possible to eliminate the risk of an explosion.
Safer and… cheaper? Discover the economic benefits and SIL levels that make a difference.
You may be surprised how often safety goes hand in hand with cost optimization. Fail-safe systems, although requiring investment at first glance, very quickly begin to pay for themselves – and not only in the form of avoided disasters. Reduced insurance premiums, no production downtime, and savings on consulting costs – all of this adds up to real numbers. For example, companies using ready-made ATEX guidelines and templates save up to tens of thousands of euros per year.
When it comes to standardization, the topic of Safety Integrity Level (SIL) arises. This is not just a dry classification—it is a level of confidence in how often a system can fail. For example:
- SIL 1: the acceptable risk of failure is between 10⁻⁵ and 10⁻⁴ per hour,
- SIL 3: up to 10⁻⁷ – 10⁻⁶ per hour.
A high SIL level guarantees that the system will always work when needed. And it’s not just about certificates – it’s about real operational safety in conditions where there is no margin for error. Importantly, DART technology allows SIL levels to be achieved even at higher power outputs, which was unthinkable until recently.
Is fail-safe worth it? See which industries and applications offer the fastest return on investment.
Not all industries face the same level of explosion risk – but there are sectors where the use of fail-safe is not only standard, but a necessity. The oil and gas industry, with its offshore installations and refineries, is the highest risk environment, where a single spark can mean dozens of casualties and an environmental disaster. But fail-safe is not only used there.
The chemical and pharmaceutical industries, where flammable gases, vapors, and dusts are handled, also require fail-safe solutions – often compliant with both ATEX and GMP. Equally important are food processing plants, where dust explosions – e.g., grain explosions – are one of the most common types of explosions in Europe. Suffice it to say that in silos and mills, even a minor irregularity can lead to an explosion of enormous force.
When it comes to costs, prices for basic components start at $1,000 for an explosion-proof camera, but that’s just the starting point. Installation and maintenance costs depend on the complexity of the system, but it is worth remembering that a well-designed system allows for longer periods between inspections and less staff involvement. This means fewer human errors and greater peace of mind.
Before choosing the right safety measures, it is important to understand what exactly can lead to an explosion—and under what conditions. Therefore, if you want to better understand the technical aspects of the risk, we recommend two complementary articles: one on gas explosion limits, the other on minimum ignition energy (MIE) – both are excellent additions to the topic of fail-safe.
What’s next for fail-safe? Trends that will revolutionize explosion protection in the coming years
The explosion protection market is currently undergoing a very dynamic change. There is increasing talk not only of responding to threats, but also of predicting them. This is where the Internet of Things (IoT), artificial intelligence, and automation come in. Intelligent sensors that analyze data from multiple sources and signal risks before a failure occurs are no longer a vision of the future—they are the direction in which the industry is developing.
DART technology is gaining further levels of standardization, including as part of the new IEC 60079-39 standard, which means that manufacturers will be able to implement it even more widely in their products. This is good news for you – the wider the availability of proven and certified solutions, the easier it is to implement them in your plant. You no longer have to choose between power and safety.
In turn, automation combined with fail-safe systems means smoother technological processes, better system integration, and less risk of human error. The future of explosion protection will not be based solely on reactions, but on predictions. And that means one thing: if you are planning to modernize your plant, it is worth considering now how fail-safe technologies fit into the Industry 4.0 strategy.
