This paper discusses a recent dust explosion event within a powder storage hopper protected by an explosion‐suppression system. In this case the system, although activated, failed to prevent overpressurization of the hopper, which failed catastrophically. The suppressant diffuser had been improperly installed and the error was undetected, in spite of numerous system inspections. This case demonstrates some significant weaknesses that can be associated with complex protection systems. Lessons learned included explosion‐suppression systems are not infallible; explosion‐suppression systems must be correctly installed and inspected at installation; and explosion‐suppressant diffusers should be periodically removed and inspected as part of a routine inspection program. © 2005 American Institute of Chemical Engineers Process Saf Prog, 2005