When designing an active noise cancellation hearing protector, it is relatively easy to implement a laboratory prototype with high performance. However, when the device is taken out of the laboratory into real extremely noisy situations, it must be capable of producing very high sound pressure levels. In this paper, the factors, which limit the low frequency performance and dynamic range are analysed. The results show that the voltage swing of the loudspeaker amplifier and the force factor of the loudspeaker are two important limiting factors in extremely loud situations. A prototype of an active noise cancellation hearing protector was implemented and its performance was measured in an authentic noisy situation. The developed device attenuated 125 Hz tonal noise by 18 dB. The active noise cancellation system attenuated noise even at a sound pressure level of 118 dB SPL. This can be considered sufficient for most situations.