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Top 10 Noise Control Solutions
Noise Management Best Practice
noise
Industrial Noise and Vibration Centre: www.invc.co.uk
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Noise Control Instead of Ineffective PPE…
PPE does not work well in the real world HSE research proving that hearing protection is not effective across most industrial applications provides a gold plated opportunity for the legal profession to drive a coach and horses through hearing damage claim defences based on PPE use.
Minimising Hearing Damage Risk Consequently, as real-world PPE performance is so compromised, the best way to guarantee low levels of risk at low cost is to reduce noise levels as far as practical.
How to Recommend Self-financing Noise Control The Noise Control Audit Process A guide that demonstrates how occupational health and other professionals can add value to noise risk assessments by linking to best practice in engineering noise control to reduce the risks of hearing damage dramatically.
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The “You must control Noise at Work Regulations”
HSE Quotes
• Health surveillance can be regarded as a tax on the failure to control risk…
• The most important thing about the risk assessment is that it identifies, in an Action Plan, what needs to be done to protect employees from noise.
• Employers would be expected to use the information and Action Plan produced by the risk assessment to set about managing noise risks…
HSE: “…if solutions have been identified “stop assessing and start controlling…..”
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The “You must control Noise at Work Regulations”
• Hearing protection cannot be used for long term risk management unless it can be proved that noise control is impractical
• Companies should not repeat risk assessments that do not include useful and practical information on noise control
• Companies should carry out a Noise Control Audit assess the noise control options using the best of current technology generate cost v noise reduction trade-offs for each item of noisy plant plan the most practical and cost effective noise control programme
HSE “…these regulations are concerned with controlling noise, not measuring it ..."
Paraphrasing HSE research: “most noise assessments aren’t worth the paper they are written on…”
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“Get a quote…”
• “We have a noise problem. Get a few quotes from silencer and
enclosure manufacturers”. Unfortunately, variations on this theme are common in meetings across the land…
• The audit process itself involves treating machines as collections of noise sources and not as monolithic "noisy black boxes". In each case, the potential noise sources for each item of plant are listed and their relative contributions ranked. Unless this has been done, the choice of potential noise control measures is based on guesswork.
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The Measurement Industry…
An assessment every 2 years is not a regulatory requirement
biannually review noise assessment requirements
Over-reliance on dosimetry
Badly written, heavily padded reports
no Action Plan
nothing on noise control
simplistic attitude to PPE
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The objective is to implement "Best Practice" for each of these elements.
1. Define company policy and procedures - documentation
2. Training/education: managers, supervisors, operators, staff
3. Assessments: surveys by competent person
4. Hearing Protection: implement effective Hearing Conservation programme
5. Noise Control: implement programme to reduce noise where practical
6. Buying Policy: control noise from new plant
7. Audiometry: pre-employment, motivational
8. Audit Programme: monitor effectiveness of elements and enforce policy
Training (at all levels), customised documentation and engineering support are all available from the INVC.
Noise Management Programme Elements
…and competent reporting. Most Noise Assessment Reports are not of merchantable quality….
?
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Real World PPE
Noise Management Best Practice
noise
Industrial Noise and Vibration Centre www.invc.co.uk/noise/noise-assessment/occupational-noise-assessment/
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80-85
Hearing protection advised. Implement education. Protectors must be available.
85-95
Hearing protection mandatory. Most protectors from reputable suppliers provide adequate protection.
95-105
Only high quality protectors, carefully used, can provide sufficient protection.
105+
Protection cannot be guaranteed without very stringent controls and checks.
dB(A) Requirements
In an imperfect real-world the actual performance of PPE may be very low (wear-rate being the most crucial factor)
Conservation v Noise Level
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Protector Rating (ref BS EN 458 : 2004)
Effective Noise Level dB(A) (Mean - 1 SD)
Protector Rating
Over 85 Insufficient
> 80 to 85 Acceptable
>75 to 80 Good
70 to 75 Acceptable
Below 70 Overprotection*
* The wearer may feel isolated, miss warnings, etc
Hearing Conservation Programme
Calculator for sufficient theoretical PPE performance @ www.hse.gov.uk/noise
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PPE in the Real World – HSE Research
Issuing PPE is not a simple or reliable solution...
No Protection • 40% of PPE users got no protection whatsoever • real world performance of a substantial proportion of the remaining 60% was inadequate • even in companies with generally effective PPE use, 14% did not wear them when and where required
Factors • peer group pressure / group behaviour; reluctance to enforce • need to hear traffic, radios - communication problems • attitude - imposition without consultation • incorrect fitting (plugs); inadequate protector provision • use of PPE as the sole control measure without a comprehensive noise control programme HSE Research Report RR720: INVC summary: www.invc.co.uk/profile/resources/technical-notes/#hseppe
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PPE – Real World Performance
In real use the performance of hearing protection is dramatically less than predicted by the manufacturers data. To estimate the performance of hearing protectors, the HSE recommendation to allow for imperfect fitting and condition has been to apply a field correction factor of 4dB - but...
Muffs – additional losses in performance… • 6dB loss after 1 month of use (headband stretch) • 2 - 10dB due to glasses, goggles, dust masks • 14 - 21dB worn over clothing (hoods etc)
Plugs • >50% of compressed foam plugs not inserted correctly • attenuation as low as 9dB if not properly fitted • banded ear-canal caps - negligible protection under band pressure
HSE Research Report RR720: INVC summary: www.invc.co.uk/profile/resources/technical-notes/#hseppe
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PPE – Performance v Wear Rate
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Measurement Errors
Noise Management Best Practice
noise
Industrial Noise and Vibration Centre www.invc.co.uk/noise/noise-assessment/occupational-noise-assessment/
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Dosemeter Practicalities
Dosemeter readings are nearly always higher than hand-held SLM readings due to body reflections, speech, impacts – and human nature… Where there is a difference between dosemeter values and SLM values, the dosemeter is always wrong by definition. The risk statistics were all compiled using SLMs.
Beware high peak levels as mechanical impacts can simulate events. If in doubt, measure peak levels separately with a hand-held meter or compare with other dosemeter results.
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Dosemeter Practicalities
Dosemeter assessments are very time consuming and do not provide you with vital operational information required for risk evaluation (activities, events, potential improvements etc).
They can, however, generate a lot of data, providing you with a host of pretty graphs to pad out a report!
In many circumstances, SLM assessments are much quicker and provide higher quality assessments.
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Reporting
Noise Management Best Practice
noise
Industrial Noise and Vibration Centre
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Check Box Mentality
Health and Safety meeting on noise: order an assessment every year or two…
This tells you what you already know – that you still have a problem…
This is easier than actually doing something to minimise the risks.
Paraphrasing HSE research: “most noise assessments aren’t worth the paper they are written on…”
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Placebo Assessments
Ask yourself …
• Why do we repeat risk assessments?
• Why do we repeat risk assessments assessments?
• Are we inflicting PPE on the workforce unnecessarily?
• Can we eliminate PPE and audiometry?
• Can we automate future assessments?
• Can we guarantee no future hearing damage claims – ever?
• Have we quantified the costs and benefits of noise control?
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Factory assessment by consultants. This much report - the rest is a library of octave bands, dose logs and other padding.
No Action Plan, no noise control options - and no-one has ever read it! Imagine trying to extract useful information in 5 years time to defend a hearing damage claim ....
"Write only" Noise Assessments…
2002 HSE figures 63% of noise assessments were deemed "inadequate" i.e. a reassessment would be required to bring them up to the necessary standard
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• Working document for manager(s) • Short and as simple as possible - loose the techno-babble and
interminable pages of overly detailed results! • Content - Conclusions and Action Plan summary - Brief review of risk areas/plant by Action Value - Noise Control Audit results costs, benefits and options for best practice noise control
- Short term recommended actions PPE zones; signs; training; noise control ....
- Longer term recommendations noise control; Buy Quiet; management practices .....
- Factory plan summary and tables of results mobile plant: use a database table
- Technical appendices
Assessment Report Evaluation
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• Audit the noise control options (options, costs, benefits and priorities) and evaluate existing noise control measures
• Short term: PPE zones and signs; types and availability of PPE; employee training requirements…
• Longer Term: noise control programme; Buy Quiet policy; company procedures / responsibilities; health surveillance
Assessment Reports: Action Plan
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Noise Management - Best Practice
Effective Assessment DNA and Corporate Amnesia
noise
Industrial Noise and Vibration Centre
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Digital Noise Assessment “best practice” report based on 25 years of reporting refinements to create the industry benchmark template.
• customisable template Word document covering all the regulatory requirements
Action Plan summary • editable managers’ Action Plan summary to track implementation of
risk management recommendations
Technical Notes • up-to-date technical notes: regulations, PPE, dose calculation, health
surveillance, Buy Quiet policy, noise control, training
Example Report • pdf report example including factory plan or tabular (mobile plant)
noise levels
DNA Report Template
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Digital Noise Assessment (DNA)
Use assessment data to create a register of noisy plant on each site
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84 84 83 8282
8888
(84 not tumbling)(84 not tumbling)
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90 tipping84 otherwise
alarm99max
denotes fixed operator position
8484
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12-hour shift report
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Assessment Data Storage: Mobile Plant
The best way to store mobile plant noise data is in a database including:-
• plant details • operating conditions (tooling etc) • operator noise level (worst ear) • working time for Action Levels • "safe" distance for PPE
This information can also be stored in a common database with associated HAV data.
Stickers can be printed for each item of plant which include the "safe" working distance i.e. PPE mandatory within X metres.
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Mobile Tools - Noise (and HAV) Database
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Risk Number Analysis - RNA
80dB(A) - 84.9dB(A): risk rating (RR) is 1. Above 85dB(A), risk proportional to energy, i.e. every 3dB increase, the RR increases by x2. Risk Number (RN) = RR x no. staff
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Risk Number Analysis – RNA Report
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Industrial Noise and Vibration Centre: www.invc.co.uk/noise/noise-control/occupational-noise-control/
Noise Management - Best Practice
Noise Control Audit Process
noise
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Placebo Silencers
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The Noise Control Audit
The audit is available as an add-on to conventional risk assessments. Objectives
• generate cost v noise reduction trade-offs for each item of noisy plant
• assess the noise control options across the company using the best
of current technology
• plan the most practical and cost effective noise control programme
possible across the company
The results of the Audit also take into account factors such as:-
• hygiene: access / maintenance
• productivity
Where the audit proves that control is impractical, it also provides certification so that PPE can be used for long term risk control.
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Site Audits: Noise Control Project Benefits
Cadbury conservatively estimate that the noise control programme will pay for itself within 7 years......
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Self-Financing Noise Control
One company had spent £1,600,000 on acoustic enclosures.The Noise Control Audit and subsequent testing proved that using BPM would have saved over £1,000,000 and noise levels would have been substantially lower and operating costs would be significantly reduced (down-time).
doubled through-put
higher efficiency, no cleaning
cleaning down-time reduced
avoided being shut-down...
no enclosures, reduced down-time
0 20 40 60 80 100
vibrators
fans
weighing
burners
presses
Pay-back Period
4 weeks
1 year
3 years
1 minute...
2 years
Noise control costs - £000's conventional best practice
Noise source category
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Chocolate enrober vibrator • Re-design eliminated fatigue cracking;
improved control of coating thickness – 10% chocolate savings…
Vibratory Feeders • Food: noise control project doubled
throughput and eliminated blockage issues
• Pharma plastics: 27dB(A) reduction plus elimination of fatigue cracking and blockages
Moulding Vibrators • Chocolate weight s.d. across moulds
reduced from 1.2gms to 0.2gms/sweet
Productivity Improvements and Cost Savings
wash line <85, lower cost, improved drying
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BPM Noise Control Audit Steps
• List all the potential noise sources on each piece of noisy plant
• Rank the sources
• Assess all the noise control options for the dominant source potential reduction in noise from this source operational, productivity, hygiene constraints operator acceptance cost
• If engineering control is not practical for the dominant source, then you have proved that screening / enclosure etc are the only options
The results are used to generate cost v noise reduction trade-offs for each item of noisy plant and to plan the most practical and cost effective noise control programme possible across the company.
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Useful Noise Generation Categorisation
Aerodynamic • fans • flow induced • pneumatics
- nozzles - exhausts
• combustion
Mechanical • impacts
- presses, stops etc - mechanical handling
• rotating machines - gears, pumps, motors - bearings - electrical forces
• friction forces - cutting tools, brakes
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Addition of Multiple Sources
Unless the dominant source is treated first, the overall noise reduction will be very disappointing
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Source Ranking Techniques
• Listen
• Run each source separately - may require manipulation of
interlocks etc
• Cover all sources and then uncover each in turn • Use narrow band frequency analysis for tonal noise and
correlate with mechanical components (gear-mesh, speed, blade pass etc) – free phone apps…
• Measure each source close in and predict contribution (close-microphone + 10log(area))
• Measure surface vibration velocity and calculate contribution
easy
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Source Isolation Techniques
• Run each source separately - may require manipulation of interlocks etc
• Cover all sources and then uncover each in turn
Power press – aerodynamic source https://youtu.be/OzoktrFxT5w
Power press – mechanical sources https://youtu.be/UQ3YBExzWiw
Production line sources https://youtu.be/3vkZcT42YCQ
More diagnostic videos on the INVC Youtube Channel at:- https://www.youtube.com/user/INVCLimited
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Vibratory Grader Diagnosis
MOTIVATION Client using the "Buy Quiet" standard.
• noise tests carried out during proving trials (in-house)
• new machine ordered subject to implementation of INVC noise control recommendations
• noise reduced from 99dB(A) down to 85dB(A) at £4k (£250k machine) without affecting hygiene, access or maintenance
If designed-in instead of retro-fit, £1k cost + £25k saved on supplier enclosure…
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Source Identification – Frequency Analysis
How else could you diagnose and rank the sources?
Narrow band frequency analysis - correlate tones with mechanical components (gear-mesh, speed, blade pass etc) – free phone apps…
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115T Bliss Press
Noise tones match flywheel vibration. Dynamic vibration absorbers designed and fitted to flywheel inside existing guards.
• 10dB(A) noise reduction • £20 materials; 1 day fitter time
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Press Noise Control Audit
102dB(A) total – down to 87dB(A) 1: tooling modifications – 97dB(A); 2: clutch – 95dB(A); 3: fan – 92dB(A); 4: cyclone 90dB(A); 5: out-feed 87dB(A)
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Quiet Tape
• quiet tape uses stronger glue - generating more tension • may have to adjust machines to use the new tape
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Innovative Noise Control Materials
We are at the forefront in developing applications for new and innovative hygienic noise control materials. The two materials that have had most impact on our work are:-
• High hygiene acoustic absorbent existing guarding and enclosures room acoustics (walls and ceilings)
• Laminated steel – sound deadened steel sheet looks like stainless steel, sounds like rubber…
These materials have provided us with two additions to our armoury in developing the next generation of hygienic noise control techniques.
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Top 10 Noise Control Solutions
Noise Management Best Practice
noise
Industrial Noise and Vibration Centre: www.invc.co.uk
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Top 10 Noise Control Solutions
Vibration Control 1 Vibration damping 2 Vibration isolation pads
Fans 3 Fan installation / efficiency 4 Aerodynamic noise control – Quiet Fan technology
Pneumatics 5 Pneumatic exhausts 6 Pneumatic nozzles
Machines 7 Chains and timing belts 8 Electric motors 9 Hydraulic power packs
Existing machine guards 10 Convert to acoustically effective guards
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1 - Damping Thin Plates
unconstrained layer of damping material
damping material in sandwich construction
sheet metal
damping material
damping material deforms only near bends
damping material made to shear over whole area
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Panel Vibration Reduction
damped
undamped
Total 8dB(A) noise reduction under chiller (damping + absorbent)
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Weighing Machine Enclosures
• 94dB(A) with enclosure • 82dB(A) with enclosure removed • PPE unnecessary; improved
productivity, cleaning, access, maintenance ...
Problem • typically 87- 98B(A) - high hygiene
Conventionally: Enclosure • Enclosures – c 5dB(A) reduction usually increases operator noise
level by c 3dB(A) under platform! c£8000+ capital + access / hygiene / maintenance problems
BPM - engineering control • engineering source modifications • 10 - 12dB(A) at <<50% of the cost • x4 performance + no effect on
access or hygiene • maintenance and cleaning
simplified
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Power Station – 600hp Water Pumps
• New water pumps generated 95 dB(A) – the subject of a dispute with the supplier re the agreed noise levels – my pump, your motor….
• Dispute based on expense of noise control measures (acoustic barriers and partial enclosures) and considerable issues re access.
• Detailed vibration analysis proved the required noise reduction could be achieved simply via constrained layer damping plus laminated close shields.
• Installed to provide a 12dB(A) noise reduction with no effect on access, operation or maintenance – and at a fraction of the cost of the dispute process.
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2 - Vibration Isolation
Tico pad
load-spreading steel washer
m/c foot
Tico pad
bolt bolt NO ISOLATION EFFECTIVE
ISOLATION
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Verso Press – Isolating Base
Problem High speed strip fed press at 101dB(A) in a quiet area
Conventional Manufacturer supplied "acoustic guards" gave only 3dB(A) reduction. Full enclosure suggested.
BPM Noise Control Audit showed dominant source to be fabricated press legs. Tico isolation fitted between frame and legs tuned to give natural frequency of 65Hz for both legs (different loads) 9dB(A) noise reduction at closest operator position. £45 materials, 1 man day to fit
isolation pads
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Fan System Noise Control Options
Aerodynamic Noise Control at Source • award winning Quiet Fan technology
• cf F1 / aerospace CFD - design retro-fit aerodynamic aids
• reduce noise and increase efficiency
• improves efficiency by c 20% over many conventional silencers
• self financing, green, highly profitable…
Only if the above is not practical should you consider… • Silencing
• Enclosures
• Lagging
• Barriers
• Building modifications
Conventionally, these high cost palliative techniques have been the only measures that are considered….
www.invc.com/noise/noise-control/fan-noise-reduction/#qft
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Centrifugal Fan Installation
high pressure
low pressure NOISY
QUIET
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Axial Fan Installations
NOISY QUIETER
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Axial Fan Installations
>2-3 duct diameters
NOISY QUIETER
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Fan: Outlet dampers
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Efficiency: Fan Speed v Noise
10% 2 20% 5 30% 8 40% 11 50% 15
noise reduction dB speed reduction
• Variable speed drives • Two speed motors (day and night) • Proportional control systems
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4 - Aerodynamic Fan Noise Control
modified fan
Problem Occupational + environmental tonal noise
Conventional • silencers, lagging and enclosures • capital cost > c£35000 +
maintenance costs
Aerodynamic Noise Control • internal fan modification reduced
tones by 23dB and overall noise by 22dB(A) using Quiet fan technology
• cost c £3000 - no maintenance costs (lasts the lifetime of the fans despite passage of cans)
www.invc.co.uk/noise/noise-control/fan-noise-reduction/
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Yoghurt-Based Noise Control - Boiler Burner
16dB tonal noise reduction
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5 / 6 - Pneumatic Silencers and Nozzles
Silencer Solutions • zero back-pressure
silencers • standardise on 3
sizes • fix piped silencers to
machine and manifold multiple exhausts
Entraining Nozzles • c10dB quieter for the
same thrust • use c 20% less air • pay for themselves very
quickly • intrinsically "safe" • reduce air pressure....
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Problem • 94dB(A) from cooling pipes for
sealed tube ends - rapid cooling a necessity
Conventional Solution • enclosure - high cost with hygiene
and productivity issues
BPM Solution • Coanda effect linear nozzles 12dB(A) noise reduction (82dB(A)) improved performance (less
turbulence disturbing tubes) 20% less air consumption - pay for
themselves very quickly no effect on access or operation
Filler Cooling Pipes
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Air-Lances: Reduce Noise and Energy
15dB quieter, compressed air savings, payback 1 week
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7 - Chains and Timing Belts
• replace noisy chains with belts
• use quiet tooth profiles on toothed belts
• chevron tooth pattern – ultra quiet
• replace wide toothed belts with a par of narrower belts
• toothed belt noise is very sensitive to belt tension
5 – 20dB noise reductions are possible
Timing belt drives
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8 - Motor Noise
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9 - Hydraulic Power Packs
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Hydraulic Power Pack
Looking at the diagnostic procedure for this power pack:-
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10 - Existing Guards
Minimise gaps • Halving the open area will reduce the
noise radiated by 3dB • Reduce opening by 90% - 10dB noise
reduction
Acoustic Absorbent • Fitting an appreciable area of acoustic
absorbent inside the guards will reduce the noise within by 5dB or more…
Guard Vibration • Radiated as noise – use damping…
Test mock-ups
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Effect of Leaks on Transmission Loss
% open
0.1
1
10
50
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Common Enclosure Problems
Enclosure issues https://youtu.be/2T4XBxyOIB4
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Industrial Noise and Vibration Centre: www.invc.co.uk
Noise Management - Best Practice
Buy Quiet
Purchasing Policy
noise
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Buy Quiet Noise Control
Probably the single most cost effective long term noise control measure that a company can take. BUT - attitude.... Do not allow your suppliers to spend your money on noise control without close scrutiny and written evidence that they have followed diagnostic best practice. Also applies to post installation retro-fit when you didn’t have a policy…
Most suppliers do not have technical expertise in engineering noise control and usually buy-in proprietary materials, enclosures, silencers etc as palliatives with no guarantee that they constitute Best Practicable Means with current technology.
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Buy Quiet BPM Standards
Require that your suppliers meet specific and measurable standards re noise
• defined target noise levels • defined measurement procedure - lay down the measurement
procedure, operating conditions etc in detail
Results format • define the format of the results (use a standard form)
BPM diagnostic procedure
• insist that they follow the BPM procedure when considering noise control - they must be able to supply you with a ranked list of sources with noise control options - c.f. Quality and testing standards for suppliers
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Remote Control of Noise
video sound photos
email -internet
Specialised modelling and analysis
database
experience
@ efficient aerodynamic solutions
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Remote Control of Noise
BP Refinery: $1.25m conventional silencers: $0.25m via engineering – no impact on efficiency, no site visit
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Noise Control Best Practice Elements
• Attitude
• Noise Control Audit based on detailed diagnosis and costing of the options and benefits
using the best of current technology
• Develop detailed noise control recommendations for each category of occupational plant implement as retro-fit on the first of each type of machine / plant
• Implement Noise Control Programme based on the results of the audit
• Update Noise Assessment de-regulate areas; reduced PPE costs ...
• Buy Quiet purchasing policy This approach can produce noise control measures that actually improve productivity and reduce costs - in contrast to reliance on conventional enclosures and acoustic guarding.
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Noise Control Instead of Ineffective PPE…
PPE does not work well in the real world HSE research proving that hearing protection is not effective across most industrial applications provides a gold plated opportunity for the legal profession to drive a coach and horses through hearing damage claim defences based on PPE use.
Minimising Hearing Damage Risk Consequently, as real-world PPE performance is so compromised, the best way to guarantee low levels of risk at low cost is to reduce noise levels as far as practical.
How to Recommend Self-financing Noise Control The Noise Control Audit Process A guide that demonstrates how occupational health and other professionals can add value to noise risk assessments by linking to best practice in engineering noise control to reduce the risks of hearing damage dramatically.
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Questions
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Contact us for copies of:- Top 10 Noise Control Solutions Guide
Digital Noise Assessment (DNA) template
Peter Wilson: +44 1753 698800 [email protected]
Top 10 Noise Control Solutions
Industrial Noise and Vibration Centre: www.invc.co.uk