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Noise control best practice and Best Available Technology (BAT)

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Examples of Self-Financing Noise Control projects across a wide range of plant categories and industries that illustrate the cost savings inherent in engineering noise control measures at source compared with conventional palliatives such as acoustic enclosures, silencers, lagging etc. In many cases, noise control modifications are installed as an extension to maintenance and can be justified simply on the grounds of increased performance, efficiency and productivity, with the noise reduction as an additional benefit. Typical noise control savings of 50-80% with no maintenance or access issues, no hygiene implications, the potential to eliminate PPE / audiometry and to remove remove existing acoustic enclosures and to improve productivity

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Noise control best practice and Best Available Technology (BAT)

  1. 1. www.invc.co.ukIndustrial Noise and Vibration Centre: www.invc.co.ukNoise Control Best PracticeNoise Control Best PracticePeter Wilson MSc. MIOAPeter Wilson MSc. MIOANoise Control Best Practicenoise
  2. 2. www.invc.co.ukIndustrial Noise and Vibration Centre• Award winning noise control technology for fans £800k capital and £250k / p.a. running cost savings for Corus• The major provider of engineering noise control case studies to the HSE the largest database of engineering source control examples available• Developers of current “BAT” noise control - food and drink, pharmaceutical and electronics industries…• Buy Quiet Policy de-facto UK standard noise purchasing policy• Presentations and Training Noise regs. Launch - HSE UK road-shows; developed and run IOSH andBOHS competency courses; Plastics Federation; Hygiene industries…• Noise Training for English, Scottish, Irish Environment Agencies
  3. 3. www.invc.co.ukThe “You must control Noise at Work Regulations”“… these regulations are concerned with controlling noise, not measuring it ..."• Hearing protection cannot be used for long term risk management unless itcan be proved that noise control is impractical• Companies should not repeat risk assessments that do not include usefuland 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
  4. 4. www.invc.co.ukNoise Control Programme Best Practice• Noise Control Audit engineering evaluation of the noise control options (costs / benefits) –both occupational and environmental• Develop detailed noise control recommendations for each category ofoccupational plant implement as retro-fit on the first of each type of machine / plant• Develop noise management programme – as required – forenvironmental noise• Buy Quiet – Occupational and Environmental Policies• TrainingMore information and case studieswww.invc.co.uk www.hse.gov.uk/noise
  5. 5. www.invc.co.ukIndustrial Noise and Vibration Centre: www.invc.co.ukNoise Management - Best PracticeEffective AssessmentEffective AssessmentDNA and Corporate AmnesiaDNA and Corporate Amnesianoise
  6. 6. www.invc.co.ukDigital Noise Assessment (DNA)Use assessment data to create a register of noisy plant on each site86838383 848486838281828184 84 83 82828888(84 not tumbling)(84 not tumbling)868483838081838383838482888890 tipping84 otherwisealarm99maxdenotes fixed operatorposition848477757612-hour shift
  7. 7. www.invc.co.ukIndustrial Noise and Vibration Centre: www.invc.co.ukNoise Management - Best PracticeNoise Control -Noise Control -the Approachthe Approachnoise
  8. 8. www.invc.co.ukPlacebo Silencers
  9. 9. www.invc.co.ukNoise Control Best Practice Elements• Attitude• Noise Control Audit based on detailed diagnosis and costing of the options and benefitsusing the best of current technology• Implement Noise Control Programme based on the results of the audit• Update Noise Assessment de-regulate areas; reduced PPE costs ...• Buy Quiet purchasing policyThis approach can produce noise control measures that actually improveproductivity and reduce costs - in contrast to reliance on conventionalenclosures and acoustic guarding.
  10. 10. www.invc.co.ukNoise Control is ....Noise control is not a safety issue• Noise control is an engineering problem that should be solved byengineering means, in particular through noise control at source.• Effective noise control must be based on an accurate diagnosis andnot on assumptions• All the options must be considered, not just the conventional highcost palliatives of enclosures and silencers. These techniques shouldonly be used where it can be proved that there is no engineeringalternative.
  11. 11. www.invc.co.ukThe Noise Control AuditObjectives• generate cost v noise reduction trade-offs for each item of noisy plant• assess the noise control options across the company using the bestof current technology• plan the most practical and cost effective noise control programmepossible across the companyThe results of the Audit also take into account factors such as:-• hygiene: access / maintenance• productivityWhere the audit proves that control is impractical, it also providescertification so that PPE can be used for long term risk control.
  12. 12. www.invc.co.ukBPM 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, thenyou have proved that screening / enclosure etc are the only optionsThe results are used to generate cost v noise reduction trade-offs foreach item of noisy plant and to plan the most practical and cost effectivenoise control programme possible across the company.
  13. 13. www.invc.co.ukVibratory GraderMOTIVATIONClient using the "Buy Quiet" standard.• noise tests carried out duringproving trials (in-house)• new machine ordered subject toimplementation of INVC noisecontrol recommendations• noise reduced from 99dB(A) downto 85dB(A) at £4k (£250k machine)without affecting hygiene, accessor maintenanceIf designed-in instead of retro-fit, £1kcost + £25k saved on supplierenclosure…
  14. 14. www.invc.co.ukSite Audits: Noise Control Project BenefitsCadbury conservatively estimated that the noise control programmewill pay for itself within 7 years......ABCDEFGHIJTotalsSites0 20 40 60 80 100 120No. of Production Areas>85 now >85 post NC
  15. 15. www.invc.co.ukInnovative Noise Control MaterialsWe are at the forefront in developing applications for new and innovativehygienic noise control materials. The two materials that have had mostimpact on our work are:-• High hygiene acoustic absorbent existing guarding and enclosures room acoustics (walls and ceilings)• Laminated steel – sound deadened steel sheetlooks like stainless steel, sounds like rubber…These materials have provided us with two additions to our armoury indeveloping the next generation of hygienic noise control techniques.
  16. 16. www.invc.co.ukSelf-Financing Noise ControlAn oxymoron? Potential cost savings at <85dB(A) include:-• PPE only advisory: £50 - £200 per head per annum savings• no requirement for audiometry• reduced management hassles (policing etc)• improved working conditions (no PPE)• improved communications• no hearing damage claimsPlus the potential for improved efficiency / productivity.
  17. 17. www.invc.co.ukSelf-Financing Noise ControlOne company had spent £1,600,000 on acoustic enclosures.The NoiseControl Audit and subsequent testing proved that using BPM would havesaved over £1,000,000 and noise levels would have been substantiallylower and operating costs would be significantly reduced (down-time).doubled through-puthigher efficiency, no cleaningcleaning down-time reducedavoided being shut-down...no enclosures, reduceddown-time
  18. 18. www.invc.co.ukOG Centrifugal Fans: Corus…for the most significant development in noise control technology>£1 million cost saving
  19. 19. www.invc.co.ukScrap Can Extract and Chopper Fansmodified fanProblemOccupational + environmental tonalnoiseConventional• silencers, lagging and enclosures• capital cost > c£35000 +maintenance costsBPM Engineering• internal fan modification reducedtones by 23dB and overall noiseby 22dB(A)• cost c £3000 - no maintenancecosts (lasts the lifetime of the fansdespite passage of cans)
  20. 20. www.invc.co.ukProblem• 94dB(A) from cooling pipes forsealed tube ends - rapid cooling anecessityConventional Solution• enclosure - high cost with hygieneand productivity issuesBPM Solution• Coanda effect linear nozzles 12dB(A) noise reduction (82dB(A)) improved performance (lessturbulence disturbing tubes) 20% less air consumption - pay forthemselves very quickly no effect on access or operationFiller Cooling Pipes
  21. 21. www.invc.co.ukYoghurt-Based Noise Control - Boiler Burner16dB tonal noise reduction
  22. 22. www.invc.co.ukWeighing Machine Enclosures 94dB(A) with enclosure 82dB(A) with enclosure removed PPE unnecessary; improved productivity,cleaning, access, maintenance ...Problem• typically 87- 98B(A) - high hygieneConventionally: Enclosure Enclosures – c 5dB(A) reduction usually increases operator noiselevel by c 3dB(A) under platform! c£8000+ capital + access / hygiene / maintenance problemsBPM - engineering control• engineering source modifications10 - 12dB(A) at <<50% of the cost• x4 performance + no effect onaccess or hygiene• maintenance and cleaning simplified
  23. 23. www.invc.co.uk115T Bliss PressDynamic vibration absorbers designed andfitted to flywheel inside existing guards.• 10dB(A) noise reduction• £20 materials; 1 day fitter time
  24. 24. www.invc.co.ukChocolate enrober vibrator• Re-design eliminated fatigue cracking;improved control of coating thickness –10% chocolate savings…Vibratory Feeders• Food: noise control project doubledthroughput and eliminated blockageissues• Pharma plastics: 27dB(A) reductionplus elimination of fatigue cracking andblockagesMoulding Vibrators• Chocolate weight s.d. across mouldsreduced from 1.2gms to 0.2gms/sweetProductivity Improvements and Cost Savingswash line <85, lower cost,improved drying
  25. 25. www.invc.co.ukInnovative Engineering DesignPumping stationvibration problemseliminated via noveldynamic vibrationabsorbers – fitted whilstin service…Domestic/commercialboilers. Innovativegeometry andsilencer eliminatedtonal content –20dB+ reduction.Now standard for allnew designs.Crisp packet pick /placeNo absorbent(hygiene), improvedefficiency to give8dB(A) reduction.Ideal Boilers Pump vibration control
  26. 26. www.invc.co.ukQuiet Tape• quiet tape uses stronger glue - generating more tension• may have to adjust machines to use the new tape
  27. 27. www.invc.co.ukAir-Lances: Reduce Noise and Energyc15dB noise reduction + 20% less compressed air: same performance…
  28. 28. www.invc.co.ukIndustrial Noise and Vibration Centre: www.invc.co.ukNoise Management - Best PracticeBuy QuietBuy QuietPurchasing PolicyPurchasing Policynoise
  29. 29. www.invc.co.ukBuy Quiet Noise ControlProbably the single most cost effective long term noise control measurethat a company can take.BUT....Do not allow your suppliers to spend your money onnoise control without close scrutiny and evidence thatthey have followed diagnostic best practice• most suppliers do not have technical expertise in noise control andusually buy-in proprietary materials, enclosures, silencers etc andadd these to the cost - regardless of Best Practicable Means usingthe best of current technology
  30. 30. www.invc.co.ukCompair Compressor Design• Target: to remove silencer element toreduce size of unit – with no increasein noise or reduction in cooling• Source control + modest geometricchanges reduced cooling systemnoise and cut tonal content (lessnuisance)• Noise reduced by 4dB(A), despiteremoving the standard silencer.
  31. 31. www.invc.co.ukMolins Mk8 Making MachineRetro-Fit Engineering Noise Control Kit• c£500 / m/c• offered as option on site or duringoverhaul – c £2k, c 90 advanced orders• no effects on hygiene, access ormaintenance• PPE became advisoryDesign process under way for latest generation to reduce noise to<85dB(A)
  32. 32. www.invc.co.ukVibratory SievesProblemManufacturer experiencing pressure fromcustomers to reduce noise levels. For manyapplications, access and hygiene are veryimportant.Conventional ApproachCovers and enclosures: high cost (up to several£000s) plus access and hygiene problems.BPM SolutionEngineering modifications – minor designchanges plus high efficiency damping of criticalcomponents - reduced noise at source by 5dB(A).Licensed to implement the technology eitherduring build or as a retro-fit kit. No access,maintenance or hygiene implicationsCost £200 / unit.
  33. 33. www.invc.co.ukRemote Control of Noisevideosoundphotosemail-internetSpecialised analysisBPMBATCostsdatabaseexperience@@
  34. 34. www.invc.co.ukRemote Control of NoiseBP Refinery: $1.25m conventional silencers: $0.25m via engineering– no impact on efficiency, no site visit. More at www.invc.co.uk.
  35. 35. www.invc.co.ukNoise Control Programme Best Practice• Noise Control Audit engineering evaluation of the noise control options (costs / benefits) –both occupational and environmental• Develop detailed noise control recommendations for each category ofoccupational plant implement as retro-fit on the first of each type of machine / plant• Develop noise management programme – as required – forenvironmental noise• Buy Quiet – Occupational and Environmental Policies• TrainingMore information and case studieswww.invc.co.uk www.hse.gov.uk/noise
  36. 36. www.invc.co.ukIndustrial Noise and Vibration Centre: www.invc.co.ukNoise Control Best PracticeNoise Control Best PracticePeter Wilson MSc. MIOAPeter Wilson MSc. MIOANoise Control Best Practicenoise

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