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Soundproofing for Manufacturing Facilities

What are the challenges for sound insulation in industrial buildings and facilities?

Sound insulation in industrial buildings and factories has two main goals: to reduce noise for employees in the facility and soundproofing for the outside.
This should prevent noise from becoming a problem for neighbors and residents.

Noise in Manufacturing Processes

Soundproofing for large manufacturing factories and facilities is a challenging task mostly because there are several noisy types of equipment that usually run at the same time within the complex:

  • Vibrating panels
  • Fans
  • Air-flow
  • Impact processes
  • Engines
  • Processors
  • Other manufacturing equipment

The large number and variety of equipment within the plant force plant operators to face unique challenges when trying to find a comprehensive solution for noise mitigation.

This combination of different noise sources can contribute to the overall noise levels. But it is not only the numerous sound sources in the facility that influence the selection of the right sound insulation elements but also the structural features of the environment in which the source takes place. For example, Sound-reflecting surfaces, e.g. concrete, stone, or metal, along with high ceilings and wide rooms, can cause strong reverberation and long reverberation times.

Sound Insulation for Manufacturing

How the noise is controlled is dependent on the source. For instance, external noise caused by HVAC units or process pumps is assessed and treated differently to internal noise sources such as plant machinery.

There are several possibilities for soundproofing in manufacturing facilities. Noise can be dampened, for example, by using soundproofing solutions on individual machines and devices such as acoustic enclosures or different types of silencers.

Because of the variety of contributing noise sources in this kind of facility, there is no one-size-fits-all solution. Due to the complexity of the acoustical challenges this sector face, a tailored solution is required to ensure the deployment of effective noise control systems.

Following an initial consultation path with a leading industrial and environmental noise control manufacturer, is the quickest and most effective way to solve complex noise mitigation challenges.

Stopson Italiana has worked internationally with plant processing engineers and their consulting teams to provide accurate and cost-efficient, site-wide noise assessments and mitigation solutions of industrial sectors such as petrochemical complexes both large and small.

 

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Stopson Italiana solutions for Manufacturing plants

 

Stopson Italiana provides a complete solution to help our customers control manufacturing complex’s noise concerns. Innovative engineering and design solutions deal with practical challenges when implementing our soundproofing systems.

Working on-site with HSE, Operation, and Plant Managers, we believe that effective noise control is a cooperative process between Stopson Italiana and our clients. From initial assessment and noise sources identification to the final result, we provide tailor-made noise control solutions that fulfill the needs of our customers and their industries.

Our offer includes:

  • SILENCERS
    Absorptive for cold and hot gases, reactive for engines or small boilers exhaust, combined absorptive and reactive for venting systems. Circular or rectangular shape, atmospheric or pressurized for any gas, temperature range, and applications, providing sound attenuation up to 70 dB and reduce residual noise to a sustainable level. → KNOW MORE

 

  • BARRIERS & ENCLOSURES
    Shaped around noisy equipment, indoor or outdoor, on-base or off-base, designed to provide optimum noise attenuation in any critical environment. Made of modular acoustic panels and linings for sound isolation while ensuring equipment maintenance, ventilation, weather protection, and fire safety. → KNOW MORE

 

⟶ For More Information about Stopson Italiana soundproofing solutions click HERE 

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Noise reduction in Petrochemical plants

Tackling Noise Containment in Petrochemical facilities: Concept, Principle and Challenges

Oil and gas infrastructure, from extraction, to refining and processing, to pipeline transmission and distribution make use of some of the largest, most powerful, and noisy equipment within the whole industrial sector.

Processes such as hydro-cracking, distillation, liquefaction, and regasification involve large scale compressors, furnaces, gas-turbines, fan-cooled heat exchangers, and large-scale evaporative cooling systems are well known to be noisy.

Acoustical challenges in petrochemical processes

Petrochemical plants face complex acoustical engineering challenges. Petrochemical processes operate largely outdoors, these operations, which include pumps, compressors, blowers, agitators, and coolers, run out in the open, with limited barriers in place to restrict equipment noise from going beyond the confines of the plant.

These plants, as we said, include large numbers of industrial tools and often moving high volumes of air or gas while operating at really high pressures and temperatures. All these combined means that such areas can be exceptionally noisy. Moreover, the large number and variety of equipment within the plant force plant operators to face unique challenges when trying to find a comprehensive solution for noise mitigation.

With noise control and environmental legislation becoming more stringent and the employee health and safety that stay at the forefront of all processing practices, ensuring that noise is effectively mitigated has become a key concern for process plant operators across the petrochemical and chemical processing sector.

Solutions

Plant operators across the industry should be considering that soundproofing installations are not the same twice, careful consideration must be given to each system’s function, permitted noise levels, and much more to determine the most effective noise control solution for the application. As a result, when it comes to specifying what is the perfect noise mitigation product for on-site equipment in such environments, there is no one-size-fits-all solution and several factors must be analyzed.

Noise control measures for such industrial plant items can be particularly complex to design from an acoustic perspective, given a large number of noise sources. Besides, any housings or anything else that is fitted around the equipment can present significant challenges for the ventilation of the analyzed equipment.

Following an initial consultation path with a leading industrial and environmental noise control manufacturer, is the quickest and most effective way to solve complex noise mitigation challenges.

Stopson Italiana has worked internationally with plant processing engineers and their consulting teams to provide accurate and cost-efficient, site-wide noise assessments and mitigation solutions of industrial sectors such as petrochemical complexes both large and small.

 

 CONTACT US!






 

 

Stopson Italiana solutions for Petrochemical plants

 

Stopson Italiana approach focuses on providing an optimal acoustic response, which satisfies functional requirements with the best price/performance ratio.

Our offer includes:

  • SILENCERS
    Absorptive for cold and hot gases, reactive for engines or small boilers exhaust, combined absorptive and reactive for venting systems. Circular or rectangular shape, atmospheric or pressurized for any gas, temperature range, and applications, providing sound attenuation up to 70 dB and reduce residual noise to a sustainable level. → KNOW MORE

 

  • BARRIERS & ENCLOSURES
    Shaped around noisy equipment, indoor or outdoor, on-base or off-base, designed to provide optimum noise attenuation in any critical environment. Made of modular acoustic panels and linings for sound isolation while ensuring equipment maintenance, ventilation, weather protection, and fire safety. → KNOW MORE

 

⟶ For More Information about Stopson Italiana soundproofing solutions click HERE 

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Noise containment in Cogeneration plants

Despite its efficiency and environmental advantages, CHP still has its issues, most notably the excessive noise levels it can produce.

The benefits of cogeneration are well known, with these systems typically cutting costs by around 20% compared to the other existing solutions. CHP can also significantly reduce emissions cost-effectively due to the possibility to be applied to existing energy equipment. Such benefits, combined with the short ROI they can bring, have seen a rise in cogeneration installations.

Due to the increasing spread of CHP plants, noise mitigation has been a key point to meet regulatory and environmental noise requirements.

What are the noise sources?

There are a few components within and connected to the CHP system that can cause noise:

  • Engine
  • Boiler
  • Exhaust system
  • Ventilation systems
  • Fans or radiators
  • Vibration from equipment

A responsible supplier will look at all the various elements in the system to identify the noise source and therefore mitigate that noise. Your supplier should have options for noise attenuation across the system that can adapt to specific equipment needs. Health and safety compliance is paramount as workers need to be in a safe environment that operates to the safest noise levels.
Assigning the entire CHP plant (or at least the main equipment) noise abatement study to a single provider will facilitate a one-stop-shop solution for either the vendor and the operator with the aim of a total peace-of-mind targeted approach.

Noise reduction in CHP systems

When specifying the right noise control products and installations methods for CHP, detailed consideration of the specific system’s functions, location and permitted noise levels, as well as other pertinent factors, is required.

CHP systems should always be paired with some kind of acoustic enclosure which provides total protection against noise by isolating the source. It is important to be aware that the enclosure allows access for maintenance of the CHP unit, which will not compromise any noise mitigation.

Engine

Different engines have different noise profiles and designs so noise reduction must be balanced to that. Your Soundproofing partner should advise you with the noise reduction systems best designed to mitigate either the in-duct and the break-out noise to the targeted residual level at the desired measurement point.

Boiler

Industrial plants, where boilers are used, need an effective degree of soundproofing.
Continuous and intermittent Vents to the atmosphere have to be silenced to the desired residual SPL, but sometimes due to their big dimension and the high Sound Power Level, the boiler structure itself has to be sound-proofed.

Exhaust

Similar consideration must be done for the exhaust system that should be implemented with a separate silencer located in the proximity of the flue. These exhaust silencers must meet the system requirements, without creating an excessive pressure drop as this can affect the CHP performance and efficiency.

Ventilation systems

Noise from the ventilation systems should be reduced by the use of a Silencer. Solutions as Ventilation & Duct Silencers reduce the generator In-duct noise and should be designed specifically for the application and to meet the customer needs.

Fan or Radiators (Auxiliary equipment)

For other equipment such as fans or radiators, often located near the CHP, the soundproofing solution need to be selected appropriately for the target noise rating required.

 

Stopson Italiana solutions for CHP

With an increasing demand for CHP systems across many sectors, stringent noise legislation, together with a general non-acceptance of environmental noise from industrial facilities, the implementation of soundproofing solutions is now a necessity for companies looking to significantly reduce their noise output.

However, as every plant installation is unique, there is no one-size-fits-all solution. Due to the need for detailed analysis, complex custom design, the variability of possible solutions and the regulatory requirements the necessity of a certified and experienced soundproofing supplier has emerged.

Stopson Italiana approach focuses on providing an optimal acoustic response, which satisfies functional requirements with the best price/performance ratio.

 

  • VENT SILENCERS
    Circular or rectangular shape, atmospheric or pressurized for any gas, temperature range, 
and applications, providing sound attenuation up to 70 dB and reduce residual noise to a sustainable level. → KNOW MORE

 

  • EXHAUST SILENCERS
    Conceived for engine exhaust these silencers are designed to be used on diesel and gas engines and, in certain cases, on industrial low/middle power gas turbines. Developed in our research Lab and tested on numerous industrial applications, our exhaust silencers are based on absorption and/or resonance sound wave attenuation principle. → KNOW MORE

 

  • VENTILATION & DUCT SILENCERS
    Ventilation and Duct Silencers, both of rectangular or cylindrical shape, have been designed to reduce noise level through the duct generated by any sound source, such as fans, conditioning units, etc. Low/high flow rates and available pressure drops can be achieved, depending on the type of source. → KNOW MORE

 

  • BARRIERS & ENCLOSURES
    Shaped around noisy equipment, indoor or outdoor, on-base or off-base, designed to provide optimum noise attenuation in any critical environment. Made of modular acoustic panels and linings for sound isolation while ensuring equipment maintenance, ventilation, weather protection, and fire safety. → KNOW MORE

 

⟶ For More Information about Stopson Italiana soundproofing solutions click HERE 

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Can noise affect workers’ productivity and accuracy?

Loud noise levels in the offshore oil industry torment workers with hearing damage and tinnitus.

Many workplaces have noise levels that are too loud for the human ear. In the long term, a loud working environment can consequently be damaging to your hearing health, therefore it affects workers’ productivity and accuracy.

Offshore oil rigs and platforms are examples of such noisy workplaces. In 2001, more than 800 workers in Norway reported hearing damage or tinnitus as a result of their line of work.

A study from 2009-2011 by PSA, the Petroleum Safety Authority of Norway, shows that 37% of workers in offshore oil productions are affected by damage to their hearing.

The importance of prevention

The National Association of Hearing Impaired in Norway, HLF, underlines the importance of hearing damage prevention and suggests lowering the noise level through usage of acoustic enclosures and silencers.

Organizations need to carefully think about the design of their workplace and how to manage noise levels. The negative effects of noise on employees can have financial impacts comparable with the positive impact of investing in acoustic improvements. Therefore, it makes good business sense to invest.

The impact of noise on performance

The British Journal of Psychology published a study that asked workers to perform two tasks, firstly tested without noise and then with a recording of general noise. The test with noise showed a decrease in the accuracy of their work by almost 67%. This test was made introducing noise at levels there are very low compared to offshore plants’ noise, it’s logic to predict that this percentage would increase when speaking of high-noise environments such as power generation plant or offshore platform.

Noise is very stressful and it can leave workers physically and mentally shaken. Prolonged exposure to loud noises can trigger physiologic stress responses in our bodies, including high blood pressure and an increased heart rate.

Studies show that workers are almost 65% less productive in a noisy work environment than employees who work in much quieter workplaces.

Moreover, HLF underlines that a person with reduced hearing is more likely to become physically exhausted at the end of a workday.

Acoustic solutions to mitigate noise

Stopson Italiana has been present for decades in the world market of soundproofing as one of the leading producers of acoustic enclosure, control cabins, and silencers.

Soundproofing solutions reduce noise pollution due to various sources and efficiently respond to any client’s needs.

  • SILENCERS
    Absorptive for cold and hot gases, reactive for engines or small boilers exhaust, combined absorptive and reactive for venting systems. Circular or rectangular shape, atmospheric or pressurized for any gas, temperature range, and applications, providing sound attenuation up to 70 dB and reduce residual noise to a sustainable level.
  • BARRIERS & ENCLOSURES
    Shaped around noisy equipment, indoor or outdoor, on-base or off-base, designed to provide optimum noise attenuation in any critical environment. Made of modular acoustic panels and linings for sound isolation while ensuring equipment maintenance, ventilation, weather protection, and fire safety.

On-Site tests to make facilities/plants compliant

Together with its soundproofing products, Stopson Italiana provides on-site services making sure to fulfill the customer needs and meet the highest quality standards.

⟶ For More Information about Stopson Italiana soundproofing solutions click HERE