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Interoffice Communication _ . ________ To Environmental File - ./ . # r *i- V" ' From V. M. Fisher Date October 31, 1983 Subject Vinyl Chloride Emissions from Light Ends Column Vapor Overhead Line Leak NON-REPORTABLE SUPERFUND & NON-REPORTABLE STATE 17.11 INCIDENT * On September 26, 1983 the Light Ends Column Vapor Overhead line developed a pinhole leak. Upon receiving a work order regarding the leak* the maintenance department immediately installed a clamp on the line temporarily stopping the leak. After many makeshift repairs, the clamp developed a pinhole leak on October 17, 1983. Attempts to stop this leak failed, and the Light Ends Column was shutdown on October 27, 1983 to install new piping to replace the leaking section. The amount of vinyl chloride leaked into the atmosphere did not represent a "reportable quantity" under the Superfund regulations and the National Response Center was therefore not notified of the release. The amount of vinyl chloride released into the atmosphere was calculated to be 0.75 lbs./day or a total of 8.25 lbs. The "reportable quantity" under the Superfund regulations is 1 lb. in a 24-hour period. The State of Louisiana Department of Natural Resources was not notified because this leak is not regulated by the State of Louisiana Air Quality Regulation 17.11 protocol since it was not an emergency occurrence, episodic or accidental event, equipment malfunction or process malfunction. Attached are the calculations used in determining the quantity of vinyl chloride released to the atmosphere. Virgin M. Fisher Process Engineer br cc: RAC-OWW-MLA-RB-DLD-SJR-MGH-ESW-JCL VVC 00001A220 ^7--' / 02- / ^ MP- /0>72TZ = (^-S3)(3S^ #, (16'7Z)(^7)(i) ~ '^S 7^1^- ^52 GO = 0. 52 5" \A <L = Y c Q. 70 cf*- a o-t-z& AP* 20 ^sA V = Z*4Z `n.3. **- a; = C. C=C^6^VW. == Pm . LA3 A^/Auysi^ ^Jtr *7q vch ' "t. f 7* ir"r,_0- %> cc;4 &>5 7* QtJcLs Za*? LT FfYb? Ov^C.^BArOs jo/ZG*/ 38 *7day O, 7S CO 21. 1058 3. 37t* ICfi.a 76ty oooo^^V Nj>jC / VVC 0000X4222 SOUND LEVEL SURVEY LAKE CHARLES VCM PLANT C FILE CH-098 OCTOBER 31, 1983 V r; vvc ooooi-'*223 (conoco) Interoffice Communication To From R. A. Conrad - Manager, Lake Charles VCM Plant W. G. Warren, Jr. - Medical Division, Ponca City, Oklahoma Date October 31, 1983 Subject SOUND LEVEL SURVEY - LAKE CHARLES VCM PLANT (FILE NO. CH098) Introduction This sound survey was performed by W. G. Warren, Jr. and P. McCombs during the week of September 19, 1983, as scheduled with Steve Ashby. The purpose of the survey was to determine the extent of noise exposures confronted by personnel, to establish current noise levels throughout the plant, and to make recommendations on noise abatement procedures for problem areas. The results of the survey are on the exhibits, charts, and table attached, and are discussed below. Current Regulations Recommendations in this report are made in accordance with OSHA 29 CFR, Part 1910.95, Occupational Noise Exposure Standard; Hearing Conservation Amendment dated March 8, 1983 (outlined in Appendix "B"), Survey Description All instruments used here, in accordance to OSHA Standards, conform to the following ANSI standards: ANSI SI.4-1983 for sound level meters; ANSI SI.25-1978 for dosimeters; and ANSI SI.11 (R1976) for octave band analyzers. Sound level meters were used to measure and to contour noise levels according to regions of constant sound pressure level in dBA. These contours were mapped for levels of 85 dBA and above, in 5 dBA increments, to determine where hazardous conditions may exist depending on exposure durations. The "A" scale designation of the decibel reading denotes a scale which is amplitude-weighted with frequency in sympathy with human hearing sensitiv ity. An octave band analyzer was used to distinguish the frequency characteristics of high noise equipment in order to identify the dominant noise sources and to suggest proper silencing devices. Sound level do simeters were used to monitor 8-hour time-weighted average (TWA) exposure levels on employees in each job area on each work shift. OSHA's recom mended action level for the implementation of a hearing conservation program is an 8-hour TWA of 85 dBA (or 50% exposure level). The employees chosen from each job area were selected as those most likely to encounter excessive noise during their work shifts. From this dosimetry information, a table was compiled listing levels of noise exposure with job descrip tion. This helps us to determine where warning signs should be posted and which employees (if any) need to be included in a hearing conservation program (those with 50% exposure or more). In some cases the noise dosage of employees is less than an 85 dBA 8-hour TWA yet exposures to noise hazard areas are still present. Dr. J. R. Drumwright should be contacted (Ext. 2794) for advice on frequency of audiomeCric exams for these employees. All other procedures listed in Conoco's Hearing Conservation Procedures Guide should be followed. See Appendix "A" for definitions of "Noise Hazard Areas" and guidelines for posting of "Warning Signs". vvc 000014224 R. A. Conrad Page 2 October 31* 1983 Results and Observations Included in this report is the overall plot plan of the VCM Plant (See Drawing CH-029-NOIS-GA-13-D). Outlined on this drawing are areas covered by detailed drawings of the process areas with corresponding drawing numbers. Also outlined are the areas where noise levels were 85 dBA or more for both the 1981 survey and this 1983 survey. Several observations can be made from this comparison: 1. The addedarea above 85 dBA west of the control room is due to the relocation of air blower BL 302 (See Drawing CH-029-NOIS-GA-15-B for details). On start-up or shutdown, when total air is being by-passed through the exhaust stacks on BL 302, this area is especially noisy. 2. The increased noise area in Blocks 1 and 2 is due to the recent VCM expansion (See Drawing CH-029-N0IS-GA-14-D). There are several sources in this area that can be looked at for noise abatement. 3. The additional 85 dBA area around the chlorine compressor building is caused by the replacement of the motor drive on cornpresssor BL-605A. The old motor mute could not be installed on the larger motor. 4. A decrease in area above85 dBA was noted around the incinerator unit. This was dueto the east incinerator being down for cleaning and repair while this survey was in progress. Dosimetry results are listed in Table 1. As can be seen in the table, no employee was overexposed to noise on the basis of an 8-hour TWA exposure limit of 90 dBA (or 100% exposure). However, one (1) of the thirty-eight (38) employees monitored exhibited an exposure level above the 0SHA action level for participation in a hearing conservation program (an 8-hour TWA of 85 dBA or 50% exposure). This exposure was to an insulator at 85.4 dBA TWA assigned to an area where noise levels ranged from 94 to 103 dBA. His length of time in this area was 45 minutes. This illustrates how maintenance personnel can easily have higher exposures depending on their area of assignment and length of time to complete the job. We can easily correct these kinds of exposures by requiring the wearing of hearing protection devices (HPD's) anytime personnel enter a "Noise Hazard Area". See Appendix "A" for definition of these areas. This, however, is not the ultimate solution to the problem. Whenever possible, every effort should be made to abate noise on all equipment whose noise output at 3 feet is 95 dBA or more. This action will reduce the chances of employee noise exposures above the action level even if they forget to wear their HPD's. vvc 000014225 R. A. Conrad Page 3 October 31, 1983 From the above results we can conclude that this plant does not have an apparent noise exposure problem. Recommendations Our noise abatement program should begin with the loudest equipment (above 95 dBA) that affect the greatest area and/or the most personnel. With this in mind, we make the following recommendations: 1. Blower BL 302 - This blower is causing a considerable area to be above 85 dBA while in normal operating mode (See Drawing CH-029-NOIS-GA-13-D). Under upset conditions, we understand the shop areas 130' away are com plaining of the noise. Upset conditions being start-up or shutdown (total air bypass). We feel the silencer on this unit may not be adequate. Replacement may be necessary. Lagging of the compressor discharge line and control valve may also be necessary. There is a small air bleed at 112 dBA that needs a discharge silencer (See Alwitco or Aeroacoustic Brochure attached). 2. Causes of the expanded 85 dBA area in Blocks 1 and 2 are several (See Drawing CH-029-N0IS-GA-14-D) for noise abatement were: (a) The exhaust system on Blower BL-301 should be lagged from the compressor up to and including the silencer. The welded support under the silencer should also be lagged. Lagging material should be Childers Muffl-lag or equal (see brochure attached). (b) Blower BL-302 appears to have a discharge piping noise problem as does the control valve to the southwest next to H-110B. Both of these problems probably could be alleviated by lagging as proposed above in (a). (c) Noise levels around Blower BL-501 are greater than 95 dBA and be reduced again by lagging of the discharge line and expansion joint overhead. (d) The line of control valves northeast of C203 are quite noisy, es pecially the control valve on the south end. The noise form these valves causes a very large area to be above 85 dBA. These valves are all insulated, but I suspect the insulation is for heat and not noise. The addition of an extra noise barrier, such as MufflJack, over the existing insulation would reduce this noise to acceptable levels. (e) Control valves above H-308 to S-303 on the third deck near Reactors R301 to R303 are causing some areas above 95 dBA and the total deck around them plus part of the deck below to be above 85 dBA. Valves and connected pipe can be lagged for reduction of noise in this area. VVC 000014226 R. A. Conrad Page 4 October 31 , 1983 3. The third area where noise levels have increased is around the Cl^ Compressor Building (108 dBA inside). (a) One source is the replacement motor on BL-605A compressor. This motor is larger than the previous motor and therefore, the motor mute for the old motor does not fit. I doubt that, in its corroded condition, the old motor mute would have done any good anyway. Future motor mutes to be installed in this corrosive atmosphere should be made of stainless steel. I also would suggest that the motor mute on BL-605B also be scrapped and replaced with a stainless steel motor mute. The corrosive condition could clog the air passage through these mutes and cause the motors to overheat. The gear box on BL^-bOSA is propagating noise of 108 dBA at three feet. Noise from this gear was abated another time by replacement of the gears. Perhaps the gears are getting bad again. I would suggest a detailed survey be made of this compressor. 4. We recommend that those items above chosen for noise abatement be referred to CED (Bill Lacey) for special noise study of equipment and recommendations for proper noise abatement methods and materials in addition to those given in this report. 5. Various air and steam bleeds throughout the plant could have small in-line silencers installed that would reduce localized noise sources considerably. Silencers made by Alwitco or equal are not expensive. If we can be of any further assistance, or if you have any questions on the above report or Conoco's Hearing Conservation Program, please feel free to Noise Control kb cc w/att: T. G. Grumbles - Houston S. R. Ashby, Safety - Lake Charles VCM Plant B. G. Lacey, CED - Ponca City Sonny Mukherjee - Ponca City File CH-098 cc: E. L. DeWhitt, Jr., Ph.D. - Ponca City J. L. Riddle, Ph.D. - Ponca City J. R. Drumwright, M.D. - Ponca City vvc 000014227 TABLE I LAKE CHARLES CHEMICAL VCM PLANT NOISE DOSIMETRY SEPTEMBER 1983 Description 8-Hr. TWA % Exp 1. Insulator 2. Boilermaker 3. Operator 2nd 4. Boilermaker 5. Pipefitter 6. Welder 7. Welder 8. Welder 9. Pipefitter 10. Welder 11. Pipefitter 12. Millwright 13. Operator 2nd 14. Millwright 15. Operator 2nd 16. Boilermaker 17. Operator 2nd 18. Operator 2nd 19. Operator 2nd 20. Millwright 21. Millwright Helper 22. Millwright Helper 23. Carpenter 24. BM/Lead Man 25. Shift Sueprvisor 26. Electrician 27. Pumper Loader 28. Instrument Man 29. Shift Supervisor 30. Incinerator Operator 31. Pumper Loader 32. Instr./Lead Man Chief Operator 34. Instrument Man 35. Safety Supervisor 36. Operator 1st (Board) 37. Operator 38. Incenerator Operator 85.4 83.5 83.5 82.4 82.3 82.2 82.2 81.3 80.6 80.3 79.9 79.9 79.6 79.4 78.8 78.7 78.7 77.8 77.7 77.2 76.9 76.2 75.5 75.4 74.7 74.2 73.8 73.2 73.1 73.1 73.0 72.4 72.1 70.3 69.4 67.2 64.2 61.4 52.9* 40.6 40.6 34.9 34.4 33.9 33.9 29.9 27.2 26.1 24.6 24.6 23.7. 23.0 21.2 20.9 20.9 18.4 17.9 17.0 16.2 14.8 13.4 13.2 12.0 11.2 10.6 9.8 9.6 9.6 9.4 8.7 8.4 6.5 5.8 4.2 2.7 1.9 ^Indicates dosage above the action level (50% exposure) for inclusion in The Corporate Hearing Conservation Program. vvc 00001*228 Conoco Medical Division Octave Band Analysis Chart No. 1 LAKE CHARLES - VCM PLANT Location Clg COMPRESSOR BUILDING Area BL-605 B_____________ Equipment Description SEPT. 22, 1983 Flat Response A' Weighted mi m m Center Frequency of Octave Bands (Hz) Location of Analyzer: 3 Feet from motor intake. Exposure (Hrs./Day) O S.H.A. = 1.7 Hrs. Comments: The motor should hove o stainless stell motor mute installed. See report for other comments. VVC 000014Z29 Conoco Medical Division Octave Band Analysis Chart No. 2 LAKE CHARLES - VCM PLANT Location Clg COMPRESSOR BUILDING Area BL- 605 B Equipment Description SEPT, 22, 1983 Date Sound Pressure Level Decibels -- RE 0.0002 Microbar Location of Analyzer: 3 Feet from north side of geor box. Exposure (Hrs./Day) O.S.H.A. = 1.3 Hrs. Comments: This unit moy hove some bod gear teeth that need replacing as was the case one other time several years ago. VVC 00001^230 Conoco Medical uivision Octave Band Analysis Chart No. __ 3 Location BLOCK 2 AREA Area BL-5QI CENTRIFUGAL Equipment Description SEPT. 22, 1983 Date COMPRESSOR Sound Pressure Level Decibels -- RE 0.0002 Microbar Location of Analyzer: 3 Feet from west side of compressor. Exposure (Hrs./Day) O.S.H.A. = 4.6 Comments: Discharge line to silencer may need to be lagged. 0oooi>231 Noise Control Materials MUFFL-JAC0 ACOUSTICAL JACKETING TESTED IN ACCORDANCE WITH ASTM E-90-70 DESCRIPTION Childers Muffl-Jac is a special composite jacketing of high quality lead laminated to Aluminum for the reduction of noise levels and protection of thermal insulation materials. It is designed to reduce the level of sound radiated by piping and equipment. Standard Childers Muffi-Jac is supplied with an outer layer of high purity Aluminum, exhibiting good resistance to most weathering and corrosive environments, and an inner layer of lead. It is manu factured in rolls, sheets, or is pre-fabricated. A 3/16" (.48 cm) corrugation is incorporated into standard Muffl-Jac; corrugated jacketing adds stiff ness and strength, reduces glare from external light sources, aliows for expansion of the jacketing, eliminating "coil break" over small size piping, and does not show dents as readily. Non-corrugated Muffl-Jac is also available for manufacture of pre fabricated Items such as flange and control valve body covers and gore elbows. For special uses, Muffl-Jac is available in a variety of metals, finishes, and with corrosion resistant film coating, as Ultrolon ADVANTAGES Muffi-Jac is applied in one operation, unlike com parable products, thereby reducing application costs. Muffl-Jac may also be fabricated into fitting covers to control noise on valves, flanges, tees, etc. The acoustical effectiveness of Muffl-Jac is superior to the separate applications of lead and Aluminum, due to the special bonding properties of the adhesive. Muffi-Jac has high transmission loss characteristics, and also serves to protect under lying sub-structures and/or thermal insulations against mechanical abuse, weather, and corrosive environments. Childers Products Company provides technical assistance in the choice, selection and applica tions of complete acoustical insulation systems for Industry. Childers Muffl-Jac has been tested by an indepen dent acoustical laboratory in accordance with ASTM designation E 90-70, standard classification for determination of sound transmission loss. Muffl-Jac has an STC-26 rating. The graphs on the reverse side illustrate sound transmission loss and insertion loss data for Muffl-Jac. USES Childers Muffl-Jac is used over mineral fiber, glass fiber, or ceramic fiber insulations. It is applied over straight runs of piping, HVAC Ducting, casings, gearboxes, and other regular surfaces. Muffl-Jac may also be used to field fabricate enclosures or as sheet stock. For irregular surfaces, such as compressors, pumps, blowers, fittings, flanges and valves, Childers also offers MUFFL-LAGTM an equally effective trowelable transmission loss compound. APPLICATION Childers Muffl-Jac is applied in a similar manner as standard insulation metai jacketing. It is applied over the insulated surface, insuring a 2" (5.08 cm) overlap exists for each circumferential and longi tudinal lap of jacketing. For vertical applications, mechanical supports should be applied to hold the insulation and Muffl-Jac in place and support the load. Muffl-Jac is then secured with strapping and wing seals. For maximum acoustical effectiveness, a separa tion should exist between the radiating surface and the Muffl-Jac. It is installed over glass fiber, mineral fiber, and ceramic fiber insulation at recommended thicknesses and densities. Like all transmission loss materials, Muffl-Jac must be sealed at all joints, laps, cutouts, and gaps with either Childers Chil-Joint (CP-70) or silicone joint sealants. vvc OOOOl'**32 "I MJE-781 Supersedes MJE-1175 Insertion Loss Results lor Typical Pipe Lagging Systems 2 5 100 2 5 1000 2 5 10000 2 Frequency in Hz (Tested m accordance with ASTM E90-70) 1) 1.3 lb/ftJ Muffl-Jac Over 2V Glass Fiber 2) 1.3 Ib/rt* Muffl-Jac Over 1 " Glass Fiber 3) 2" of 4 lb/fts Density Glass Fiber Test conducted on 3' dia. pipe Ha,e' M- E- 4 Kugler' B A V VVC 000014233 R 0. Box 22228 OTHER PLANTS AT 2061 Hartei SI Bristol. PA 19007 (21 SI 943-7600 Telex 84-3408 (23350 Mercantile Rd.) Beachwood, Ohio 44122 1370 East 40m St. Houston TX 77022 i713|691-366l Tele 77-6164 1160 Soutn Vail MonieBeilo. CA 90640 (213)728-6306 Telex 67-3639 7305 Torbram Rd Mississauga, Onl L4T 1G 0 (4161 676-1444 Telex 06-966800 (216) 464-8020 '.5727 116th Ave Edmonton. Alta T5M 3W1 i403) 452-4860 Telex 037-42697 Noise Control Materials MUFFL-LAG HIGHLY EFFICIENT TRANSMISSION LOSS COATING FOR EFFECTIVE NOISE CONTROL TESTED IN ACCORDANCE WITH ASTM E 90-70 DESCRIPTION Muffl-Lag' is a tough, durable, and flexible polymer based acoustical coating for use in conjunction with fibrous glass (minimum 4#density)or mineral fiber (minimum 8# density) and other insulations.lt maybe used over contours requiring sound attenuation. Muffl-Lag has excellent insertion loss character istics. and a Sound Transmission Class rating of STC-28. MuffIlag is waterproof, is thixotropic, is mechanical abuse resistant, and forms an air-tight seal. (1 Vi gallons or 5.677 liters supplied in a 2 gallon container, with separate containers of thickener and hardener in pre-measured quantities) USES Muffl-Lag is a superior noise control coating which was developed for use over surfaces such as piping, fans, HVAC Ducting, compressors, pumps, fittings, flanges, valves, and other large and irregular surfaces. It has found many applica tions in the Petro-Chemical, Power, Chemical Processing, Gas, and Heavy Fabrication Industries. Muffl-Lag is gray in color, harmonizing with process equipment and Childers metal jacketing. ADVANTAGES Muffl-Lag is a highly efficient noise reduction coating which provides the necessary air-tight seal required for sound control. It has a rating of STC-28 (Sound Transmission Class). Muffl-Lag contains no lead, is easy to apply by trowel or palm, has high mass, sets up quickly, and cures to a limp condition. Muffl-Lag requires no maintenance; areas damaged are easily repaired by recoating tne break with Mufll-Lag. When catalytically cured, Muffl-Lag remains permanently flexible to permit limited expansion and contraction. After curing, Muffl-Lag will withstand temperatures up to 3506F (177C) on the outer surface of the acoustical insulation, with no effect upon the coating. It is non-corrosive and impervious to most chemicals, acids, alkalis, and oils. COLOR Gray WET WEIGHT 17 ibs./U.S. gal. approx. 2.04 kg/iiter AVERAGE NON-VOLATILE 95% by volume SERVICE TEMPERATURE RANGE (Temperature to which dry coating is subjected) -10"F to 350F ~23C to 177C APPLICATION TEMPERATURE RANGE (Including wind chill factor) 20F to 100F -6'C to 38C CURING TIME To touch--60 minutes (Curing time will vary depending upon temperature, humidity, and amount of hardener used.) Operational within 24 hrs. after application. COVERAGE 11 sq. ft. per U.S. gallon .27 sq.m./liter CLEAN-UP Methylene Chloride (use with adequate ventilation) FLAME RETARDANCY UL-94, SE-0 Vertical test ('/,") FLAME SPREAD INDEX ls = 24 (ASTM E-162) Flash Point (wet) 88 "F (31 C) (Red Label) Autoignition Temperature 914 F (490 6C) APPLICATION Muffl-Lag is catalyzed by the addition of the hardener thoroughly mixed, and applied by trowel or palm over contours onto energy absorbent fibrous glass or mineral fiber insulation of specified thickness. The insulation is first secured in place and the Muffl-Lag applied to yield a finished .140" (.36 cm) film thickness after curing. Chil-Glas #5 is recommended as the reinforcing membrane and shall be embedded between an initial tack coat and the finish coat of the material during its application in the liquid state. Note: Do not attempt to use Muffl-Lag to flash over adjacent metal surfaces. Use Chil-JointTM CP-70 for flashing or sealing protrusions. Check with your Childers Sales Representative for additional information. VVC OOOOlA*3*1, See other side for specifications and application information 2 ML-781 Insertion Loss dd ey 1) 1.5 Ib/ftJ Muffl-Lag Over 2" Glass Fiber 2) 1.5 Mufti-Lag Over 1" Glass Fiber 3) 1.5" Cellulose Blanket d) i" of 4 ib/fts Density Glass Fiber Test conducted on 3" dia. pipe hale. M. E. 6. Kugler, B. A. Handling, Mixing & Application Instructions STORAGE 1. Keep the materials stored in a cool location (approximately 50 to 80F) (10C to 26C) prior to application. 2. Avoid prolonged storage. Material must be used prior to six (6) months after date of manufacture. CAUTION: High temperatures will shorten the shelf life of this product. Do not store in direct sunlight. MATERIALS & MIXING EQUIPMENT 1. 1 Vi gallons (5.677 I) of Muffl-Lag in 2 gallon container 2. 2 oz. (.059 I) squeeze bottle of thickener 3. 2 oz. (.059 I) squeeze bottle of hardener (part 2) 4. An air-operated paint type mixer with a 12" long shaft is rec ommended. Caution: Electric mixers are not recommended. MIXING INSTRUCTIONS To mix the totai contents (percentages also apply) 1. Add a sufficient portion of the thickener squeeze bottle for desired viscosity to the contents of the bucket and blend in. Mix thoroughly for 1-2 minutes. Do not use more than 1 bottle of thickener per container ot Muffl-Lag, as cure may be affected. 2. Add the contents of the hardener squeeze bottle to the mixed Muffl-Lag and thickener and blend in. When ambient tempera tures are above 90F (32 C) add only one half the contents of the hardener squeeze bottle to extend the pot life. Mix thor oughly for 1-2 minutes. NOTES: 1. Unnecessary mixing beyond two minutes only reduces the time available for application prior to cure. 2. Part 2 (the hardener) should be handled with care. If contact with skin or eyes occurs, flush with water, and seek medical attention. 3. Be certain to wipe cling on side walls and base of container into mixture. APPLICATION INSTRUCTIONS The contents of the container in which the Muffl-Lag is shipped will cover approximately 16 square feet (1.5 sq.m) at the recommended dry film thickness of 0.14 inches (.36 cm). 1. Spread a thin coat over the surface to be treated. Using a trowel or other application tool, apply pressure to the coating when spreading to assure contact and impregnation of the glass or other type insulation being coated. 2. Embed Chii-glas #5 into coating. 3. Appiy flood coat of Muffl-Lag to desired wet film thickness. NOTE: To help determine proper wet film thickness, small swatches of desired dry film thickness can be attached to insulation using catalyzed Muffl-Lag as the adhesive, and used as a gauge, 4. Use only in well-ventilated areas. Avoid prolonged breathing of vapors and prolonged or repeated contact with skin. 5. For a detailed specification, contact your nearest Childers representative. / (:./ . '; '' R 0. Box 22228 OTHER PLANTS AT. 2051 Ha-i 5! Bnslol. PA '9007 ' 51SI 543 7503 rifix SA-jJ:-c (23350 Mercantile Rd.) Beachwood, Ohio 44122 (216) 464-8020 '3?0 Easi-torn SI Ho-jsion l x 7 7022 64i-1661 '`'e>77 51o4 (ISO South vail Ucnienem CA 90640 ?U: '29 630b 'eiex 67-3639 7005 TorBram fid V.ississauga Cnt l4T 1CB 1416i 675-'l44J Tele* 06 96BB00 '5727 iigth Ave Edmonicn Alia T5M3W1 1403)462-4860 Telex 037 42697 .^Childers Products Co. 1980 this sheet supersedes all previous Muffl-Lag data sheets WC 000014235 NOISE INSULATION: If the treatment is not con tinued onto all surfaces of the quipment, some areas may still radiate noise escaping from un treated adjacent locations. Nearby walls or other struc tures associated with the equipment or building may re flect some of the escaping noise energy and alter 'near field" readings significantly. These conditions must be con sidered and understood by the contracting parties. Otherwise, a disappointed owner may feel he was cheated by a "sharpy" dealer. The treatments that were ap plied to the noisy compressor are listed below: 1. To the compressor housing, 2 inch thick closed cell rubber (Armaflex type) was adhered to the surface as the energy absorb ing material. All adjoining edges were cut to assure a snug-tight fit and sealed with joint sealant to prevent air and or noise leaks. Muffl-Lag was selected as the noise barrier and#was trowel applied directly onto the closed cell rubber and developed its own bond. Muffl-Lag was applied in a .140 inch thickness using Chi l-Glas #5 membrane rein forcement. The trowel quality of Muffl-Lag simplified the applica tion of the coating over the ir regular surface contour and provided a complete air tight monolithic acoustical finish as part of the system 2. To the discharge piping. 2 inch thicx heavy density glass fiber was attached as the energy absorbing material. Tight fitting premolded glass fiber pipe cover ing was wired on with stainless steel Tie-Wire and then covered with Muffl-Jac as the nose barrier for the acoustical system em ployed on the less complex pipe shape. Muffl-Jac Gore Elbows were used on the variable diame ter piping over the H.D. glass fiber from the compressor to the water chiller. All longitudinal and circumferential joints were sealed with Chi 1-Joint CP-70 to prevent noise leaks. The acousti cal mastic was overlapped 3" by the metal and sealed with CP-70 at all such locations. si Verne Traudt inspects 5200-ton Chiller-Compressor #3 at the city power plant (left). Chiller #4 is seen (right), as well as compressor, and freon discharge line. . .If~ 00001>236 Larry Paulsen of Eagle Com pany in Lincoln, Nebraska, worked with Ken Holton of Chil ders Products Company of Cleve land, Ohio on an acoustical prob lem at the University of Nebraska. Verne Traudt, Manager of Util ities at the University, was con cerned about the noise level around some large chillercompressors and chiller piping. The problem was analyzed and treated with such success that Darwin Traver, Staff Acoustical Consultant of the Carrier Corpo ration in Syracuse, New York, and others in the field are now recommending this form of treatment for this and compara ble type certrifugal compressor installations across the country. The noise as indicated on the "contour" map was not reduced to the same degree everywhere it was measured subsequent to the treatment. This difference in re duction of noise levels is quite significant considing the type and thickness of materials applied, which was essentially equivalent on all surfaces treat ed. This is a graphic illustration of the variability of noise prob lems. The difference in effective ness of reduction can be attrib uted to four primary factors: The extent of noise reduction will vary considerably with ma terial differences in the con struction of the equipment. The contribution of noise by other equipment which was not a factor in the initial survey may now be sufficient to show up and reduce expected efficien cy. Reprinted ham October 1977 OUTLOOK vvc 000014237 2' P'Der glass wrlh Muffl-Jac1 2" Armadex wiih MufU-Laq1 hemical rogress JUNE, 1976 Protecting protection Insulation is protection --against economic loss from vanishing BTU's: against injury to workers contacting hot tanks and pipes: againstannoytnganddamaging noise. But. insulation needs protection against rain and sun, condensation and dirt, and Childers Products Company, headquartered in Cleveland. Ohio, with branch plants throughout the United States and Canada, has for years offered such protection with its metal jackets for piping and equipment and its mastics for rounded and irregular surfaces of spherical tanks and of valves. Tees, and other pipe line fittings. Last year, the company added another protective element to its line to handle the problem of noise. As with its insulation-protecting products, Childers supplies sound attenuating agents in metal jacket and mastic forms. "Muffl-Jac" acoustical jacketing is a composite of lead and aluminum available in rolls, sheets, or prefabricated forms with smooth or embossed finish, if desired, "Muftl-Jac ' sheets may be corrugated at the factory to add stiffness, reduce glare, allow expansion, and eliminate coil breaks" over small piping. The adhesive joining the lead and aluminum was selected by the firm to provide better acoustical attenuation than that from separate applications of the two metals. Used over mineral fiber or glass fiber insulations, "Mufft-Jac" jacketing has an STC-26 rating in ASTM test method E 90-70 for determination of sound transmission class. "Muffl-Jac" metal composites are readily applied over piping and cylindrical surfaces. For large irregular surfaces or to seal gaps, cutouts, and overlaps in a "Muffl-Jac" installation, Childers offers "Muffl-Lag" mastic, a tough, durable, flexible polymer applied by trowel or palm over fiber glass or other fibrous insulations (see the illustration). Its thixotropy allows vertical application without runs or sags. Its STC rating is 28 and the company will furnish information about its FDA status on request. Childers points out that, in addition to easy application, "Muffl-Lag" installations require minimum maintenance and are easily repaired if impact damage occurs. The product is available in various colors and functions as its own weatherproof finish. Moreover, it is formulated to be non-corrosive, to withstand temperatures upto350F., and to be impervious to most chemicals and oils. The Childers sound attenuation products are of more and more interest today with the increased attention to pollution -- in this case sound pollution. At least equally important today are the firm's mastics and jackets to protect thermal insulations -- to keep them at peak efficiency and thereby conserve as much energy as possible. And, the cost of installing a thermal insulation system makes protection of that system a true economy. Childers manufactures some 15 types of coatings, sealants, and adhesives for protecting insulation in addition to its aluminum, steel, and stainless steel jacketing. Some are water base products, some solvent base, some 100 per cent solids. Fire-resistant, vapor barrier, and vapor permeability properties are available from Childers on request. The company displays the UL listing on all these mastics. Childers cites "Vt-Cryl" mastic as an example of its line. The material is a tough, durable, UL-listed coating that spreads easily on all types of thermal insulations and on masonry. The company states that it gives unsurpassed mechanical and weather protection and is therefore suitable for exterior and interior application to hot, cold, or dual temperature surfaces. "Vi-Cryi" mastic supplies a breathing coating that allows vapors under pressure to pass through it -- condensation in the insulation can thus escape. Eight standard colors are stocked: Childers will match other colors on special order. "Vi-Cryl 'C mastic is a modification of the basic "Vi-Cryl" product that uses a high percentage of cork filler to damp vibration and to give a roughened surface with additional area tor evaporation of condensation. Corrosion protection is available by using inhibitive metal primers on underlying steel. Choice of the best protection for insulation involves many engineering factors in which Childers and its customers consider the company an expert. The firm's experienced advice is a major factor in its success in its chosen field -- as is its selection of quality raw materials -- such as Ucar Latexes -- for its products protecting protection. VVC 000014-238 6 CHEMICAL PROGRESS ACOUSTICAL. MATERIALS INSTALLATION P ES The Leading Supplier of Noise Control Materials INTRODUCTION This specification provides a typical, historically successful method of treating pipes and equipment with a control treatment to re duce harmful noise levels by using a combination of f-ibrous or similar absorptive materials and a sound transmission loss barrier outer finish, to assist in complying with CSHA and EPA regulations and/or corporate requirements. MATERIALS 2.1 Piping shall be acoustically insulated with sectional preformed pipe covering consisting of one of the following materials: A. Minimum 4 pound per cubic foot density glass fiber, or (Note #10). B. Minimum 8 pound per cubic foot mineral fiber, or (Note #10). C. Minimum 10 pound per cubic foot ceramic fiber (stitched .k glass blanket insulation distributed by Pittsburgh Corning, Carborundum, or Burlington Industries). When piping temperatures exceed the recommended operating temper atures of the above materials, calcium silicate insulation shall be employed as a thermal barrier to reduce interface temperatures at the energy absorptive layer to meet the manufacturer's recommendations. Note, calcium silicate does not contribute to noise reduction sig nificantly and only adds to thickness of piping or equipment being insulated. 2.2 The weather proofing jacket shall be Muffl-Jac, a lead aluminum laminate (.016 aluminum bonded to .015 lead with a viscoelastic film) manufactured by Childers Products company. The jacket finish (smooth, corrugated, stucco embossed) shall conform to desired finishing stan dards. (Note #11) In the areas of high corrosion, and/or in areas where a tough resistanc finish is required, Muffl-Jac may be supplied wTith stainless steel or Ultraion Muffl-Jac. VVC 000014239 childers products company, inc. 1370 EAST 40TH STREET. BLDG. 7 SUITE 1 HOUSTON. TEXAS 77022 C.i. F.XiF.i. JLN-0-. jl. Ei.ll PHONE: 71 3/691-3661 TELEX: 77 5164 CABLE ADDRESS. "CHILPRO I.R.FBT A 2- - Ultrolon is a Tedlar coated aluminum manufactured by Childers Products Compa ny. To avoid fish mouthing at tne longitudinal laps, Childers recommends a 2" hem. For special applications, the lead can be laminated to metal of thick nesses up to .05. Note, thicker laminates add additional mass to acoustical treatments to assist in controlling low frequency acoustical problems. INSTALLATION PROCEDURES - HOT SERVICE 3.1.1 The glass or mineral fiber insulation shall be applied to clean, dry surfaces. 3.1.2 If multiple layers are needed to obtain the desired thickness for additional noise reduction, the longitudinal and circumferential joints shall be staggered 2" and 90 degree respectively. 3.1.3 Longitudinal seams of the glass or mineral fiber insulation shall be tightly butted. To insure a tight and well-sealed seam, CP-82 adhesive as manufactured my Childers Products Company is recommended. 3.1.4 Adjoining sections of insulation must be firmly butted. To insure a tight, well sealed joint, CP-82 adhesive as manufactured by Childers Products Company is recomnended. `3.1.5 To further secure the insulation to the pipe, secure the insulation with H" x -020 Type 304 Stainless Steel strapping bands as manufactured by Childers Products Company. 3.1.6 All gaps in the insulation or joints shall be filled and sealed with a patching material combining loose insulation and CP-82 as man ufactured by Childers Products Company. 3.1.7 Secure the jacket over the insulation with 3/4" x .020 Type 304 Stainless Steel strapping bands as manufactured by Childers Products Company. The bands shall be applied on 9" centers. Screws or rivets shall not be used. The longitudinal and curcumferential laps shall be 2" minimum with the longitudinal overlap located at 4 or 8 o'clock position. 3.1.8 All longitudinal and circumferential joints in the jacketing shall" be sealed with CP-70 as manufactured by Childers Products Company. 3.1.9 All flashing requirements shall be done with CP-70 as manufact ured by Childers Products Company unliss surface temperature exceeds 300 degrees F. If this condition exists, a silicone sealant such as Dow or G.E. silicone sealant shall be used. 0OOOl>^ 1 For flanges, valve bodies, elbows,-tne insulation shall be cut and fitted togetner to avoid gaps. All open spaces shall be packed with loose insulation and CP-32 as manufactured by Childers Products Company. 3.2.2 The exterior weatherproofing coating shall be Muff1-Lag as manufactured by Childers Products Company. The coating .to be applied to provide an air-tight monolithic protective system. The cured film thickness shall be minimum of .140". When both acoustical mastic and metal are to be installed, it is recommended that the mastic be applied initially and allowed to cure. Where adjacent jacket to mastic sealing is required, use CP-70 sealing compound as manufactured by Childers Products Company. Apply the adjacent metal jacketing over the caulking and band. {Note #13) 3.3.1 If an all metal acoustical jacketing system is required, MufflJac prefabricated, gore type elbows (lobster back style), as manufactured by Childers Products Company are available, starting with size 4" X 2". Each section of the gore elbow shall be individually sealed and banded. Screws and rivets shall not be used. Prefabricated control valve body covers, flange covers and tees are also available. (Note #11) INSTALLATION PROCEDURES - COLD SERVICE 4.1 Cold piping requiring noise abatement shall have a base layer of Armaflex, (closed cell rubber sheet manufactured by Armstrong Cork) or approved equal. Material to be installed as the sound absorptive layer. Fibrous insulations with an ASJ jacket are also a possible absorptive layer. (Note #12) 4.2 The surface shall be clean and dry when Armaflex insulation or approved equal such as Rubatex or Halsted is applied. 4.3 Armaflex or approved equal shall be banded or adhered to the surface. If adhering, Armstrong 520 adhesive is recommended. 4.4 All gaps and voids shall be filled with strip insulation and Armstrong 520 adhesive. 4.5 The weatherproof!ng jacket shall conform to'sections 2.2 or 3.2.2 depending upon the surface complexity. 4.6 Consideration shall be given to miterinq joints of insulation and jacketing design where maintenance requires jacket system removal. NOTES: 1). The use of metal screws and rivets must be avoided on noisy piping. They tend to vibrate out. 2) . Foamglass tends to break down under loading and vibration. Armaflex or approved equal is recommended as an alternate material. If using an Armaflex-type product, a vapor barrier may be required. CP-32 or Encacel V as manufactured by Childers Products Company are recommended. vVC 000oi*Z*l err. and are usuallv nc mm a ldc: ae _m_rectlv ever fibrous irsuiari-cr's er comoatbble vjsather-- 3. If vertical piping is included as a section of the acoustical part of a job, special attention and detail is necessary and we encourage you to contact your local Childers Products Company representative. 9. "or appearance purposes on flanges and elbows, suitable metal flange covers and two piece elbows may be applied ever the Muffl-Lag. 10. Pxercise care concerning temperature limits of fibrous insulation. Binders may migrate at temperatures less than those listed in the manufacturer's technical data for thermal systems. Unless rec ommenced by manufacturers, use cf fiberglas above 250 degrees ? and mineral fiber above 4 50 degrees ? may cause fracturing cf fibers in systems exhibiting vibrational energy. 11. Manufacture of items such as control valve body covers, flange covers, gore elbows, and tees require ncn-coirrigated jacketing. 12. Insulation systems requiring a vapor barrier must be sealed when installed. Leaks will permeate the entire system -unless vapor steps are installed. Leaks can also be caused by system abuse. 13. Childers Chil Glas - 5 is recommended as a reinforcing membrane and is usually embedded between an initial tack coat of the mat erial during its acolicaticn in the liquid state. Weaves other than 5 x 5 to the inch are not recommended. specification. Please contact your local Childers Products Company representative for assistance. OOOOl^2 vve Revised -15-52 BLOWOFF SILENCERS THE AEROACOUSTIC CORR Is Pleased To Announce... We Will Be Relocating Our Office And Factory To 4876 VICTOR STREET JACKSONVILLE, FLORIDA 32207 PHONE: (904) 731-3577 Effective June 12, 1978 THE AEROACOUSTIC CORP jm. eottCD .'AHmrTLui, .Wj roimuTm 4.. VVC 000014243 BLOWOFF SILENCERS Whenever gas under h<ih pressure discharges miD the: atmosphere ;h to a lower pressure in a pipeline, a large amount of obiuctiunabie noise is qenerated. A I,true steam boiler blowing off excess steam at 2600 p.s.i. mroudh y power relief valve will generate noise levels of 140 db. <it 60' Noise levels of this magnitude wll permanently damage the hearing of people in the vicim ty of the discharge and will provoke neighbomood oompiaints Worn ns far away as two miles. A type RBS (see Fig. 1) biowoif silencer will bring these levels down to a safe, under 90 dbA level at 60' -and eliminate neighborhood ..omplain ts. A small 1/4" air line, discharging 100 p.s.i. air from a pneumatic cylinder, will generate 100 ob. 5' from the discharge. This is above the present GSHA 90 dbA limit for continual exposure. It is an annoying and distracting noise that can easily and cheaply be eliminated bv using a small type SBL (see Fig, 21 blowoff silencer. The noise of these discharges is generated bv the turbulent reaction of tne jet with the surrounding atmosphere plus me noiscj generated by tne shock waves associated with supersonic flow. Tht: Aeroacousbc blowoff silencers auiet these jets by first diffusing the ;et down to a relatively low subsonic: velocity. The small type SBL depends entirely on the diffuser for its noise reduction. An acoustically aosorptive section follows the diffuser section in the large type RBL, HBL, RBS and HBS silencers, providing the additional silencing required by large volume flow. BLOWOFF SILENCER DESIGNATIONS When the gas being silenced is dry (air, methane, etc.) and ram is kept out of the silencer, the less expensive types RBL and HBL silencers are satisfactory. Fur use with steam or where rain can enter the Silencer, types RBS and HBS must be used. The Models RBS and HBS incorporate our proprietary water resistant acoustic packing m the absorptive section to minimize the effect of water on their operation. The Model SBL silencers are inexpensive units for flows below that of the smallest RBL series. BLOWOFF SILENCER SIZING The maximum permissible flows for Model RBL, RBS, HBL and HBS silencers are given in TABLE 1. These units wll handle and silence any flow up to that tabulated. Exceeding the tabulated flow rales may result in damage to the si encers. so be certain of the design Mow. Flow' rates for Model SBL's are given n TABLE 2. CLUSTERING DISCHARGES Models RBL, RBS, HRL and HBS i an be provded with rev'iYi inlet ennneot'pns. to allow one silencer w serv re si'v ni 1 in lijrae Si.'ing is -.till based on max.mini cj r, H : low pi T 1 ABLE I SILENCER EXIT & INTERNAL VELOCITY T I , : Ii-I u 11 ii: i 11 ' .'I 1 " 1 II `Ij. J11 < I '1. HI-......... .. i' 1 r 11( ly' i. i: r i u -|i : i > -I.r -I ; i . 11 run i hi -.ii. tii.i'i y r ay irn- -,,i. ry t <\ h, m\t, 11 o !, s 11 n >, '(1 a M 1 1 I v I' I' t ri.il tt>:l I'Xh.lii-.t - >;.11, Ai.r. J.H -.1.1 .III i_..r 1'. l-C, ! iViiors ,;r. . V>-11 ->w .i.-.'Jii-v J Am. L h BLOWOFF SILENCER ACOUSTIC PERFORMANCE F:<|. 3 gives doA values at various distances Mom an unsdenced, vertical discfiarge steam jet, based on actual measurements of a typical system. Figs. 4 and 5 q've the corresponding noise levels, also based on actual measurements wnen using RBS and HBS blowoff silencers. Tne small SBL silencer gives a 25 to 30 dbA reduction when used on 100 p s.i. air. FIGURE 1 Long Island Lighting Company Northport Power Station 360,000 KW power control valve silencer (Blowoff Silencer) 220,000 PPH steam -- 1.00CTF-2695 PSIG FIGURE 2 MODEL SBL 412 VVC 00001*244- SOUND PRESSURE LEVEL db re .0002 db - A weighted 50' 100r 200' 400' 800' 1600' 3200' DISTANCE FROM DISCHARGE, FT FIGURE 3. UNSILENCED STEAM JETS Over 200 PSIG; 1000F SOUND PRESSURE LEVEL db re .0002 db A weighted FIGURE 4. SILENCED STEAM JETS Model RBS SILENCER vvc OOOOl^5 TABLE 1 Model No. Dimensions Incites AB C MAXIMUM FLOW CAPACITIES-STEAM Wt.. Lbs. Model RES Silencer In 1000 PPH Steam 250'F 500' F 1000`F Model H6S Silencer In 1000 PPH Steam 250 F 500" F 1000" F 1 -1.5 2 3 -4 5 6 7.5 9 10 11 12 13.5 16 20 25 -30 36 42 49 56 -64 72 81 -90 -100 110 121 132 -144 12 12 12 18 12 24 12 36 24 24 24 30 24 36 24 45 36 26 36 40 36 42 36 48 42 48 48 48 48 $0 60 60 60 72 72 72 72 84 84 84 84 96 96 96 96 108 108 108 108 120 120 120 120 132 132 132 132 144 144 144 60 60 60 60 60 68 68 68 69 75 75 75 84 84 84 84 102 102 102 108 120 123 123 123 129 129 135 135 141 141 220 275 410 550 650 780 880 1.050 1.465 1,685 1,753 1.902 2,525 3.275 3.900 4,740 5,550 6,210 6,950 7.940 10,025 11,200 12,350 13,900 15.500 17,200 19,800 21,800 23,800 26,000 8.4 12.6 16.8 25.2 33.6 42 50.5 63 76 84 92 101 113 135 168 210 252 303 354 412 471 540 605 695 770 860 945 1040 1140 1240 7.3 11 14.6 22 29.2 36.5 44 55 65 73 80 88 96 117 146 182 220 260 304 354 405 462 520 607 675 750 825 910 990 1080 6 9 12 18 24 30 36 45 54 60 66 72 81 96 120 150 180 216 258 294 336 384 431 486 540 600 660 725 795 865 10.5 15.8 21 31.5 42 52.5 63 78 95 105 116 126 141 169 210 263 315 380 442 515 590 675 755 870 960 1070 1180 1300 1420 1550 9.1 13.7 18.2 27.5 36.5 44.5 55 69 81 91 100 110 120 146 182 229 275 325 380 442 506 580 650 760 845 940 1030 1140 1230 1350 7.5 11.2 15 22.5 30 37.5 45 56 67 75 82 90 101 120 150 IBS 225 270 323 368 420 480 540 610 675 750 825 905 990 1080 HORIZONTAL MOUNTING INLET AVAILA8LE WITH WELD NECK Ofi FLANGED CONNECTION MAXIMUM FLOW CAPACITIES - AIR Model RBL Silencer In 1000 PPH Air 60 F 25ITF 500 F Model H8L Silencer In 1000 PPH Air 60 F 250 F 500 F 14 21 28 42 56 70 84 105 126 140 154 168 189 224 280 350 420 504 590 685 785 900 1010 1135 1260 1400 1540 1700 1850 2020 11.5 17 23 34 46 57 69 86 103 115 126 133 155 184 230 288 345 415 483 565 645 735 825 930 1030 1150 1270 1390 1520 1660 10 15 20 30 40 50 60 75 90 100 110 120 135 160 200 250 300 360 420 490 560 640 720 810 900 1000 1100 1210 1320 1440 17.5 26 35 52 70 87 105 131 157 175 192 210 236 280 350 437 525 612 735 857 980 1120 1260 1410 1570 1750 1920 2120 2300 2520 14.4 21.5 29 43 58 72 86 108 130 144 158 173 194 230 288 360 432 520 605 707 808 922 1040 1160 1285 1435 1580 1740 1900 2070 12.5 18.8 25 37 50 62 75 94 113 125 137 ISO 169 200 250 312 375 450 525 612 700 800 900 1010 1120 1250 1370 1510 1650 1800 VERTICAL MOUNTING T CI A BLOWOFF SILENCER CONSTRUCTION The Blowoff Silencer has to handle very larqe amounts of energy, during its1 operating period and hence, has to be of very rugged construction. For example steam, at 1,000F and 1,000 PSI pressure, vented to atmosphere through a A" valve, will flow at a rate of 910,000 PPH and dissipate energy equivalent to 141,000 horsepower Unsilenced, this jet will produce 1 70 db of acoustic power referred to 10* 1 watts. The AeroAcoustic Blowoff Silencer dissipates this velocity energy in the silencer diffuser section. In order to handle these tremendous amounts of power, the internal diffuser section of the AeroAcoustic Type RBL Blowoff Silencers is made of 1/2" steel plate in the larger models. To be sure ot getting a Blowoff Silencer that can do the job and also stand up under the tremendous forces involved in the blowoff gas velocity, specify the AeroAcoustic Type RBL or SBL Blowotf Silencer, Acoustical Insulation Reprinted from Construction Specifier March '76 Kenneth D. Holton i 1 VVC 000014247 Historically, thermal insulation has been employed by the design engineer for essentially three basic reasons: 1. To conserve energy by reducing eat losses, 2. To maintain constant process temp eratures. and 3. To prevent injury to personnel. Now, a fourth, less obvious reason has been added by federal order: 4. To help industry provide a safe and healthful workplace by reducing poten tially hazardous noise levels. To determine what constitutes this environment and to insure that such conditions are being provided, two federal agencies, OSHA and EPA, are currently actively involved. OSHA is in specting facilities to assure that mea sures are being taken to comply with the noise regulations set forth in the Occupational Safety and Health Act of 1970. Whereas the Environmental Pro tection Agency (EPA), established by the Noise Control Act of 1972, is pro vided with broader responsibilities and power to monitor all federal agencies engaged in environmental activity in cluding noise abatement. Until recently these agencies had not been able to agree upon the maximum allowable - noise exposure that provides a safe nd healthful workplace for a major portion of the population. OSHA prescribed a 90 decibel (A) weighing or 90 db (A) level for eight working hours. EPA proposed an 85 db (A) level for eight working hours. 90 db(A) is considered by OSHA to be the upper limit of daily noise exposure that will not produce a disabling loss of hearing in more than 20% of a popula tion exposed through a working lifetime of 35 years. Because of the potential disabling ef fect on that 20%. EPA was reluctant to concede its position. However, in hear ings recently concluded in Washington D.C., it was tentatively agreed that the 90 db(A) level will be the acceptable upper limit for an eight-hour daily ex posure. But, for a sixteen-hour expo sure, or more, 85 db(A) is the maximum limit. From the adopted curve, a twelve-hour exposure would require a noise level not exceeding 87.5 db(A). Some companies, in anticipation, have generally adopted 85 db(A) as the long-range upper limit and are using it as their present-day guide (Fig. 1). This compromise agreement will re main in effect until findings based on regularly scheduled employee physical exams prove the exposure limits are adequate or inadequate. Tentative though it may be. this agreement has lessened, to a degree, the anxiety of many corporations faced with the costs of applying the type(s) of appropriate noise control. 5 db(A) may not seem an extreme difference, but the comparison of costs for various industry segments to achieve this difference is significant and is shown in Table 1 (Courtesy of Business Week, July 20, 1974 issue). Realizing its position, industry is at tempting to institute controls and prac tices by applying treatments it hopes will enable it to comply with the noise standards and the 1978 schedule. To help industry meet the challenge, a new capability has emerged combin ing the talents of acoustical engkteers with the products, knowledge and assistance from sources within the thermal insulation segment of industry. Acoustical insulation for Lagging Mechanical Equipment Today thermal insulation is one of the primary materials of design selected to solve many of the noise problems as sociated with the function and design of mechanical equipment. Since noise is a form of energy, dissipation of that energy to reduce noise levels is an im portant aspect of design. Certain insu lations, although excellent energy ab sorbers, can treat only a portion of a noise problem, usually the high fre quency end of the noise spectrum. Therefore, it is usually a combination of materials such as insulations, jacketings, coatings and finishes that are used as a lagging system to totally combat such problems. Energy not ab sorbed by the insulation initially is re flected into the insulation by the acous tically treated jacketings, coatings and facings preventing much of the energy or noise from becoming airborne. How effective the combination will be is a question. The usual method of measurement of noise reduction effi ciency for flat panels is transmission loss' through a panel from a sound The reduction in magnitude of some characteristic of a signal between two stated points in a transmission system. Figure 1: OSHA's proposed new noise standard would set these time-weighted limits on employee noise exposure. Sound Level (dBA) Time Permitted (hours-minutes) oei jl HcQ'S'er Table 1: What it wil cost industry to reduce noise Total I97lcapital compliance cost investment Millions ot dollars EPA Industry Proposed standard Utilities............................................... .. .. $ 6.300 Nonelectrical machinery .... 4,200 Fabricated metal products .... 3.200 Transportation equipment 2,900 Textile mill products .. . . 2,700 Food & kindred products ......... 2,600 Electrical machinery .................. 2.300 Primary metals . 1.900 Chemicals & allied products ... 1,400 Printing & publishing Lumber & wood products 1.000 650 Furniture & fixtures 580 Stone, clay & glass . 520 Paper & allied products 500 Rubber & plastics products 500 Petroleum & coal products . . 260 Tobacco ......... Apparel & related products 90 10 Leather & leather products Total........................................ 8 S31618 Dura Don Di`f.ir.i?k A Vwm.in in OSHA Present standard $ 3,200 1.400 1.100 1.100 1.100 590 780 900 1.100 870 160 190 290 140 300 210 45 0 0 S 13.480 $15,290 2.803 312 2,143 610 2.693 2.125 2.803 3,438 1.733 214 33 850 1 253 845 5.875 26 53 24 553 13e CS March 76 VVC 000014248 source to a sound receiver under acoustically controlled conditions. A sound transmission class (STC) rating is assigned based upon the results. This STC rating is a single number #sed for comparing flat partitions for eneral building design purposes. Vet, this same rating is being used as a guide in many cases, to determine the suitability of that system for application to curved surfaces of piping, compres sors, pumps, turbines, valves, gear boxes, fans and duct work and other industrial type equipment. The application of materials used or tested as flat partitions bears little rela tionship to the functionality of those same materials to the curved industrial equipment mentioned previously. STC should not be the only criterion utilized for design purposes until analyzed for use in critical frequency ranges prior to a specific application. How then can one design for a given noise source and feel confident that the system derived is both effective and economically efficient, if little reliable data are available? The answer is, "very carefully!" To this purpose, all seg ments of the thermal insulation indus try are presently undertaking investiga tive efforts in conjunction with acousti cal engineers and testing facilities to provide the necessary information and/or the test methods to determine the effectiveness of an insulation sysem in controlling excessive noise. Although it is the equipment that generates the acoustical energy and is 31 5 63 125 250 500 1000 2000 4000 1 KlO'i3 1' A Octave Band Center Frequencies m Hz 8000 16.000 the noise source, the noise is usually radiated throughout a plant by a re lated piping system. Therefore, the acoustical lagging of the piping as well as the source must receive attention when reducing noise levels throughout an existing plant. How do you treat pip ing tied in to a noisy compressor or a pump? The means of control are: source, path, and receiver. In most cases, source control is the most economical. However, unless re placement with a quieter unit is possi ble, as well as practical, the alternate means are normally employed. The choice between path and receiver con trol is based upon plant operations and isolating the noise from the receiver or vice-versa, whichever is more practical or economical. There are many ways to control noise. Vibration damping, vibration iso lation, absorption, constrained layer construction, and, enclosures are all widely used alternates. But what are the most appropriate alternates? Why are certain type insulations and materi als used or not used? What assistance can be expected of the suppliers of noise control systems or materials? Who should be called on to identify a noise problem7 What type of reference information should be used? These are the questions to be answered and are the substance of this paper. To give the VVC OOOOl^Z1^ CS March 76 Insertion Loss d8 2. The insertion ioss results for typical pipe lagging systems (Fig. 4). figure 4 3. Typical sound level* reductions achieved with acousti cal laggings treatments for different sources'* (Tables 1 and 2). designer the direction and tools wm-. which to develop the right lagging sys tem to reduce noise levels and to help engineer the safe and healthful work place industry is seeking. Before actually discussing the fun damental considerations and details to be employed to reduce noise levels on piping or ducting and the related energy source, it is the writer's opinion that the validity of the recommenda tions be reviewed so that those indi viduals interested not only in the mechanics but also the theory are satisfied. Much of the information pro vided is through the courtesy of the American Society of Mechanical En gineers and the reports submitted to that organization at the Houston, Texas, Winter Meeting in December 1975. (References for reports will be given at the end of this paper.) The reports evaluate several types of pipe lagging treatments and combina tions of materials applied to piping, measuring performances under specific test conditions outlined in the papers themselves. The differences ar significant between laboratory flat panel transmission loss test data ASTM E-90-70, and insertion loss data' ob tained from lagging a noisy pipe with the same materials (Fig. 2). From the differences shown in Figure 2, it is obvious that unless the critical frequencies are known, miscalculation of potential decibel reduction can be introduced and failure of the system performance can be the result. * The lest methods submitted to theASTM-E-33 committee ere being studied as potential standard methods. Table 1 Table 2 Treatment 1 inch*** glass fiber 1.5 inch cellulose blanket 2 inch glass fiber Mastic over 1 in. glass fiber Metal over 1 in. glass fiber Metal over 2 in. glass fiber Mastic over 2 in. glass fiber Test Valve Piping 12 17 27 32 33 38 43 Process Process Valve Compressor Piping Piping 85 86 15 10 22 16 23 18 26 19 35 25 Pipe Lagging Materials Treatment Product Glass fiber Cellulose blanket Lead/ Aluminum Mastic Preformed pipe cover K-13,m Acoustical Blanket Muffl-Jacim Acousti- cal jacketing Muffl-Laglm Acoustical coating Supplier Certain-Teed Products National Cellulose Company Childers Products Company Childers Products Company * A-weighted sound pressure levels in units of dBA. Hale. ME t Kugier. 8 A. *' Peak noise levels occur in the respective piping at different oc tave band center frequencies, as follows: Test valve, 4 KHz; Pro cess valve. 2 Kllz; Process compressor, 1 Kllz. The materials used in conducting these tests were selected only to illustrate the variations in performance of materials in test and does not constitute endorsement or recommendation Dy the source. *** 1 inch (in.) is equal to 2.540 centimeters (cm). A lagging system designed to reduce noise levels consists essentially of an absorber over the surface radiating the noise, and a noise barrier sometimes referred to as a sep tum. The absorbers are primarily thermal insulations and the barriers are usually dense, metal or mastic exterior finishes. The following charts are compiled as guides to simplify the selection of materials presently available and used suc cessfully in the design of such a lagging system. yyC 000014250 CS March `76 Materials Guide Acoustical Insulation for Lagging Application Type Description Inorganic Glass Fiber 1 to 3#/cu. ft. density blanket 2. Inorganic Glass Fiber 4 to 7#/cu. ft. density board and pipe covering 3. Mineral Wool 4 to 6#/cu. ft. Board 4. Mineral Wool 5. Calcium Silicates 6. Cellulose Fiber 7 to l2#/cu. ft. Board and pipe covering (Densities higher than those shown are not recommended) 12 to 14#/cu. ft. Board and pipe covering 3.5#/CU. ft. 7. Cellular Glass 8.5#/cu. ft. 8. Flexible Urethane Foam (Rigid urethane foam board and pipe covering not recommended) 2#/cu.ft. 9. Ceramics to 18#/cu. ft. Note: There are other insula tions that are effective acousti cally also, such as Gypsum and ^particle board. However, due to their nature, they do not lend themselves to curved sudace applications. Advantages Disadvantages Low cost Efficient energy absorber Easily applied Compress and compact under fastening, loading and vibration Excellent energy ab sorption quality Dimensionally stable with acoustical surface loadings Easily installed Requires cutting to conform to unusual shapes Requires mechanical or ad hesive attachment to surfaces Moderate service temps Excellent energy ab sorption quality Easily installed Compress and compact under loading and vibration Fibers separate under trowled coatings Requires mechanical or adhesive attachment to surfaces Excellent energy absorp tion quality Easily installed Dimensionally stable under accoustical surface loadings Requires cutting to conform to unusual shapes Requires mechanical or adhesive attachment to surfaces Used as thermal breaks for absorptive type insulations Excellent absorption qualities Can be spray-applied Cannot be used for absorptive purposes Adds additional weight to structure without acoustical benefit Area clean-up after spraying Must be tamped after spraying Susceptible to water damage Deforms under loadings Limited continuous service temperatures Vapor barrier type insulation Easily installed Light Weight Limited absorptive capacity Adds additional weight to structure Limited service temperatures Damping materials often re quired for use as a noise barrier Low service temperature range Poor fire resistance Toxic by-products from burning Compacts under attachments and sudace loadings Higher limiting frequencies than other type insulations Thermal break for more efficient energy absorbing type insulations Cannot be used for absorptive purposes Adds additional weight to structure OOOOl^51 \fVC CS March 76 Materials Guide Noise Barriers for Lagging Applications Type Description Advantages Disadvantages I. Lead Va to 3#/sq. ft Limpness, mass Easily damaged Requires additional mechanical attachment and sealants to obtain air-tight seal Requires protective finish for USDA and FDA approvals and prevention of corrosion Lead-Laminated to: .75 to 3.25#/sq. ft. Limpness, mass combined laminated weights plus the following: 2. Aluminum (3003-H-14) .016" thickness Ease of handling Mechanical and chemical protection Requires additional mechanical attachments and sea lants to complete installation 3. Galvanized Steel .010 to .040" thick Fire resistive Mechanical protection Requires additional mechanical attachments and sealants to complete installation May require structural redesign to carry weight in heavier thicknesses Potential corrosion 4. Stainless Steel .010 to .016" thick Corrosion and fire resistance Mechanical protection Requires additional mechanical attachments and sealants to complete installation Costs 5. Coated Metals 010 to .040" thick 6. Heavy Gauge Metals .032 to .050" thick Corrosion and fire resistance Mechanical protection Mass Requires additional mechanical attachments and sealants to complete installation May require structural redesign to carry weight in heavier thicknesses Requires additional mechanical attachments and sealants to complete installation May require structural redesign to carry weight in heavier thicknesses Potential corrosion 7. Asphalt Roofing Felts .40 to ,50#/sq. ft. Ease of application Requires additional mechanical attachments and sealants to complete installation Poor mechanical resistance Limited noise barrier characteristics 8. Lead Filled Vinyls 3/i# to 3#/sq. ft Mass, limpness Easy fabrication and installation Requires additional mechanical attachments and sealants to complete installation Flammability characteristics Low temperature stiffness 9. Lead Filled Coatings 15 to 20#/gallon Mass, limpness Ease of application Monolithic covering to ir regular or simple surface contours Poor chemical resistance Limited application temperature range Toxicity Requires ventilation during application Potential lead oxide hazard Requires multiple coats to obtain necessary dry film thickness Extended drying time between coats lengthens application time Relatively limited operating service temperature range 10. Lead Free Coatings 17#/gal!on ii. Sealants--polysulfides if0#/galion Mass, limpness Ease of application for monolithic coverings to ir regular or simple shapes Single coating application to build required thickness Fast set Two or three components Requires mixing Limited working time Reinforcing membrane recommended Ventilation recommended Retains flexibility through operating life Inexpensive Not effective as a noise barrier material Limited to sealing laps and |omts of construction materials Ventilation recommended CS March 76 wtfC 00001^252 Note 7: It is sometimes less expensive to protect the per sons) from the noise source by using personnel enclosures consisting of panels of conven- onal building materials. An closure should be investi gated and selected in order to insure proper protection from the type and extent of noise to which the person(s) is exposed. Note 2: Heavy, limp vinyl cur tains and partitions are also used as noise barriers but un less the degree of isolation be tween sources and receiver(s) within a room is essentially 100% complete, the installation may be ineffective and a total waste of money. Note 3: Absorbent materials such as fiberglass louvers and baffles only reduce the reflec tion of the generated noise and cannot reduce noise levels below those emanating from the source. The effectiveness of the absorbent surfaces in creases with distance from the source. Considering the available data and materials, the noise problem itself must be clearly and properly defined, Sound is a unique force and tciot ntinues to test even the nowledgeable engineer with e extent of its influence on design. Because this influence is a form of energy, an im proper or inadequate installa tion may have ramifications of unknown proportions. There fore. to avoid failure and re lated costs, it is essential that basic acoustical engineering precede any installation. An ef fective engineering program embodies three phases: 1. Definition--Noise control problems must be clearly de fined. A trained person is re quired to determine the main source of noise especially in a complex, multi-source envi ronment. 2. Competence--It requires specific technical competence to solve noise control problems and to develop alternate solu tions. Recommendations may take the form of revised work traffic patterns along with other treatments. The nature and ex tent of such treatments for an entire piant necessitates varied studies and recommendations Evaluation--The selection of the appropriate solution trom alternatives requires evaluation in terms of dollars as well as effect. Obviously then, knowing how to overcome typical industrial noise control problems de pends on: 1. Identifying the noise source. 2. Selecting the correct mate rials. 3. Applying the treatment to the affected area. 4. Measuring the effectiveness of the installation. Installation is no less an im portant contributor to the solu tion of the problem than any other aspect of design consid ered to this point. Improper ap plication or careless attention to any of the details associated with good workmanship will de tract from, if not prevent, reach ing design goal levels. Therefore, it is necessary that the tradesmen who will be in stalling noise control materials have the training enabling him to produce a proper and quality job. It is here that organizations such as the National Insulation Contractors Association are so important in seeing their mem bers are kept informed about products which affect the type and extent of work in the insu lation field. Other trades groups such as the Heat and Frost In sulators Union with their ap prentice training programs are vital In assuring industry of a qualified source of labor. When specifications are gen erated, it is also helpful to con sider the type of labor condu cive to producing a successful job. Disputes over jurisdictional control can be eliminated thereby preventing unneces sary delays and costs and po tential misapplication. In realizing the importance of specifications, we must recog nize that noise control treat ments will be exposed to the same environments as conven tionally designed thermal insu lation installations. Allowing that the nature of the insulation treatment between acoustical and thermal happens to be dis tinct, the conformity to codes and standards must not be dismissed. From an appearance viewpoint, many successful noise reducing installations consist to a great degree of the same exterior materials applied over conventional insulations for regular pipe lagging treat ments. except that the noise barrier has been added This makes it possible for the en gineering of both acoustical and thermal treatments to ap pear similar, have each perform its distinct function, yet comply with established codes and standards. Because of the dissimilarity of contributing noise factors to each noise problem, the selec tion and application of materi als must be individually consid ered. Therefore, it would be an impossible, as well as an im practical task to attempt to write a "typical" specification for a lagging treatment for a pipe system. However, the fol lowing points should be con sidered in each specification. A specification calling out preformed insulation and a noise barrier for a typical pipe lagging application should di rect attention to the following detail: 1. Apply absorptive insula tion with a snug, tight fit at all joints, longitudinal and cir cumferential. If a thickness of two inches or more is specified, apply the insulation in multiple layers, staggering all joints. Pack all openings with loose insulation using rubber based adhesives. Do not pack with in sulating cements. 2. Avoid the use of pins and clips to secure insulation. Each pin transfers noise energy from the weld or adhesive contact point along the pin to the clip and if in direct contact with a metal jacket, will act as open ings in the treatment. 3. For elbows, two-piece pre formed glass fiber insulation covers can be used having equivalent thicknesses to the pipe lagging. The elbows can also be field cut from the pipe insulation and applied to an equivalent thickness assuring snug, tight fit at all joints. 4. For other items like flanges in the system, the same treatment should be applied in the most efficient manner. 5. Isolate all saddles and hangers structurally tied to the piping with sound absorbing and/or vibration isolation mate rials such as closed cell rubber. If isolation is not practical, then coat the exposed surfaces of those items with a vibration damping compound. 6. The noise barrier jacket ing, usuaWy metal jacketing such as an aluminum and lead laminate is used for the straight funs of piping. To properly in stall the jacketing one should overlap at least two inches and VVc band the overlapping seams. Caulking all longitudinal and circumferential seams is rec ommended. Rivets or screws tend to loosen under vibration and therefore are not recom mended, unless no other means of attachment can be used! 7. Stainless steel bands should be placed at nine inch centers along the pipe lagging. Expansion springs may be in cluded in the attachment if pip ing or equipment diameters ex ceed six feet. 9. Care should be taken to keep all cuts and openings for projections as tight as possible. Seal such openings with a non-hardening, non-shrinking type caulking compound. The lagging treatment should be applied like a vapor barrier in stallation to be effective. 9. For irregular surfaces ap propriate acoustical coatings may be used in place of the metal jacketing. To help obtain the desired thickness of coating, one can pre-cast sheets of Vz the de sired dry film thickness. Cut swatches (approximately one inch square) to be adhered to the insulation's surface at con venient locations using a touch of the coating itself as the adhesive. Then firmly trowel a thickness of the coating to the acoustical insulation surface to the depth equal to the thick ness of the swatch. Embed a #5 reinforcing, open-weave fi berglass fabric into the wet coating. The swatches will help prevent the fabric from being forced to the insulation's sur face. Follow this by applying a second swatch atop the previ ously applied swatch sandwich ing the glass fabric. Finally, apply the finish coating to a thickness equal to that of the second swatch. This method will give the recommended dry film thickness. If only the first coat can be applied because of cir cumstances. be certain the reinforcing fabric is applied be fore the coating sets up. The second coat can be applied anytime thereafter. 11. If the acoustical coating is used on irregular surfaces and the metal jacketing is used on piping in conjunction, be certain that the mastic is over lapped at least three inches oy the jacKeting and banded and caulked at the extreme end of CS March '76 (he overlapping jacketing. 12. Expansion joints ana vessels may require more elaborate application detail and 'ould be treated individually. 13. Acoustical enclosures may also be prepared from the same materials used to lag the piping but their installation and/or attachment to a piping system should be carefully evaluated. 14. Consult your acoustical engineer and supplier of acous tical materials for any addi tional assistance. It is the writer's objective to alert the prospective purchaser of any noise control installa tion, whether simple or com plex, to the tact that he can avoid mistakes and keep costs to a minimum by recognizing that his problem is distinct, that specific engineering is essen tial, and the installation must be completed by competent people. As stated earlier, one should proceed very carefully in sol ving and treating'noise control problems. Successful instal lations have been developed and installed by and for: Company Equipment Materials National Steel & Shipbuilding Public Service of N.J. Ballast Pumps Compressors Scott Graphics DuPont Union Carbide ACO AMOCO GULF Tow Motor Boiler piping Fluid bed Cooler Vacuum Jet Piping Process Valving Process Piping Boiler Piping Fiberglas & Acoustical Coating Fiberglas & Acoustical Coating & Acoustical Jacketing Fiberglas & Acoustical Jacketing Mineral wool & Acoustical Jacketing Fiberglas & Acoustical Coating Fiberglas & Acoustical Coating Fiberglas & Acoustical Jacketing Fiberglas & Acoustical Coating Note: Company names included in the above listings do not infer endorsement of products referred to in the article. Definitions 1. db{A)--is a one number weighting expression of a sound pressure level read from a scale indicator contained within a sound level meter. Such a db(A) decibel reading is made possible by exciting an indicator needle via the sound pres sures generated by the noise incident on the microphone portion of the meter, The A weighted sound pressure level or A scale ab breviated by the letters dbA or db(A) equates a single number indicator used widely to rate the relative loudness at a sound (noise source) heard by the human ear. So when any readings are taken, the designation attributed to the scale used is associated with the decibel measurement. There are normally three weighting networks in a sound level meter: A, B, and C. The "B" scale has fallen into disuse whereas the "C" scale is used when the critical frequencies do occur in the lower portion of the noise spectrum, 2. Transmission loss is the reduction in magnitude of some characteristics of a signal between two stated points in a transmission system. 3. Insertion loss is defined as the acoustic difference at a given point before and after inserting a sound absorber or barrier between the point and the noise source. Bibliography Business Week--July 20, 1974 Federal Register ASTM Paper--75 WA/PET 2 ASTM Paper--75 WA/PWR 7 American Petroleum Institute Medical Research Report #EA 7301 Plant Engineering--December 14, 1972 Sound and Vibration--August 1975 Donley Miller and Nowikas Acknowledgment The writer wishes to acknowledge the technical support and assistance provided by Dr. Marlund Hale, Senior Consultant, Bolt, Beranek & Newman, Canoga Park, California. The writer also acknowledges the cooperation of the Na tional Insulation Contractors Association. Kenneth D. Holton. Manager of Technical Sales Childers Products Company, Cleveland Ohio. is a graduate ol Latayelte College with a Bachelor Degree in Chemistry. Mr Hollon has been active m the Thermal Insulation Industry since 1955. He Delongs to the Society ol Plastic Engineers and to the Society ol Plastic industries childers products oompan World's Largest Manufacturer of Metal Jacketing, Coatings, Adhesives, and Sealants P. 0. Box 22228 (23350 Mercantile Rd.) Beachwood, Ohio CUiEH PLAN li'-.ui P* 11)007 14 i hHKj 84 3408 i.mnn. 1 ; ;n?? ' 3 r.'Ji .iuul 'jll>4 i ai-hhh\ r.,,i i : I J "hi 0 ,:v. r-l... : TI I .'li1 . [,'ij4 . r,4 / 44122 (216) 464-802 ..JI'M'V A- I" 1.1 I'.n 111 J u c j '> i.r.tH CS March 76 WC 000014254 FOR: Cylinders Motors Valves Tools Vacuum Pumps Air-Operated Devices Soeed Control Parts ejection btean *' x* . r ^ `i , . V -K-..- '* -j VVC 000014255 CONTENTS Page Allied Witan Design for Noise Control 1 Noise Control Data........... 2 Typical Applications 3 Atomuffler Air Exhaust Muffler EP Type--Single Chamber (Air Operated Equipment) 4 Atomuffler Air Exhaust Muffler EP Type--Multi-Chamber (Large Volume, High Velocity) 5 Atomuffler Air Motor......................................................... EP Type (Air Motors, Starters, Vibrators, Aerators) 6 Atomuffler Vacuum Pump Muffler........................................ VP Type (Pumps, Blowers, Feeders, Chucks) 7 Filter Silencer FS Type (Air Compressors, Intakes, Vents, Breathers) 8 Atomuffler Speed Control Muffler CS Type (Air Operated Equipment, Variable Orifice) 9 Atomuffler Steam Exhaust Muffler SM Type (Steam Exhaust) 10 Micro-Miniature Muffler ............................................ MM Type (Low Volume Air Exhaust, Variable Orifice) 11 Porous Metal Muffler PM Type (Valves, Cylinders, Presses) 12 Porous Metal Speed Control Muffler 13 PC Type (Air Operating Valves on Welders, Presses, etc,) Air Ejector Muffler, Collimator Die Inserts AE Type (Parts Ejection) 14 Bantam Muffler BN Type (Limited Space Applications) 15 End Flow Muffler DF Type (Single Direction Air Flow) 18 High Pressure Mufflers PH Type (Ultra High Pressure Service) Inside Back Cover Thru-Flow Mufflers TF Type (Air Slurries, etc.) Inside Back Cover Breather Vent Filters Inside Vacuum Relief, Pressure Equalization, Port Filter, etc. Back Cover Special Mufflers (Customized Sizes. Types, Material) . Inside Back Cover Customer Services (Engineering Assistance, Factory Services) Inside Back Cover January, 1970 00001A2*6 vvc Alwitco products lioi'-'.seil ,-irici r-,.n]i> i.ikU'i U. S. Patents 2o0023u -- 20 ! r-,0(3R--2t`b483'.l -- 3 3t30r>R3 -- ,3:>3/M-'43 --3047233 ADVANTAGES O Noise cancelled by interposing sound waves. 0 Multiple stage velocity deceler ation. e Disseminator completely dissi pates harmful exhaust blast. o Radial full-flow design. Q Obstruction free expansion chamber. 0 Capacious peripheral exhaust surface diffuses air blast, lowers velocity and reduces noise. The Allied Witan Atomuffler Design for Noise Control --Stops Noise Before It Starts . i..-;' Kill the air blast that causes it and you completely prevent the deafening roar of air : :v:; exhaust noise--before it even starts. Furthermore, let the air stream literally destroy itself--by effectively dividing and turning it back upon itself. This, with no need for : baffles, packing or screening, is the basic principle of the Allied Witan Atomuffler V- system of air exhaust noise control. As it enters the muffler at high velocity, the air exhaust mass is effectively redirected `- and subdivided into separate, infinitely smaller air streams. Directed in a continuous stream at the wall of the obstruction-free expansion chamber, they rebound freely to collide head-on with opposing air streams of equal force at a point pre determined by ; ;the design of the muffler. / v/,- At the greatly reduced velocity thus effected, the air is then softly dispersed through the openings in the large area disseminator surface provided by the perforated cylinder V ' , wall of the muffler.. .free of noise, with negligible impairment of mechanical efficiency, V and with complete protection to personnel from injurious air blast. With the proved ability to eliminate deafening, nerve-wracking air exhaust noise, the Allied Witan Atomuffler Design for Noise Control has for many years been widely utilized in thousands of plants for providing better, more pleasant working conditions, for safety, and for protecting and insuring the physical wel fare of employees. With sound intensity attenuations as high as 104, documented by qualified sound engineers. Allied Witan Air Exhaust Mufflers will more than meet the re quirements for satisfactory reduction of noise levels--whether it be for already established shop practice, or pending regulatory legislation. 00001*4'1, VMC PERFORMANCE DATA Atomuffler has set the industry standards for years in sound control applications the world over and are now setting the pace in space. Witness the fact that Atomuffler is specified on missile projects where no compromise can be made on efficiency, de pendability or performance. Not only does the Atomuffler possess superior sound silencing properties but its value as an air diffuser is unsurpassed in the muffler field. Air diffusion positively prevents troublesome air flow and dangerous after-blasts. The Atomuffler's unique patented system is a new approach to sound control and is uncomplicated in use and installation and widely recommended by leading casualty insurance companies and safety engineers throughout the world. You can be confident of getting the ultimate in noise reduction, advanced muffler design, exceptional service and economy, wheri'you specify . 1 . Atomuffler. FREQUENCY BANOS Frequency Band Nol and Attanuatad Level* (Decibels)--Curve A--noise level whan exhaust air Is discharged directly into atmosphere with out a muffler (note--noise level in the higher frequency bands exceeds accepted danger level. Curve B). Curve B--Injurious noise level. Prolonged ex- finsure to noise exceeding this level can result n progressiva hearing loss. , -- ' Curve C--Attenuated level when ATOMUFFLER is attached to the exhaust opening of air equipment Shaded area illustrates the effective elimination of air exhaust noise with an Atomuffler used on air-operated equipment Noise Level and Attenuated Level (At Various Air Una Pressures)--Curve A--noise level when exhaust air is discharged directly into atmos phere without a muffler. Curve B--attenuated level when ATOMUFFLER is attached to the exhaust opening of the equip ment. Shaded area illustrates the effective elimination of air exhaust noise with an ATOMUFFLER used on air-operated equipment. Curve A--magnitude of loudness when exhaust air is discharged directly into atmosphere without a muffler. Curve B--Exposure to noise above this level is difficult to endure, hearing loss can result from continuous exposure, protection required. Curve C--Exposure to noise above this level causes fatigue, poor efficiency and costly errors, protection recommended. Curve 0--attenuated level when ATOMUFFLER is attached to the exhaust opening of the equipment. Shaded area illustrates the effective elimination of air exhaust noise with an ATOMUFFLER used on airoperated equipment. This 8.r?Pb was prepared to show exhaust noise loudness in sones ranging from loud to soft as distinguish ed by the human ear, In defining loudness sones differ from decibels in that a decibel is a numerical value indicating intensity of noise, whereas sones indicate the actual loudness as heard by the human ear. vvc 00001A258 WELDING EQUIPMENT FOUNDRY EQUSPM RS AND PUMPS AIR PRESSES AND HOIS *'5 ASSEMBLY EQUIPMENT AIR TOOLS Ml HD CLUTCHES AND PRESSES AIR BOOSTS ,FTS SIMULATION CHAMBERS MEAT PACI EF & CONTROL VALVES FOOD PROCESS! ERIES CHEMICALS TIRE TREADING EQUIF r ' Air Exhaust Muffler EP TYPE-SINGLE CHAMBER WITH THE ALLIED WITAN ATOMUFFLER DESIGN FOR NOISE CONTROL Stops Noise Before it Starts Description--Page 1 Noise Control Data--Page 2 Thoroughly proved by years of use in thousands of plants, Atomuffler EP Type Air Exhaust Mufflers more than meet all requirements for the effective control of air exhaust noise from air cylinders, valves, tools, hoists, clutches and other air operated devices--with negligible impairment of operating efficiencies. Like all Allied Witan Atomufflers, the EP Type Muf fler is constructed with an expansion chamber com pletely free of obstructions, from which the exhaust air, at reduced velocity, is softly dispersed through the openings of the perforated cylinder wall of the muffler--free of noise and providing complete pro tection to personnel from injurious air blast. Constructed entirely of corrosion resistant material for maintenance-free performance, EP Type Mufflers are supplied with standard male pipe thread connec tions for quick, easy attachment to the air exhaust port and may be mounted in any position. EP TYPE 4-44 SERIES SPECIFICATIONS Model MQ1 M02 MOO M05 M07 M10 M12 MIS M20 A Vfe lA % Vz Va 1 l'/4 lVi 2 8 1ft 1 Vs 2% 314 3% 3 V* 3ft 5 Vs 5'i C 3 4 4H I1/, 6-Va 8 814 1314 18;/a D 2% 3:A 4Va 5 6`/ti 7 l4 7 V. 12 17 E v'z x>-'z Ve % 1 114 l1 i Wght./lb. ,?b .31 .50 .62 .7b 1.0 l.U 4.Q b.O Exhaust r" Surface Area/IN2 4.6 7.1 12.2 16.9 24.1 31.8 39.9 79.5 119.3 (All dimensions in inches) 1 Air Exhaust Muffler EP TYPE-MULTI-CHAMBER A 111 r LOW (SCFM) . . . WITH THE ALLIED WITAN ATOMUFFLER DESIGN FOR NOISE CONTROL Stops Noise Before it Starts Description--Page 1 Noise Control Data--Page 2 8 15 HO 45 60 75 100 200 STATIC PRESSURE (PSIG) Developed by Allred Witan for effectively eliminating the roar of air exhaust blast created by large, air operated equipment, the Atomuffler EP Type MultiChamber Air Exhaust Muffler gives you these out standing advantages: Large total exhaust area provided by the com bination of the perforated surfaces of four exhaust cylinders insures soft, quiet dispersement of large volume, high velocity exhaust-- quietly and with negligible reduction in the operating efficiency of the equipment. Compact multi-chamber design, incorporating four air exhaust cylinders into relatively limited space, eliminates necessity for otherwise bulky, heavy unit requiring undue amount of space-- provides unit that is lightweight, more econom ical, and is easier to handle and maintain. Like all EP Type Single Chamber Air Exhaust Mufflers, each of the four air exhaust cylinders in the EP Type Multi-Chamber model is constructed with an expan sion chamber completely free of obstructions, from which the exhaust air, at reduced velocity, is softly dispersed through the openings of the perforated cylinder wall of the muffler--free of noise and pro viding complete protection to personnel from in jurious air blast. Constructed entirely of corrosion resistant material for maintenance-free performance, EP Type MultiChamber Air Exhaust Mufflers can be quickly at tached to the air exhaust port with a simple pipe thread connection and may be mounted in any position. 300 NOTE: For extremely demanding service, EP Type Multi-Chamber Mufflers can be supplied, when specified, with special heavy duty all metal cylinder wall disseminators. EP TYPE 4-A SERIES SPECIFICATIONS Modal M30 M40 j A 34 S 6*4 7V4 C 23% 2 3 Vi D 15% 21 Vi E 2Va 2 Vi F Wght./lb. V* 11 9Vb 14 Exhaust Surface Area/IN* 294.4 344.0 (All dimensions in inches) M60 6 10% 303/4 27% 3>/s 13ys 26 636.4 VVC 000014261 A Air Motor Moffler SINGLE CHAMBER . WITH THE ALLIED WITAN ATOMUFFLER DESIGN FOR NOISE CONTROL Stops Noise Before it Starts Description--Page 1 Noise Control Data--Page 2 The EP Type 4-44 Series Muffler is particularly ap plicable for silencing the objectionable whine created by air motor exhausts. Like other mufflers with the Atomuffler design for noise control, this 4-44 Series Air Motor Muffler is constructed with a unique obstruction-free expansion chamber, from which the exhaust air, at greatly re duced velocity, is softly and quietly dispersed through the extra large disseminator area provided by the perforated cylinder wall of the muffler. With negligible mechanical impedance, the 4-44 Series Air Motor Muffler effectively eliminates the air exhaust noise, with little impairment of the air motor operating efficiency. Ordinarily supplied with standard pipe thread con nections for quick, direct attachment to the air exhaust port, Air Motor Mufflers can also be supplied, when specified, with special inlet fittings to fit your particular equipment. Note: For use with air motor starters used on trucks, trailers and other vehicles, Air Starter Mufflers are specially constructed and assembled to withstand road vibration. To order, add suffix "AV" to part num ber of model required. Example: EPType-4-44Series Model M10-AV. EP TYPE 4-44 SERIES SPECIFICATIONS * Model M01 MOZ MOD M05 M07 i M10 M12 M20 1o L ... A B C E Wght./lb. Exhaust Surface Area/IN2 Va -A Ys 1,;. Va i 1 VA 1 1-/2 2 ji y* 1J-8 2 V6 3 Vi V/s iVa 3% : 5 Vs 5 Vs 3 4 4% 63/4 ! 8 SVa 13 vi 18 Vi 2% i-A 4 `--j b 6 Va : 7 '/, 7 74 12 17 y3 '.i ii 1 1',-i Pi .25 .31 .50 .62 .75 1.0 1.0 4.0 5.0 j -- i! 4.6 7.1 12.2 16.9 24.1 ' 31.8 39.9 1 79.5 119.3 (All dimensions in inches) 6 lJhr,o< l vvc 000014262 1 Vacuum Pump Muffler VP TYPE WITH THE ALLIED WITAN ATOMUFFLER DESIGN FOR NOISE CONTROL Stops Noise Before it Starts Description--Page 1 Noise Control Data--Page 2 VACUUM/IN-H VP Type Mufflers are designed to muffle the annoying and distractive noise of vacuum pump exhausts. An efficient and inexpensive addition to your pump, they are recommended for expirators, suction apparatus, vacuum frames, chucks, simulation chambers, trans fer and control devices--where quiet and efficient pump performance is essential. Attenuation of the irritating exhaust pulsations is achieved by an obstruction-free expansion chamber, from which the exhaust air, at lowered velocity is softly dispersed through the openings in the large area cylinder wall disseminator of the muffler... free of noise and without causing mechanical impedance. Mufflers are ordinarily supplied with standard pipe threads for direct connection to the exhaust port of the pump. Where required, they can also be supplied with special inlet fittings to fit your particular equip ment. Constructed entirely with corrosion-resistant materials. Note: For handling of extremely high vacuum applica tions, VP Type Mufflers will be furnished, when specified, with special heavy duty all metal cylinder wall disseminators. PUMP EFFICIENCY VP TYPE 4-44 SERIES SPECIFICATIONS Model V01 V02 voo V05 V07 V10 Vl2 V15 V20 A B C D E Wghf./lb. Exhaust Surface Area/IN* `/a 17a 3 2% % .25 4.6 `.4 i ;- 4 V/.: '/? .31 27a 454 4 V, .50 3 `4 5 '/< fl /> .52 3i-a 654 6 v;j 'a .i 1 37s 8 7-4 1.0 1 '4 1 Vs 2 3'/S 5'/s 5'4 8-,4 13 Vi 18'4 7 7: 12 17 1 Ui 14 10 4.0 :>.o 7.1 12.2 16.9 24.1 31.8 (All dimensions m inches) 39.9 79.5 119.3 VP TYPE 4-A SERIES SPECIFICATIONS Model V30 V40 V60 A4 B 654 754 C 23-1 D 15 7s 214 E 2`4 2-.4 F !/.i 9 ' ,, Wghl./lb. n 14 Exhaust Surface Area/INJ 294.4 344.0 (All dimensions i ri inches) 6 107/b 3054 27% 3 /a 13 Vo 26 636.4 vvc 000014-263 7 Filter Silencer FS TYPE The FS Filter-Silencer is a highly efficient dual-stage filter plus an effective muffler for equipment such as compressor intakes, pressure blowers and pumps, reservoir vents, and gear housing breathers, used wherever it is essential that air be free of contami nation. FEATURE BENEFITS: Dual-stage depth filtration filters out extremely fine dirt particles. Excellent attenuation of noise for quieter operation. Performs equally well at high or low velocities. Simple and easy to service. Long service life. Filter elements are designed for heavy duty and sized for high flow rates and continuous operation. Filter elements consist of two separate independent filters providing positive filtration and protection of vital equipment from damaging airborne dust. Elements can be cleaned, if necessary, simply by detaching and immersing the entire Filter Silencer unit in any readily available solvent. Replacement filter elements for Filter Silencer units can be obtained from the factory. SPECIAL APPLICATIONS FS Filter Silencer. .. For Use As a "Dehydrator" When required for removal of excessive moisture from the air, FS Filter Silencer units can be ordered complete with Adsorptive Agents (Desiccant, etc.) prepacked in Filter Silencer cylinder by the factory. Replacement supplies of Desiccant may also be ordered separately. FS Filter Silencer . .. With Activated Carbon To provide an inexpensive, effective method for protecting vital equipment from corrosive air con taminants. FS Filter Silencers are available with cylinders prepacked with Activated Carbon at the factory. Replacement supplies of Activated Carbon only also available separately. Write to the factory for further details. DUAL-FILTER STAGES ;n T. Com aLh* j FS TYPE 4-44 SERIES SPECIFICATIONS Model F01 FQ2 FOO F05 F07 F10 F12 F15 F20 Flow Rate-- CFM 6 A '/e B 17s C O 2Va E Wght./lb. <? .25 9 ! 6 61 69 81 l4 'i 34 1 17s 27s 3'.! 3% 37s 4 5 7. 674 ' 8 3`/2 4'.:, - 6 % 77 '/2 V? i . '4 .31 .50 .62 .75} 1.0 (AM dimensions in inches) 139 17, 3 7s 8Vi 7 'A i 1.0 205 l'/2 5Vfr 13-4 12 Vi, 4.0 345 ? 5`/8 18 '4 n 74 5.0 FS TYPE 4-A SERIES SPECIFICATIONS Model F30 F40 Flow Rate-- CFM 670 '50 A 34 B 63/4 77i C 2 3 Vi 2 3 Vi D E F Wght./lb. 157b 21/8 a4 li 21'4 2' 4 9 7? 14 (All dimensions m inches) F60 950 6 10 7b m* S:K 13 26 vvc 00001^264 Speed Control Muffler CS TYPE W . . . WITH THE ALLIED WITAN ATOMUFFLER DESIGN FOR NOISE CONTROL Stops Noise Before it Starts Description--Page 1 Noise Control Data--Page 2 Inexpensive, and highly effective for eliminating air 1000 exhaust noise, the CS Type Speed Control Muffler 9e provides the added feature of speed control for air ? operated devices. s 6 Connected directly to the exhaust port of the air operating valve, CS Type Mufflers are extensively used to regulate cylinder or actuator speeds on weld ers, presses, riveters, stitching equipment, etc.-- wherever it is desirable to regulate air fiowforthe con trol of cycle time, and to reduce wear and tear on the equipment. 10 4 8 15 30 45 60 75 90 STATIC PRESSURE (PSIG) Note: Ordinarily supplied with male pipe threads from Vs" through 3/b inches, CS Type Mufflers can also be satisfactorily used for pipe sizes larger than Ys inches. With ample capacity to regulate the flow of larger pipe sizes, the CS Type Model COO Muffler (see table), with the use of a simple reducing bushing, can be quickly and easily installed into the exhaust port of the air operating valve. Adjustment to the cylinder speed desired is ac complished by regulating the flow of exhaust air through the muffler, simply by turning an external adjustment screw which accurately varies the orifice opening of the muffler, from closed to full flow. Ample latitude provided by adjustment screw insures smooth even adjustment of airflow--makes it easy for operator to "zero in'' to exact setting required. Se curely locked at the required setting with a locknut, the adjustment screw cannot be removed or blown from the muffler. Constructed with the Allied Witan Atomuffler design for noise control, the CS Type Muffler is provided with an expansion chamber completely free of obstruc tions, from which the exhaust air, at reduced velocity, is softly and quietly dispersed through the openings of the cylinder wail of the muffler--with nothing re maining of the high pitched noise often characteristic of metered air discharge applications. c D----------------- - E-- CS TYPE SPECIFICATIONS Model CM C02 A B C D E Wght./lb. Mi 14 17/b 1% 34 2% 3!/2 3/i3 -/2 .31 .37 (All dimensions in inches) COO % 2% 4Va 4 '/4 l/2 .56 vvc 00001A265 9 A Steam Exhaust Muffler SM TYPE Low in cost, compact, lightweight and easy to handle, SM Type Mufflers effectively silence the annoying and objectionable noise created by steam exhaust outlets. Unlike other mufflers for steam exhaust service, they are constructed with expansion chambers com pletely free of obstructions, in which the exhaust steam is expanded, then disseminated at reduced velocity through the perforated cylinder wall openings of the muffler-without noise, and with negligible mechanical impedance. As an additional safeguard for meeting the require ments of unusually demanding applications, SM Muf flers are supplied with heavy duty metal cylinder wall disseminators for successfully combating the other wise potentially damaging effects of high flow rate and temperatures up to 1000* Fahrenheit. Constructed of corrosion resistant materials and treated with a special coating for resistance to con ditions where alkalis could be a problem. For quick, direct connection to steam exhaust ports, SM Mufflers are supplied with standard pipe thread connections in a full range of sizes from 1 to 6 inches. STEAM TEMPERATURE *F (SATURATED) PRESSURE absolute (P S i i Nu-u te.r> NsJ Company SM TYPE SPECIFICATIONS Cudv/r.LMo j Ohio Model S10 S12 SIS S20 S30 S4D S60 A B C D E F Wght./lb. Exhaust Surface Ara/IN* 1 1ft 1ft 2 3 3ft 3ft 5ft 5ft 6ft 8 m 13 Vi 18 ft 23 ft 7ft 7 Vi 12 17 15ft a/a 1 IVi ift 2ft 8 '/a 1 1 4 5n 31.8 39.9 79.5 119.3 294.4 (All dimensions in inches) 4 7ft 23 ft 21ft 2ft 9ft 14 344.0 6 10ft 30ft 2 7`ft i'/s 13ft 26 636.4 in VVC 000014266 COLLIMATOR AE TYPE--MODEL T Vi" to TUBE 3 Tube Type Air Ejector Muffler AE TYPE - MODEL T Pinpoints Highly Concentrated Air Stream for Noise-Free Parts Ejection Units are made with the unique air savings collimator muffler insert mounted in a tube. Permanently installed in a 12" length of copper tubing, the collimator accur ately directs a highly concentrated and intensified air stream to the exact point required. Uses less air to do the job--as much as 75% less. Drastically cuts air consumption and operating cost. Reduces noise level well below OSHA requirements. Easily bent, the tube may be cutto any desired length and positioned to suit set-up. Makes it easy to getinto even extremely tight quarters. Supplied with either lA" or 3/a" tubing. Can be quickly connected to air line with standard tube fittings. SPECIFICATIONS AE TYPE-MODEL T MODEL Tube Diameter Overall Length T2B l4 12 T38 Va 12 -- Air Ejector Collimator Muffler Insert -- AE TYPE - MODEL I For Direct Installation into Air Hole Outlets of Dies, Molds, and Other Equipment. Used for Air Ejection, Eduction, Blow-offs, Wipes and Air Cleaning. These collimator muffler inserts are used where it is necessary to drill air holes directly into the equipment. Provides a highly concentrated air stream with intensi fied thrust for effective noise-free ejection. They can be easily installed directly into the air hole outlet, merely by drilling or reaming the proper hole size to accommo date the collimator muffler insert. <t tt X* SPECIFICATIONS AE TYPE - MODEL I MODEL 108 118 128 133 148 168 188 Diameter Length * i 1 V,2 l,3S Sl.M 5 2 6-1 IVm l;i 1 V 3J ,s33 '-a *Vb2 1 ' :e Patents and Patents I'endmi: Allied Witan Company 13805 Progress Parkway Cleveland, Ohio 44133 VVC 000014267 Printed in U.S.A. LHfl74-5M 17