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Noise Abatement Techniques for Construction Equi Pment

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Noise Abatement Techniques for Construction Equi Pment PB300-948 1111111 III II I1/ I1/ I1111111111 11111111 REPORT NOS. DOT-TSC-flHTSP.-79-45 HS-803 293 NOISE ABATEMENT TECHNIQUES FOR CONSTRUCTION EQUI PMENT Hilliam J. Toth SOCIETY OF AUTOMOTIVE ENGINEERS, INC. 400 Commonwealth Drive Warrendale PA 15096 . ' :~ . , . AUGUST 1979 FINAL REPORT DOCUII.1EN r IS AVAI L ABl.E TO ','Hlo PUBLIC THROUGH ,HEo NATIONAL TECHNICAL INFORMATION SERVICE, SPRINGFIELD, VIRGINIA 22161 Prepared for U,S, DEPARTMENT OF, TRANSPORTATION NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION Office of Research and Development Washington DC 20590 REPRODUCED BY U.S. DEPARTMENT OF COMMERCE NATIONAL TECHNICAL INFORMATION SERVICE SPRINGFIELD, VA 22161 NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange: The United States Govern­ ment assumes no liability for its contents or use thereof. NOTICE The United States Government does not endorse pro­ ducts or manufacturers. Trade or manufacturers' names appear herein solely because they are con­ sidered essential' to the object of this report. T ec:hnicol keport Documentation Page .. I. R.port No. - ----- 2. Gov.,nment Ace.'lion No. HS-B03 293 3. PiBt~oOtl9 Jf 8 4. Titl. and Subti.,. 5. Report Da.e NOISE ABATEMENT TECHNIQUES FOR August 1979 CONSTRUCTION EQUIPMENT 6. Performing Organi zotion Code 8. Performing Organi zation Report No. 7. Authorl.) William J. Toth DOT-TSC-NHTSA-79-45 9. Performing Organization Name and Addre .. 10. Work Unit No. (TRAIS) Society of Automotive Engineers, Inc. "1( HS93l/R9402 400 Commonwealth Drive 11. Contraet or Grant No. Warrendale PA 15096 DOT-TSC-9l5 13. Type of Report and Period Covered 12. Span,aring Ageney Name and Add,... U.S. Department of Transportation Final Report Jan. 1976-Feb. National Highway Traffic Safety Administra'tion 1977 Office of Research and Development 14. Sponsorino Ageney Cod. Washington DC 20590 IS. Supplementary Note, U.S. Department of Transportation *Under contract to: Research and Special Programs Adrnini~t:~ra~iQn_,_ Transportation Systems Center f1'~produced from Cambridge MA 02142 best available copy. 16. Abstraet The primary objective of this work was to transfer technology developed in the area of truck noise reduction to that of construction equipment. Included is information gathered from previous contracts, surveys of manufacturers, a noise impact ranking by equipment type, engine and equipment test results, specific information to enable equipment owners to reduce noise from their equipment, and recommendations dealing with reasonable noise level goals for used equipment. Work accomplished under this contract involved the compilation of comprehensive specifications for diesel engines greater than 50 horesepower used in the construction industry, the development of a comparative muffler selection procedure, and the collection of costs for mufflers and complete exhaust systems. A noise impact ranking was developed to characterize equipment types with respect to degree of noise pollution. This ranking was based on: the average machine noise level, the typical percentage of time the machine was at ful load, the~ average production rate per year based on production figures of the last ten years, and proximity of machine use to human population. Using the noise impact ratin~ system, front-end loaders, tractors, and backhoes (excavators) were identified as the three machines of the greatest impact. Detailed tests conducted on two classes of tractors, a front-end loader and a backhoe, identified the contributions of the variouf major component noise sources to overall machine noise levels. Results indicate that t construction equipment produced s~nce the late 1960 s have utilized reasonable mufflin~ such that exhaust noise is not generally the dominant noise source. 17. Key Wa,ds 18. Distribution Statement N0ise, Construction equipment noise, DOCUMENT IS AVAILABl.E TO THE PUBLIC Ground transportation noise, Diesel THROUGH THE NATIONAL TECHNICAL INFORMATION SERVICE. SPRINGFIEL D, engine noise, Engine exhaust noise, VIRGINIA 22161 Engine mufflers 19. Seeurity CloOlI/. (of thi' report) 20. Secu,'ty Clo ..il. (01 thlo paO.) I 21. No. of Pal/e" I 22. Priee Unclassi:f;ied Unclassified 1J~9- /JtJ/ Form DOT F 1700.7 (8-72) Reproduction of completed pOlle outhorlzed PREFACE This report summarizes the subcontractual effort on the Society of Engineer (SAE) Contract R-22, The Application of Truck Noise Abatement Techniques to Off-Highway and Station­ ary Equipment. The U.S. Deportment of Transportation awarded the prime contract to the SAE who subcontracted to Donaldson Company. Technical efforts were basically performed during the months of January through September 1976, with the final report completed February 1977. The main objectives of this contract were: (1) to compile comprehensive specifications of all diesel engines greater than 50 horsepower used in the construction industry, (2) to develop a comparative muffler selection procedure, and (3) to provide costs for mufflers and com­ plete exhaust systems. These objectives were requested because engine exhaust noise was assumed to be the dominant noise source in construction equipment. This report was written by Stephen Schmeichel and David Winnes. Donaldson Company, Inc. relied on the assistance of many engine, equipment, air cleaner and muffler manufacturers for their contributions. In addition, numerous iron mines, gravel quarries, construction sites, coal mines, etc., contributed greatly to the contractual effort by allowing their equipment to be tested on site. We wish to extend thanks to the above companies and people for their contributions and especially to extend thanks to Paul Schomer, Charles Sanders, and Walter Page, members of the SAE monitoring panel, who contributed immeasurably to the contract effort. Preceding page blank iii METRIC CONVERSION FACTORS M .Approxim.'1 Conversions 'A Mltrie Measures N - Approximl'l Conver.ions from Mltric ~lSurl' N - N h.hl Who , .. KR •• Mllli,l, h T. fi.4 S,...I W~ •• , .. Itol. - S,.~01 Mlhi,ly ~, To fi.4 S,.~.I ;; - LENGTH ~ ~ LENGTH millimeters 0.04 Inches :!: an . centimeters 0.4 Inches - meters 3.3 I... It ;n inch•• 2.S centimeters - meters 1.1 yards It f ••• 30 centlme.ers em ~ !un ktlorNters mil•• m; yd 0.9 met.rs - 0.6 '" V.... • - mir •• 1.6 kilometers !un =-- :: AREA AREA ~ - - m?- squ.... centimet.,. 0.18 square inches in! in2 square inch•• 6.S squilr. centimeUKI em' := m' square met.... 1.2 square yarda .... It' square fHt 0.09 squar. meters m' !un' squ.r. kllarr.I.... 0.4 IqUMe mil•• m,' - 2 yd' aqua,. yarda 0.8 squilr. noel." m' no beet_.. 110.000 m , 2.5 2 - :: ..... ..... mi square mil.. 2.6 square kilometer, !un' - <: Kr•• 0.4 hec"-r•• h. - ::: MASS !wli,.'1 MASS !Wli,.'1 - ~ gr... s 0.036 0UftC.. .z • z ounc •• 28 grams g - . • Itllogr...... 2.2 Ib Ib _. 0.45 kilograms kg _ = -. tonnes (1000 kg) 1.1 short tonI sh(Wt tons 0.9 lonne. - - (2000 Ib) - ~ VOLUME - VOLUME I.p t ••spoons milliliters ml - ml millilit.,. 0.03 fluid ounce. II .. Tbop gbl•• poona 15 milliliter" ml - I liters 2.1 pmta .. II .. fluid ounc •• 30 milliliters ml -- ht.... 1.06 quarts .. cup. 0.24 IIt.,,1 I lit.... 0.2t Q8l1ona gol pi pints 0.41 liters -- m' cubic meters 35 cubiC 'nt II' ql q ...rts 0.95 Iners - m' cubic meters 1.3 cubic yarda ",' gol gallons 3.8 Illers I - It' CubiC fee, 0.03 cubiC meters m' - yd' cubic yards 0.16 cubic meters m' TEMPERATURE ,"Ie'l - TEMPERATURE !.. Ie,} - 'c CelSIUS 9/5 (..... Fehrenhe.t ·f - temper.ture _32) .........ture ·f Fah,.nhei. 5/9,.h_ Celaius ·c - tem.... tute subIrIIC1ing temperature - OF 32t OF 12 .... 212 - -40 40 ! ' , I , .~ , t ,'~O! I " ~o , I ! 2':" ~ I I iii i i I I 100 1 20 40 &0 ~ - -40 -20! '.' 0 '0 ~ 57 'c .M - - ·c TABLE OF CONTENTS Section Page 1. INTRODUCTION 1.1 Background 1.2 Scope of the Contract 2 2. SUMMARY 4 2. 1 Overview of Work Accomplished 4 2.2 Conclusions and Recommendations 5 3. SUPPORT INFORMATION 7 3. 1 Theoreti ca I Considerations 7 3. 1. 1 Intake and Exhaust System Operation 7 3.1.2 Types of Muffler Devices 8 3.2 Background Data 11 3.2. 1 Manufacturer-Equipment-Engine Matrix 12 3.2.2 Engine Manufacturer Survey 14 3.2.3 Equipment Manufacturer Survey 15 3.2.4 Field Survey 21 3.2.5 Exhaust System Survey 21 3.2.6 Intake System Survey 21 3.2.7 Literature Search 21 3.3 Noise Impact Ranking 25 3.4 Muffler Appl i cation Eval uation 33 3.4. 1 Test Procedure 33 3.4.2 Engine Tests 39 3.5 Equipment Tests 43 3.5.1 Machine Test Results 44 3.6 Conclusions and Recommendations 52 v TABLE OF CONTENTS (continued) Section 4. EQUIPMENT NOISE REDUCTION 56 4. 1 Noise Reduction Procedure 56 4.1.1 Step-by-Step Procedure 57 4.1.2 Determination of Dominant Noise Sources 59 4.2 Diesel Engine Specifications 63 4.3 Engine Muffler Recommendations 66 4.4 Muffler Horsepower Guide 67 4.4. 1 Development of Muffler Horsepower Guide 67 4.4.2 Description of the Muffler Horsepower Guide 68 4.4.3 Muffler Style-Exhaust System Configuration 71 4.4.4 Procedure for Use of Muffler Horsepower Guide 71 4.4.5 Muffler Horsepower Guide Organization 73 4.5 Muffler Costs 75 4.6 Exhaust System Costs 76 4.7 Exhaust System Installation Procedure 77 4.7.1 Back Pressure Limits 77 4.7.2 Silencing Effectiveness 77 4.7.3 Structural Considerations 78 BIBLIOGRAPHY 90 APPENDIX A Engine Specifications A-l APPENDIX B Muffler Horsepower Guide B-1 APPENDIX C ~1uffl er Cost C-l APPENDIX D Exhaust System Costs D-l APPENDIX E SAE J88a Procedures and Rationale for Using Fast Response for IMI Testing E-l APPENDIX F Precise Technique for Noise
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