Multi-Muffler Sound Attenuator for Oilfield Noise Reduction
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Solution Overview
Problem
The noise emitted by multiple diesel engines during oilfield stimulation operations poses a health hazard to operators and a nuisance to nearby communities, with conventional mufflers failing to adequately reduce noise levels and hospital-grade mufflers being costly and impractical for widespread use.
Innovation Solution
A multi-muffler sound attenuator assembly that orients multiple muffler devices to achieve synergistic noise cancellation, directing exhaust sound flows towards a central location or each other for maximum noise reduction, potentially combined with a central attenuating filter and anti-noise generators, without the need for heavier or more expensive muffler components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional industrial mufflers are used, then cost is reduced, but noise levels remain above 85 dB which is hazardous to operators
Solution Approach 1:
The system divides noise control into multiple independent muffler units, each handling a specific engine or exhaust source. By segmenting the noise attenuation function across multiple devices rather than using one large muffler, the system achieves better overall noise reduction while maintaining flexibility and cost-effectiveness.
Solution Approach 2:
The system combines multiple muffler devices into a coordinated array that works together to achieve synergistic noise cancellation. The mufflers are positioned and oriented to create interference patterns that cancel noise waves, merging individual muffler effects into a collective noise reduction solution.
2Object-affected harmful factors
If hospital grade mufflers are used, then noise levels are reduced below 80 dB, but weight increases by 400-500 lbs and cost increases by 20%
Solution Approach 1:
Instead of using one or two large hospital-grade mufflers, the system segments the noise control function across multiple smaller conventional mufflers. Each muffler handles a portion of the total noise load, allowing the use of lighter, less expensive components while achieving the same overall noise reduction effect through their coordinated arrangement.
Solution Approach 2:
The system replaces the purely mechanical approach of using oversized mufflers with a combination of conventional mufflers and acoustic positioning. By using the environment and spatial arrangement to enhance noise cancellation, the system avoids the need for heavier muffler construction.
3Object-affected harmful factors
If hospital grade mufflers are used, then noise levels are reduced below 80 dB, but equipment cost increases by 20%
Solution Approach 1:
The noise control function is segmented across multiple conventional mufflers rather than requiring expensive hospital-grade units. This segmentation allows the system to use off-the-shelf, cost-effective components while achieving superior noise reduction through their coordinated deployment and acoustic interference effects.
Solution Approach 2:
The system uses multiple conventional, easily replaceable mufflers instead of expensive hospital-grade units. The conventional mufflers are more cost-effective and can be readily replaced if needed, providing an economical solution that achieves the same noise reduction performance without the premium cost of specialized equipment.
4Productivity
If multiple pumps and engines are used for fracturing operations, then productivity is increased, but total noise emission increases proportionally
Solution Approach 1:
The system merges the noise control function across multiple engines and pumps into a coordinated noise management approach. By positioning mufflers from multiple engines to work together and create collective noise cancellation effects, the system achieves noise reduction that scales with the number of engines, allowing productivity increases without proportional noise increases.
Solution Approach 2:
The system converts the harmful effect of multiple noise sources into a benefit by using the multiple engines' exhaust flows to create synergistic noise cancellation. The presence of multiple engines, which would normally multiply noise problems, is instead leveraged to create an array of mufflers that work together to cancel noise more effectively than a single muffler could.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces noise levels to below 80 dB without the added expense and weight of hospital-grade mufflers, providing a cost-effective and user-friendly solution for noise attenuation in oilfield operations, while maintaining engine performance and reducing exhaust emissions.
Implementation Method 1
The mufflers include an inlet for coupling to its corresponding source as well as an outlet to direct sound therefrom. The outlets are configured to direct sound to a location for attaining a degree of sound cancellation.
Data Source
AI summary
A unitary, skid-type sound attenuator assembly for simultaneously managing sound from multiple sources. The assembly may include a dedicated muffler for each sound source. In turn, each of these mufflers includes an outlet for directing sound toward a location such as between the various mufflers of the assembly so as to provide an added level of noise cancellation. Additionally, the assembly may include an attenuator at such a common central location for further noise reduction. The attenuator may also serve a filtering function, for example where the sound sources are engines and the assembly is utilized for managing exhaust therefrom such as in an oilfield environment.