In an effort to lessen the amount of noise created by the gasket machine exhaust system, Code 960 Nuclear Continuous Training and Development (CTD) Subject Matter Expert (SME) Paul Foster created an innovative sound dampening device to ensure a safer and quieter workplace for Bldg. 202's workforce.

The CTD office in Bldg. 202 is one of the offices aligning the gasket cutter room. Though the gasket cutter machine is an innovative piece of equipment, the ambient noise levels measured during its performance at the exhaust opening into the shop were reaching around 97 dBA, equivalent to a gas lawn mower operated three feet away. In addition, the exhaust opening was at eye level with workers without any sort of dampening material in place, the speed reaching at about 50 mph. And with the machine used daily, it was a consistent issue that needed to be addressed.

A cone was created to attach to the exhaust opening, similar to the aft exhaust cone on on a jet engine; however, when the air accelerated against the flaps the noise reached to about 117 dBA.

Seeing the need for improvement, the shops CTD Lead Andy Barrett reached out to Foster in hopes to develop a new device to dampen the sound for Code 960. He knew that Foster had already been recognized for development of devices like this before.

"My supervisor came to me and asked me to think of what I would do to solve the noise problem," said Foster. "I'm never satisfied with just the thought process and I have experience in many disciplines, including engineering and construction. So I began to think about it and from there I had a design in mind. I reached out to Stan Bailey in Code 920 who drew up my design so we began to create it. I wanted to put my skills to use to find a solution."

The noise attenuation device is a square-like box developed with noise dampening material lining the inside. It is attached to the exhaust system and points the air downwards to avoid it traveling straight out at eye level to the workers. In addition, the noise levels reach at about 79 dBA, close to a gas lawn mower operated 100 feet away, a huge improvement from previous iterations.

"If we were sitting in the CTD office when the previous device was in place, we wouldn't be able to hear each other if the machine was on," said Foster. "Now, you can't even tell the machine is on unless you're about 15 feet from the hood. It's a drastic improvement."

Foster added that seeing a solution to the problem is the first step in providing innovation to the shipyard. "Everyone at the shipyard works hard each day and we want to ensure they are safe on the job," he said. "If you're able to find a way to make the job safer and easier, take those steps to make the change happen."

Paul's other device; http://www.navsea.navy.mil/Media/News/Article/1100290/norfolk-shipyard-employee-innovates-to-reduce-hearing-risk/

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