The new fan has been installed, along with the larger smokestack. We are currently monitoring noise levels while we operate the fan at various speeds and make adjustments to the equipment. We would appreciate any reports of noise be directed to firstname.lastname@example.org with your general location. We will have more information in the next few weeks. Again, we appreciate the patience of the community as we work to solve this problem.
The cement has been poured and pipes have been designed for the new fan. We’re ready for the install once the fan arrives. We have not received any updates from the manufacturer; however, when the order was placed in mid-January, we were told to expect a minimum of 12 weeks for manufacturing and delivery. We are still operating on that timeline unless we hear otherwise.
We continue to operate the fan at a lower (quieter) RPM and in pilot-light mode in the evenings and on weekends.
After consulting with three different manufacturers, we’ve ordered a new custom fan that is being designed to produce significantly lower sound levels. This larger fan contains 20 blades (vs 8 blades on the current fan), runs at a slower RPM (1700 vs 2200), and its blades are specifically designed to reduce noise (backward curved vs radial blade). Along with the fan, we’ve ordered a new stack and all new pipes. We’re expecting the design and delivery to take 12 weeks, at a minimum. We will post updates as we receive them from the manufacturer.
We have been running slightly above pilot-light mode during the day and in complete pilot mode in the evenings since December 21. We will continue to operate at these levels until the new equipment is installed. As always, please feel free to email us at email@example.com with questions or concerns. Thank you.
After working with engineers and having a second muffler custom designed and expedited, we are sorry to report the second muffler has failed to solve the issue. This obviously is not the situation we were hoping for. We apologize to the members of the community who have been affected by the noise for the past four months. Please understand that we want this resolved as quickly as possible, as well. Our company has been a part of this community since 1949. We are committed to being a good neighbor. We wish there was a quick and easy fix to the noise.
We have located a manufacturer who is willing to design an alternate fan, which we are told will produce much lower sound levels. A new fan will most likely result in the need for a larger smokestack. We are waiting to hear how long this will take. We have asked that the fan be expedited at our expense.
Again, we apologize for the disturbances our operations have caused. We will continue operating the fan in pilot-light mode in the evenings until a solution is determined. We will operate in pilot-light mode completely on Dec. 24-25 with the hopes that everyone can have a peaceful holiday.
We are testing the new muffler tonight. Please email us at firstname.lastname@example.org with your general location if you hear the noise. Any descriptions of the noise you can provide would be helpful, as well. Thank you.
The new muffler has arrived. Our team is working to build the frame and install it. There may be some noise as we test it to ensure everything is installed correctly. Please email us at email@example.com with your general location if the noise becomes bothersome. Thank you.
We received confirmation that the new muffler shipped on Friday. We were not given an estimated delivery date, but we are assuming it will arrive within 7 business days (based on the schedule of the previous muffler). Please keep in mind that the muffler is traveling from Canada and has to go through customs. We will keep everyone posted on the schedule as soon as we know more. The plan is to have it installed within 24 hours of its delivery date.
A second sound muffler has been ordered. The new muffler will work in conjunction with the current muffler to further reduce the sound level generated by the boiler’s exhaust fan. This muffler is specifically designed to reduce only the sound level of the fan’s tone (about 315 Hz), whereas the current muffler has shown to be more effective at reducing non-tonal sounds. We are working with the manufacturer’s engineers and our sound consultant on the project. We are having it expedited, so instead of the typical 8-10 week design and delivery time frame, it will be delivered in about four weeks. We understand this isn’t ideal; however, it’s the quickest they can have it to us. We will continue to operate in pilot-light mode in the evenings and on weekends until the second muffler is installed. We also will continue to share progress on this site.
We wanted to send a quick update to let everyone know that we will be operating in pilot-light mode for the Thanksgiving holiday weekend. This will start at the end of the workday on Wednesday afternoon through Monday morning. We hope everyone has a wonderful Thanksgiving.
Pilot-light mode seemed to have been a short-term solution a few weeks ago; however, we have received a few emails from the community and understand the noise is now being heard in the evenings in pilot-light mode. Based on the data from the noise monitoring, the only thing we can attribute this to is the change in weather since all other factors have remained the same. Again, we apologize. We are working as quickly as possible toward a more permanent solution for the community and our company and wanted to provide an update on where we are in the process.
We were looking at installing a second fan to run with the existing fan, both at lower RPMs. We have now been advised that will not solve the issue. We are working on three additional options:
1. The muffler did not meet the performance specifications provided to us. We have been in contact with the manufacturer of the muffler to request they fix the problem or replace the muffler.
2. We are in discussions with a manufacturer to have an alternate fan designed and installed. The existing fan is an Industrial Radial Blade Fan that incorporates a wheel with (8) heavy-gauge blades. The new fan would be a Backward Curve bladed fan, which produces much lower sound levels. This larger fan moves more slowly and has (20) blades.
3. A new fan would most likely result in the need for a larger smokestack. Currently, the stack is 21” in diameter. We would look at increasing it to 36”.
We are working with a team of manufacturers, engineers, sound experts, and other consultants. Unfortunately, these solutions all take time. In the meantime, we will continue to operate the boiler in pilot-light mode beginning at 5 pm each evening. This is the best we can do at this time, as running it in pilot-light mode keeps the decibels (dBA) within the county’s compliance levels, and it drops the frequency of the sound from 315Hz to around 200Hz, while maintaining the health of the boiler.
We thank everyone for emailing us with their noise reports and locations. We’re working as quickly as we can to find a solution and will continue to post updates to this site to keep everyone informed on the progress.