DG Set Performance with Elastomeric Type Isolators

How to Reduce Vibration in Diesel Generator (DG) Sets for Smoother Operation

Diesel Generator (DG) sets are widely used in commercial, industrial, and residential applications to provide backup or primary power. However, one of the biggest challenges in their operation is managing vibration. Uncontrolled vibration can lead to:

• Structural damage to building foundations
• Misalignment of mechanical components
• Increased noise levels
• Reduced equipment life

To combat these issues, Resistoflex provides a comprehensive range of vibration isolation solutions tailored specifically for DG sets.

Why Vibration Control is Crucial in DG Sets

Diesel engines produce both low- and high-frequency vibrations due to internal combustion and rotating components. If these vibrations are not properly isolated, they can propagate through the structure, causing significant mechanical stress and noise pollution. Proper vibration isolation enhances:

• Equipment longevity
• Operational reliability
• User comfort and safety

Vibration Isolation Solutions by Resistoflex

Below is a list of high-performance vibration isolation products by Resistoflex, each engineered to suit different installation scenarios and load conditions:

1. Open Spring Damper
   The Open Spring Damper is designed with a stable steel base and free-standing spring for high static deflection and effective vibration control. The spring is powder-coated and color-coded for easy identification.
   Application: Diesel generators, HVAC units
   Features:
   • High deflection steel spring with leveling bolt
   • Neoprene acoustical pad to prevent noise transmission
   • Epoxy powder coating for corrosion resistance


2. Seismic Restrained Spring Mounts
   These mounts are tested for seismic applications and feature a limit stop design that restrains equipment during seismic or wind events.
   Application: Installations in seismic zones
   Features:
   • Restrained spring with vertical and horizontal limit stops
   • Complies with seismic code requirements
   • Designed to prevent tipping or excessive movement


3. Enclosed Spring Mounts
   This mount features a complete steel enclosure with a load-transfer plate, making it ideal for visible installations and protection against mechanical damage.
   Application: Generator sets in sensitive or exposed areas
   Features:
   • Heavy-duty steel housing
   • Spring loaded with leveling adjustment
   • Noise isolation and protection in harsh conditions


4. Genflex Rubber Mounts
   Genflex mounts are molded from high-grade elastomers and are ideal for isolating vibrations from small and medium generators.
   Application: Light and medium-duty DG sets
   Features:
   • Compact design
   • Simple installation with through bolts
   • Resistant to oil and environmental degradation


5. Fleximount Rubber Isolator
   This mount features a bonded rubber-in-shear construction with a heavy-duty base, suitable for engines and compressors.
   Application: Small generators and similar equipment
   Features:
   • High damping in vertical and horizontal planes
   • Bolt-on installation
   • Excellent isolation in compact configurations


6. Importance of Vibration Isolation in DG Exhaust Systems
   The exhaust system of a Diesel Generator is highly susceptible to both thermal expansion and mechanical vibration. If not properly handled, these stresses can lead to:
   • Fatigue cracks in exhaust pipelines
   • Loosening of joints and flanges
   • Increased noise and vibration propagation
   • Damage to engine manifolds and silencers
   
   

   How Resistoflex Solves This with Metallic Expansion Joints

   Resistoflex Metallic Expansion Joints are specifically engineered to handle both high-temperature exhaust gases and mechanical movement caused by engine vibrations.
   
   Functionality: Absorbs axial, lateral, and angular movements
   Material: Stainless steel bellows with reinforced connectors
   Construction: Designed to withstand high temperatures, pressure fluctuations, and corrosive exhaust gases.
   
   Benefits:
   • Prevents stress buildup in exhaust systems
   • Compensates for thermal expansion
   • Isolate engine vibration
   • Enhances the durability of connected components
   
   Ideal Placement:
   • Between the engine outlet and the silencer
   • Before long, vertical risers
   • Near wall/roof exits
   • At bends or lengthy pipe runs
   This solution ensures the smooth and safe operation of DG exhaust systems, especially in commercial and industrial settings where reliability is paramount.

Best Practices for Effective Vibration Control

To achieve optimal performance and reliability from vibration isolators, consider the following technical guidelines:

1. Operating Speed
   Isolation efficiency depends on the natural frequency of the isolator versus the operating frequency of the DG set.
2. Load Distribution
   Accurate weight calculation is essential. Overloaded isolators may fail, while underloaded ones won’t provide effective damping.
3. Installation Accuracy
   All isolators must make full surface contact with the DG base and foundation. Misalignment can reduce performance and increase wear.
4. Seismic Safety
   In seismic-prone areas, always use seismic-restrained mounts as per zone classifications.
5. Routine Inspection and Maintenance
   Regularly check for signs of wear, deformation, and corrosion. Replace any isolators affected by chemical spills or UV exposure.

Conclusion

Effective vibration control is not just about reducing noise — it's about protecting your investment, enhancing performance, and ensuring long-term operational safety. With a wide range of engineered solutions from Resistoflex, including spring mounts, rubber isolators, and metallic expansion joints, you can ensure your Diesel Generator operates smoothly, quietly, and efficiently.

Choose quality. Choose performance. Choose Resistoflex.