Expansion Joints for Generator Sets Case Study
What is a generator set used for?
A generator set transforms the thermal energy coming from a fuel engine into mechanical energy by turning a shaft, and then in electrical energy in the form of alternating current.
There are three main reasons for buying this type of equipment:
- Solving problems of power supply in remote areas where the conventional electric network doesn’t come up or gets often cut off.
- When more electrical power is required than that provided by the network.
- As a protection mechanism against possible regular losses of power of the electric network, that can cause significant economic losses and even endanger the life of people.
In addition, it will also be necessary to install this type of systems when it’s requested by the legal framework.
Parts of a generator set
A generator set consists mainly of an internal combustion engine and an alternator.
(1) Engine; (2) Alternator; (3) Fuel Tank; (4) Voltage Regulator; (5) Exhaust and Cooling System; (6) Lubrication System; (7) Battery charger; (8) Control panel; (9) Bench
Other elements that are part of the generator sets are:
- Fuel tank.
- Voltage regulator.
- Exhaust system.
- Cooling system.
- Lubrication system.
- Battery charger.
- Control Panel.
- A bench.
The engine (that can be gasoline-powered, but it can also be fuelled with natural gas, diesel or propane) provides the mechanical energy required for the operation of the generator set, being this energy used by the shielded alternator to generate electricity, as the output power of the equipment.
The choice of fuel depends upon many factors such as the cost and availability, power of the generator set or scope of application (residential, commercial or industrial).
Importance of the exhaust system
Inside the exhaust system we have several main elements: exhaust pipe, flexible element to compensate dilatations and contractions, ceiling fixing and a silencer. Its main function is the evacuation of high temperature gases that come from the engine as silently as possible.
(1) Metal mesh; (2) Expansion joint; (3) 3-point fixing; (4) Insulation with mineral wool; (5) Silencer; (6) Flexible coupling; (7) Fiberglass texture.
Solution to efficiency problems in generator sets
Maximum power levels are always expected from the turbocharger, improving fuel efficiency, as well as having better air quality and the lowest noise levels in the engine room.
By isolating vibrations and absorbing normal movements, we can minimize the stresses on the screws, cast or welded elements, elbows, etc., thus drastically reducing the risk of cracks in manifolds as well as preventing damages to the turbocharger.
SACOME designs and manufactures complete systems of metal expansion joints with special designs and customized configurations, which make it possible to keep the pressure, stresses and movements throughout the service life of the equipment. This also includes modifications and substitutions for both, new and old engines.
Ultimately, many generator sets manufacturers use metal expansion joints in their exhaust manifolds. SACOME manufactures and stores these units for many models from the most important manufacturers.
Our company is qualified to manufacture these models of metal expansion joints, totally or partially, on the basis of samples or drawings. An adequate stock ensures, in most cases, a fast delivery of the metal expansion required with the corresponding connection accessories under the customer specifications: flanges, clamps, ferrules, purge accessories, anchors, tie rods, etc.
Metal expansion joint with loose flanges.
On the other hand, in some cases, it is very difficult to find spare parts or updated parts for generator sets of the old models. SACOME has improved customized designs adapted to many old exhaust systems. This ability to adapt the designs will certainly allow you to take advantage of the maximum performance of your generator sets in place.
Sometimes the best option may be the repairment of the expansion joint or the complete exhaust system can also be carried out when this is the best option. After the inspection of your equipment by one of the SACOME technicians, their first consideration will be to determine the cause of the failure and correct it, if possible, without considering new design changes.
SACOME is a regular suppliers of the main manufacturers of generators and motors
SACOME has been manufacturing its expansion joints since 1978, thus having more than 40 years of experience in this sector. In addition, our technical department is made up of engineers having a long career in this field and we are specialists in offering customized solutions, adjusted to the needs and requirements of each of our clients.
Different models of SACOME expansion joints for exhaust systems of generators and combustion engines.
We perform a rigorous mechanical calculation in the bidding stage, which results into the absence of problems of all sorts in the units supplied throughout all these years. Therefore, the proper functioning of our expansion joints and compensators is more than guaranteed. In addition, a fast development of drawings and an efficient manufacturing process allows us to shorten the delivery times.