Products & Solutions

Exhaust & Emissions Solutions

Bergari Solutions is a manufacturer and provider of custom engineered exhaust systems for a wide range of industrial engine applications.  We design and build engine exhaust silencers suitable for Diesel and Gaseous engine applications ranging from 50 hp up to 5000 hp. In addition to the silencers, we also design and build custom exhaust emissions reduction systems. Our full line of custom exhaust accessories are available to complete your specific application. 

Exhaust Silencing Solutions

Emissions Solutions

Accessories

Exhaust Solutions

Engine exhaust silencers are designed to reduce exhaust noise within the allowable backpressure of the engine.  The noise reduction performance of a silencer is achieved by applying engineering principles of fluid dynamics, thermodynamics and acoustical absorption characteristics of certain materials.  Bergari Solutions designs a wide range of silencers using these engineering principles to arrive at an overall exhaust system package to meet the specific customer requirements. 

Cylindrical Silencers (CS)

Traditional cylindrical shaped silencers range in performance from basic industrial grade (10-15 dB(A) reduction) up to extreme grade (45-50 dB(A) reduction). These silencers are typically uninsulated internally and perform based on volumetric ratios and reactive engineering principles.  Single chamber and multi-chamber designs are inherent to our product line providing increasing levels of performance across the range.

All engines vary in the exhaust noise spectrum they produce.  A specific silencer installed on one engine may perform differently on another engine of a similar rating from another manufacturer.  These differences may be subtle but may influence certain noise frequencies higher or lower.  For this reason, Bergari Solutions offers a specific application performance data sheet using the engine physical characteristics and untreated raw exhaust noise data to arrive at a predicted level of sound reduction performance, based on that input data.

Standard Features Include:

  • Continuously welded heavy duty steel construction
  • Reactive chamber designs
  • Dual wall outer shell to reduce break out noise
  • ANSI 125/150# flanges
  • High temperature black finish rated to 1,000 F

Available Grades

CSI - Industrial // 10-17 dB(A)

CSR - Residential // 18-24 dB(A)

CSC - Critical // 25-32 dB(A)

CSH - Hospital // 33-40 dB(A)

CSX - Extreme // 40-50 dB(A)

Optional Features

Dual Inlets

Spark Arresting

Special Flanges & Port Connections

Mounting Brackets

Support Structures

Integrated Catalyst & DPF

Ultra-Low Backpressure Designs

Fully Insulated

Materials

CS - Carbon Steel - Black HT Paint

304 Stainless Steel

316 Stainless Steel

CS Aluminum Thermal Spray Coating

Disk Silencers (DS)

Disk type silencers are highly desirable for applications within an enclosed space.  Typical modular power generation units and enclosed diesel or gaseous power plants utilize a disk type silencer to optimally utilize physical space within that enclosure.  Bergari’s disk silencers are thermally insulated using 2” of thermal/acoustic insulation throughout its construction. The benefits result in a low thermal rejection from the exhaust gas into the enclosure and a high performing acoustical noise reduction overall.

Standard Features Include:

  • Continuously welded heavy duty steel construction
  • Internally insulated with 2″ insulation on all surfaces
  • ANSI 125/150# flanges
  • Four standard mounting lugs
  • High temperature black finish rated to 1,000 F

Available Grades

DSC - Critical // 25-32 dB(A)

DSH - Hospital // 33-40 dB(A)

DSX - Extreme // 41-50 dB(A)

Optional Features

Dual / Multiple Inlets

Spark Arresting Chamber

ISO Container Top Mount Design

Special Flanges & Port Connections

Support Structures & Brackets

Integrated Catalyst

Integrated DPF

Ultra-Low Backpressure Designs

Materials

CS - Carbon Steel - Black HT Paint

304 Stainless Steel

316 Stainless Steel

CS Aluminum Thermal Spray Coating

Rectangular Silencers (RS)

Bergari’s rectangular shaped silencers are an extension of our Disk silencer design and technology.  These designs are internally insulated with thermal acoustic insulation throughout for high performing thermal management and acoustical noise absorption. The rectangular shape of these designs most effectively utilize the space available for any application but especially inside power module enclosures.  These silencers are designed for applications with high performance sound reduction requirements.

Standard Features Include:

  • Continuously welded heavy duty steel construction
  • Internally insulated with 2″ insulation on all surfaces
  • ANSI 125/150# flanges
  • Four standard mounting lugs
  • High temperature black finish rated to 1,000 F

Available Grades

RSH - Hospital // 33-40 dB(A)

RSX - Extreme // 41-50 dB(A)

Optional Features

Dual / Multiple Inlets

Spark Arresting Chamber

Multi Chamber Designs

ISO Container Top Mount Design

Special Flanges & Port Connections

Support Structures & Brackets

Integrated Catalyst

Integrated DPF

Ultra-Low Backpressure Designs

Materials

CS - Carbon Steel - Black HT Paint

304 Stainless Steel

316 Stainless Steel

CS Aluminum Thermal Spray Coating

Spark Arresting Silencers

Effective spark arresting for engine applications is available as a specific design feature applied to any of our cylindrical, disk or rectangular silencers. The design approach utilizes a cyclonic action of the exhaust gas as it passes through the silencer. Our spark arresting silencers are designed to meet the performance levels defined by the USDA – Forest Service. 

Standard Features Include:

  • Continuously welded heavy duty steel construction
  • Dual wall outer shell to reduce break out noise
  • ANSI 125/150# flanges
  • High temperature black finish rated to 1,000 F
  • Clean out ports

Available Grades

RSR - Residential // 18-24dB(A)

RSC - Critical // 25-32dB(A)

RSH - Hospital // 33-40dB(A)

Common Features

Dual Inlets

Special Flanges & Port Connections

Support Structures & Brackets

Integrated Catalyst

Integrated DPF

Materials

CS - Carbon Steel - Black HT Paint

304 Stainless Steel

316 Stainless Steel

CS Aluminum Thermal Spray Coating

Emissions Solutions

Selective Catalytic Reduction (SCR)

Bergari custom SCR systems offer an effective solution to meet strict NOx emission requirements for Diesel and Gaseous Engines up to 5,000 BHP. Our SCR solution is designed to be completely integrated to your system with a closed loop DEF injection control system, custom reactor housing, mixing duct, and DEF storage tank. Systems are also designed for extra capacity allowing for future expansion for higher NOx reduction capabilities.

Our closed-loop control system optimizes NOx reduction up to 98% by continuously measuring raw NOx levels produced and continuously adjusting for best reductant injection rates for best performance NOx reduction. 

Bergari Solutions SCR systems utilize industry proven components to provide high performing, reliable operation. SCR Reactor Housings are custom designed to fit customer application requirements. Housings and components are constructed of 304 or 316 stainless steel, continuously welded. For diesel applications, our SCR system combined with our DPF solution can be designed to meet EPA TIER 4 compliance. 

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NOx Reduction

Nitrogen Oxide (NO) and Nitrogen Dioxide (NO2) is created in the combustion process. Current and future air quality regulations may require NOx emissions reduction aftertreatment depending upon your application. SCR is an effective approach to achieve up to 98% NOx reduction in typical diesel engines.

Nitrides of Oxygen (NO and NO2) are converted to Nitrogen and water through the SCR process. Urea injected into the exhaust stream converts to Ammonia (NH3) then reacting with the NO and NO2 converting to N2 and H2O.

SCR reactor

SCR Reactor Housing installed into ISO container application together with DPF.

SCR control cabinet integrating the digital control, DEF injection pumps, air compressors, and DEF day tank. 

Complete TIER 4 compliant SCR/DPF system integrated into a custom ISO containerized package. 

Optional Features

Open Structural Frame

ISO Containerized Packaging

Thermostatically Controlled Heated DEF Injection Lines

Custom DEF Tanks with Thermostatically Controlled Heaters

Complete SCR / DPF System Integration

Optional Services

On-Site Commissioning

Remote Monitoring

3rd Party Testing

Diesel Particulate Filters (DPF)

Bergari Solutions has developed Diesel Particulate Filter solutions for Power Gen applications from 50 kW up to 4000 kW. Our custom solutions are designed to fit your application needs as stand-alone DPF modules or DPF elements integrated into an exhaust silencer design.

Our engineers and catalyst partners utilize catalyzed wall-flow DPF elements to deliver high performance in the reduction of diesel exhaust emissions. These DPF systems are carefully designed to balance allowable engine exhaust backpressure with a high degree of particulate matter collection efficiency and regeneration light off temperatures. 

Custom housing desings feature bolted flanged catalyst access panels for inspection and servicing. Housings are constructed of 304 stainless steel throughout for corrosion resistance and long life. 

DPF solutions can be integrated with many different silencer designs to offer a more compact and efficient solution for your exhaust system. Bergari Solutions is your source to provide custom engineered DPF and Silencer solutions to meet your specific requirements. 

Furthermore, these DPF systems can be applied together with our SCR system to achieve TIER 4 emissions compliance. 

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Optional Features

Custom DPF Housing Designs

DPF ΔP Pressure Monitoring

Fully Insulated Internally

Weather Proof Exterior Grade Insulation Blanket

Special Monitoring Ports

Specialty Catalytic Converters

Bergari Solutions has developed a full line of catalytic converters suitable for Industrial Gas Compressions and other applications. Tested and proven, 3-way and Oxidation catalyst coating formulations are available to precisely meet your emissions reduction requirements for reciprocating diesel and gaseous engines from 50 to 5000 HP. 

Catalyst elements are heavy duty vacuum brazed metallic substrates with a stainless steel mantle, available in typical industry sizes from 11.5″ up to 33.5″ diameters x 3.5″ wide. Cell density options and special sizes are available to optimize applications performance for emissions reductions and allowable engine backpressure. 

Bergari Solutions offers customized integrated silencers and spark arrestors to effectively address both emissions reductions and exhaust noise reduction into a single package. 

Features & Options Available:

  • Combination Catalyst / Silencer
  • Heavy Duty 304 Stainless Steel Construction
  • Custom Engineered Catalyst Formulations
  • Single and Multi-Catalyst Capabilities
  • Full Completement of Exhaust System Accessories
  • Air-Fuel Ratio Controllers
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RICE/NESHAP Oxidation Catalysts

Bergari Solutions is offering specifically designed emissions reduction solutions to meet and exceed the EPA’s RICE/NESHAP initiative (Regulation for Internal Combustion Engines / National Emissions Standard for Hazardous Air Pollutants). 

Typical applications are comprised of a specifically sized Diesel Oxidation Catalyst (DOC) into a unique housing mounted upstream of the exhaust silencer. The EPA may also require a CPMS (Continuous Parametric Monitoring System) for measuring and recording differential pressure across the catalyst and pre-catalyst exhaust gas temperature, in effort to ensure compliant operation.

Bergari Solutions provides the engineering expertise and manufacturing capabilities for a complete RICE/NESHAP compliant system. Our range of products for these systems extends up to 3 MW diesel engines. Our options include the integration of an exhaust silencer in the system in various sound performance ranges, as well as a complete monitoring (CPMS) package and installation hardware kits.

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Standard Features

Continuously Welded Heavy Duty Construction

ANSI 125/150# Flanges

Inlet Flow Diffuser Plate

Bolted on Easy Access Catalyst Cover

Leak Tight Vermiculite Seals Throughout

Multiple 1/2" NPT Measurement/Test Ports

Optional Features

304 & 316 Housings

Single, Double & Tripple Catalyst Tracks

Combination Silencer Configurations

CPMS Monitoring Kit

Roof Mounting Kit

Accessories

Flex & Bellows

Bergari Solutions offer flex and bellows assemblies to complement almost every engine exhaust application. Our most common range of sizes are 3″ to 12″ for flex, and 6″ to 36″ for bellows. 

Flex assemblies are a lower cost solution as flex hose is primarily designed for thermal expansion and limited axial movement. 

Bellows are the best choice for cyclical and axial movements as these are designed with a very low spring rate and deeper convolutions. In addition, bellows are fitted with a flow liner to minimize the effects of flow induced noise. 

Bergari engineers are available to assist you in the design and selection of flex or bellows depending upon your application. Custom sizing and connecting flanges are available in ANSI flanges, engine specific flanges, V-Band / Turbo connections and more. Flexes and bellows elements are made of stainless (304, 316, 321) and can be completed with carbon steel and stainless steel connections. 

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Elbows & Piping

At Bergari Solutions we strive to provide a complete exhaust system solution for your application. Exhaust piping systems vary by each particular application. Our engineers will assist our customers with the total exhaust system design from the turbo outlet to the end of the piping run. Custom Elbows, Extensions, Wyes, Tees, Stacks, Rainguards, Wall & Roof Thimbles, Mounting Bands, and everything else in between are available from Bergari Solutions. 

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Roof and Wall Thimbles

Bergari Roof and Wall Thimbles are available in sizes ranging from 3″ up to 16″ pipe diameters. These Roof and Wall Thimblles are designed to UL standards featuring a full air-gap around the pipe and a 1″ thick high-temp thermal insulation barrier against the inner wall. All versions are available with optional rain shields and inside mating flanges. Materials available are High Temp Black Painted carbon steel, 304 and 316 stainless steel.

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Mounting Bands

Circular mounting bands are available from 8″ up to 60″ diameter applications. These mounting bands are suitable for all Bergari cylindrical silencer applications as well as piping supports. These feature heavy duty, all welded construction with dual mounting brackets and raised mounting feet. Materials available are High Temp Black Painted carbon steel, 304 and 316 stainless steel. Mounting bracket hardware is included. 

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Raincaps

Bergari Solutions offers a full line of exhaust Raincaps ranging from 4″ up to 30″ diameter. All of these are available in carbon steel (HT black painted), 304 and 316 stainless steel. Tube and pipe sizes are available from 4″ to 12″. 

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Insulation Blankets

Bergari Solutions offers custom manufactured insulation blankets for all of our silencer and exhaust system products. These insulation blankets are made of the highest quality materials conforming to industry standards. 

Standard materials offered are 32 oz. fabric, silicone impregnated, backed with stainless steel mesh and sewn with Kevlar thread. Major construction materials meet Military Specification MIL-I-24244 Type 11 and US Coast Guard Specifications for incombustible material #164.009. 

The silicone impregnated fiberglass outer fabric is rated for 500 °F continuous while the inner mat insulation material is rated for 1200 °F maximum, 1000 °F continuous. 

Stainless steel (304) attachment hardware is used throughout each insulation blanket assembly for durability and corrosion resistance. Standard assembly hardware consists of riveted hooks and stainless steel wire. 

Optional “Spring & Ring” fastening hardware is also available.

Weather resistant outdoor rated insulation blanket assemblies are available in 1″ and 2″ thicknesses. 

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Gaskets & Hardware Kits

Bergari Solutions offers a full line of standard ANSI pipe flange gaskets from 3″ up to 30″ diameter. In addition, we offer engine specific CAT, Cummins, MTU, and Mitsubishi flange gaskets. These high-temp rated (1800 °F) gaskets feature a durable vermiculite coating backed with a metal core providing excellent sealing for exhaust system flanged connections. Complete Bolt, Nut, and Gasket Kits (BNG Kits) are available for all flange sizes in zinc plated GR5, 304 and 316 stainless steel. 

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