Space Requirement for EA set

The various accessories and equipment associated with an EA set for which space is required are:

  1. EA Set.
  2. Control panel.
  3. Batteries.
  4. Fuel tank.
  5. Exhaust pipe silencer.

A typical diagram of EA Set Room is given below:

Based on the above drawing and as per the data collected for Koel / Greaves / Cumins engines and Kirloskar / NGEF /Stamford / Crompton coupled alternator, the sizes of the rooms required and other relevant data are detailed in table of EA SET READY RECKONER.

Also the physical data for water cooled EA sets and approximate room size to accommodate two engines are given below:

Physical Data for DG Sets/Room (415 V, 50 Hz, 1500 rpm, Water Cooled)
S. No.kVA (at NTP)Dimension in ft (L × H × W)Room Size in ft (L × H × W)Forced Ventilation (Air Volume in cfm)
1 75 9.0 × 4.5 × 2.720 × 10 × 155,100
2 1009.5 × 5.1 × 2.720 × 10 × 157,000
3 1259.5 × 5.1 × 2.820 × 10 × 157,700
4 16011.3 × 5.6 × 2.825 × 15 × 159,600
5 20011.3 × 5.6 × 3.325 × 15 × 1514,000
6 25011.4 × 5.8 × 3.325 × 15 × 1516,800
7 32012.5 × 6.1 × 3.725 × 15 × 2021,000
8 38012.5 × 6.1 × 4.425 × 15 × 2025,000
9 45014.3 × 6.7 × 4.830 × 15 × 2029,250
1052514.3 × 6.8 × 4.830 × 15 × 2033,800
1162515.8 × 9.1 × 6.335 × 20 × 2541,250
1275015.8 × 9.1 × 6.335 × 20 × 2549,000
13100018.7 × 9.1 × 6.340 × 20 × 2565,000

These data are approximate and manufacturer should be consulted for the exact dimensions. The dimension and weight of some of the manufactures are reproduced below:

PHYSICAL DATA FOR DG SETS WITH GREAVES ‘Y’ SERIES ENGINES
KVABHP @ 1500 rpmENGINE MODELCOOLINGSET DIMENSION IN MMWT. IN KG
LENGTHWIDTHHEIGHT
1523.62YWA MK VAir17565371164572
2534.13YWA MK VAir19375701214792
3037.03 YWA 30Air205775911371064
4056.14YDA MK IIAir219675911621654
5065.84YDAXMKIIIAir228087012501700
62.584.36YDA MKIIAir261681612701621
7591.06YDA MKIIIAir261681612701621
3038.01000 3WRadiator205775911371064
62.584.03 YDC MK IIIRadiator261681612701621
7593.04 YDX MK IIIRadiator261681612701621
100126.04 YDC MK IIIRadiator257580713701960
125156.06 YDC MK IIIRadiator276986514482350
PHYSICAL DATA FOR DG SETS WITH GREAVES ‘D’ SERIES ENGINES
KVABHP @ 1500 rpmENGINE MODELCOOLINGSET DIMENSION IN MMWT. IN KG
LENGTHWIDTHHEIGHT
125156TD2 V6Radiator252077012891930
160197TBD2V6MKIRadiator261084014891980
160197TD2 V8Radiator269690014552130
200253TBD2V8MKIRadiator3260100016102400
250313TD2 V12Radiator3280100015952970
320396TBD2V12MKIIRadiator3413106017503300
380453TBD3 V12Radiator3500135017603450
500604TBD4 V12Radiator3985132119704600
400463TBD3 V12Heat Exch.3000111317003400
520604TBD4 V12Heat Exch.3385111318204600

SPACE REDUCTION FOR EA SETS: 

To reduce the space required for a EA set, the Engine, Alternator, Fuel Tank, Electrical Panel and Instrument Panel all can be mounted on the common base plate. Also the size of EA set is reduced by the use of disc made of laminated sheet steel of required thickness and of diameter matching to the Engine flywheel called flex disc as a coupler. The flex disc is connected to the fly wheel directly by means of required numbers of nuts and bolts. The fuel tank can be accommodated in the base frame itself. The control panel monitoring the parameters of the Engine and Alternator are combined in a single panel and is mounted on the base frame itself at the non-driving end of the Alternator. The maintenance free Batteries can be used as they require less space and they can be kept inside the base frame.

In addition to the space saving, these sets are having following additional advantages:

  1. Assembly of Engine Alternator set and accessories forms a very compact arrangement leading to considerable space saving.
  2. Perfect alignment due to flex discs.
  3. Ease of coupling and decoupling leading to easy maintenance.
  4. Enhanced bearing life due to lesser vibration.
  5. No necessity of fuel lines across the floor.
  6. Easy and convenient operation.
  7. Factory wired incomer (from Alternator to Control Panel).
  8. Reduced installation period.
  9. No. of AVMs can be reduced.

Also to reduce the need of EA room itself sound proof canopies can be used. For these purposed FRP/SMC canopies can be used. (Discussed in Chapter on noise control).

Also we can go for DG sets with inbuilt canopies (though they are costly). One such manufacturetr is the Control & Switchgear. In their Silent Sets Engine and Alternator are mounted on a common skid base and special vibration pads are used to minimize vibration. The enclosure is made of colled rolled steel duly surface treated, phosphated and powder coated. To take care of higher ambient temperature, a large capacity fan is also provided for effective cooling of the Engine body and surrounding air. It is provided with hatch open door for maintenance. The base frame incorporates facility for simple handling and for single point lifting. The data for this set is given in the following table:

KVAMODELDIMENSION IN MMWT. IN KGFuel Tank Cap. (L)
LENGTHWIDTHHEIGHT
10CWS 102720100015001600105
15CWS 152720100015001600105
25CWS 252900100015002000120
30CWS 303300100015002500210
40CWS 403300100015002500210
50CWS 503650115016003300240
62.5CWS 62.53850115016003800250
75CWS 753850115016003800250
100CWS 1004900130020505000270
125CWS 1254900130020505200270
160CWS 1604900130024005700520
200CWS 2004900130024006000520
250CWS 250670026002600  
320CWS 320670026002600  
380CWS 380670026002600  
500CWS 500960026002600  
625CWS 625960026002600  
750CWS 750960026002800  
1000CWS 10001100026002800  
1250CWS 12501100026002800  
1500CWS 15001100026002800  

Also some manufactures (like Lonoiz) offer the same material, but they provide sliding door for the ease of maintenance. The dimension of their canopies suitable for Cummins engine is given below:

KVAENGINE MODELDIMENSION IN MMPLINTH SIZE
LENGTHWIDTHHEIGHTLENGTHWIDTH
100NT 495 G40001800200042002000
125NTC 495 G42001800215044002000
160NT 743 G45001800215047002000
200NTA 743 G50002250240052002450
250NTA 855 G52002450250055002700
320KT 1150 G58002650250061003000
380KTA 1150 G60002650250063003000

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