Length
Power
kW
lb / ft3
centipoise
1000
hp
1.341022038
lb / ft . sec
0.000671969
Volume
Energy
1
gal (US)
3.785412483
lit
1
0.3786675
Volumetric Flowrate
Density
5326
150815.5431
lit / min
4479.938225
lb
lb / ft3
SG (liquid)
Pressure
kg / min
2326
joule / kg
Specific Heat
1
lb / hr
Btu / lb
Mass Flowrate
2
Long Ton
0.000001
m2 / sec
Mass
lb-mol / hr
ft 3 / min
4.000420515
kW . hr
3.154591
watt / m2
Specific Energy
1
centistoke
Btu / hr . ft2
Kinematic Viscosity
13650
Btu
Molar Flowrate
Mscf / hr
Heat Flux
m
mm
Dynamic Viscosity
0.007559873
Btu / lb . F
joule / kg . C
4186.8
Heat Transfer Coefficient
62.4
Btu / hr . ft2 . F
0.999551904
watt / cm2 . C
0.000567826
Area
Thermal Conductivity
Pa
1000000
m2
6000
Btu / hr . ft . F
bar
10
ft2
64583.4625
watt / cm . C
0.01730735
PROCESS ENGINEERING TOOLKIT
PROCESS & CONTROL SYSTEMS DEPT.
UPSTREAM PROCESS ENGINEERING
UNIT CONVERSION PROGRAM
YUKEN INDIA LIMITED
Hydraulic System for 30T Laddle Furnace
Electric Motor & Pump Selection for Main Pumping Unit
Electrode Regulating Cylinder in MM:V= Speed
P=Operating Pressure
PD=Operating Pressure
Bore Rod
250
0
= 133 mm/sec
FA=Actual Load
= /4*D
A'=Rod End Area
= /4*(D2-d2)
QE=Flow Required for Each Cylinder = A*V
A=Head End Area
n = No. of Cylinders
Q =Pump Flow requirement for all Cylinder
N = No. of Pumps
QPUMP= Flow of each Pump
Electric Motor Size
Power :
N = No. of Motors
Actual Power requirement of each El. Motor
Selected electric Motor
Stroke
200
=
798
=
100
cm/min
kgf/cm2
100
kgf/cm2
30000
kg
490.63
cm2
490.63
cm2
=
=
=
=
391.52
1
391.52
1
L/min
Nos.
L/min
Nos.
=
=
391.52
100
L/min
L/min
=
=
=
=
18.16
1
18.16
24.3
kw
Nos.
kw
kw
Accumulator Size Selection for Main Pumping Unit
Electrode Regulating Cylinder in MM:
V = Speed
SE1 = Emergency Lift
Bore Rod
80
0
= 100 mm/sec
n = No. of Cylinders
A = Head End Area
= /4*D2
= /4*(D2-d2)
A' = Rod End Area
QE1 = Emergency Lift Flow Requirement = SE1 x A x n =
=
=
=
=
Stroke
1800
600
100
3
50.24
50.24
cm2
1.51
cm/min
mm
Nos.
cm2
EMERGENCY ENERGY RESERVE
Typical occasion when storage is slow (Isothermal) and Discharge is quick (adiabatic).
Differential Volume (Adiabatic Condition)
V = Volume of discharged Oil (Litres)
V0 = Nitrogen Pre-charged Volume at Pressure P0 (Litres)
= Nominal Capacity =
P0 = Pre-charge Pressure (Bar) = 0.9 P1 =
=
=
50
72
Bar
P1 = Minimum Operating Pressure (Bar) =
80
Bar
P2 = Maximum Operating Pressure (Bar) =
=
=
120
1.4
Bar
n = Adiabatic Coefficient =
V = Vo [ (Po/P1)1/n - (Po/P2)1/n ] =
11.7
Litres
N = Number of Accumulator (nos.) =
Nos.
QA = Total volume discharged (Litres) =
23
Litres
QE = Total Emergency Flow required =
1.51
Litres
FS = Factor of Safety =
15.47
Page 2 of 8
Pressure, Flow & Power Calculation
Pressure Relation
To Calculate Area:Diameter=
200
mm
Area=
To Calculate Time:Distance =
0.025
m
cm2
Velocity =
0.005
m/sec
To Calculate Diameter:Area =
314
cm2
Time =
5.00
sec
Diameter =
314.00
Flow Relation
200.00
mm
To Calculate Force:Area =
125
cm2
To Calculate Distance:Velocity =
1
m/sec
Time =
Force =
150
18750.00
To Calculate Pressure:Area =
125
cm2
Pressure =
18750
150.00
kgf/cm2
Time =
Area =
125.00
60
0.17
sec
m/sec
To Calculate Area:Flow =
100
L/min
Velocity =
Area =
18750
4
4.17
m/sec
cm2
kg
cm2
100
Eta () =
0.90
Power =
18
L/min
kW
kg
To Calculate Area:Pressure =
150
kgf/cm2
Force =
60.00
To Calculate Velocity:Distance =
10
m
Velocity =
Force =
Flow =
sec
kgf/cm2
kg
To Calculate Power:Pressure =
100
kgf/cm2
Eta () =
Distance =
Pressure =
60
Power Relation
To Calculate Velocity:Area =
4.17
cm2
Flow =
100
L/min
Velocity =
4.00
m/sec
To Calculate Flow:Area =
4.17
cm2
Velocity =
Flow =
m/sec
100.08
L/min
Vane Pump
Piston Pump
80%
90%
Pipe Size By Flow Rate
Suction Line Tank Line Circulation Line
% age is for
1 inch
0.5
m/sec
2
m/sec
Flow Rate Q =
100
Q=A.V
A=Q/V
A=Q/(6.V)
1.5
m/sec
L/min
A=(*D2/4)
Pressure Line
4
m/sec
4 < 150 Bar
4.5 > 150 Bar
*D2/4 = Q/V
D=((Q/V)*(4/6))^(1/2)
Diameter D =
65.2
32.6
37.6
23.0
mm
Diameter D =
257%
128%
148%
91%
% age
Diameter D =
1 0/4
5/4
6/4
0/0
inch
EPE Accumulator Selection
Caluculations / Formulae:-
V0=
DV
[(P0/P1)^(1/n) - (P0/P2)^(1/n)]
V0T= Vo*(T2/T1)
n=
1.4
1/n= 0.7143
V0 - V2 is the Mininum Required Accumulator Capacity
Where:-
P0
72
kgf/cm2
P1
80
kgf/cm2
P2
120
kgf/cm2
0.90
DV
138
Tmax
40
Tmin
10
Tmax
313
Tmin
283
V0
592
Ltrs.
V0T
654
Ltrs.
VOA =
268
Ltrs.
VOB =
387
Ltrs.
Ltrs.
C
V0= Total Volume of Accumulator (in Ltrs.)
V1= Volume at Min. Pressure (in Ltrs.)
V2= Volume at Max. Pressure (in Ltrs.)
P0= Precharge Pressure (kgf/cm2) = K x P1
P1= Min. Working Pressure (kgf/cm2)
P2= Max. Working Pressure (kgf/cm2)
DV= Stored / Displacement Volume (Ltrs.)
K= Constant
For Piston Acc. 0.9 - 0.95
For Bladder Acc. 0.8 - 0.9
DP= P2 - P1
V0T= Accumulator Volume by considering Temp. in mind (in Ltrs.)
Accumulator + additional Gas Bottles
VOT = VOA + VOB
VOA >= DV + (VOT - VO)
0.75
Vo=Total Volume of Accumulator Without Gas Bottle
Voa=Volume of Oil In Bottle.
Vob=Volume of N2 in Bottle
Flow Rate (Q) =
100
H=Qx60x0.45 (Delta T)x0.85
Conversion Factor = 60
Specific Heat = 0.45
Specific Gravity of Fluid = 0.85
HEAT CALCULATION =
2295 DONT REFER
Gage Pressure (psi)
Temperature
(oF)
< 100
200
300
400
500
600
650
700
750
800
850
900
950
1000
150
285
260
230
200
170
140
125
110
95
80
65
50
35
20
300
740
675
655
635
600
550
535
535
505
410
270
170
105
50
400
990
900
875
845
800
730
715
710
670
550
355
230
140
70
Flange Class
600
1480
1350
1315
1270
1200
1095
1075
1065
1010
825
535
345
205
105
900
2220
2025
1970
1900
1795
1640
1610
1600
1510
1235
805
515
310
155
1500
3705
3375
3280
3170
2995
2735
2685
2665
2520
2060
1340
860
515
260
2500
6170
5625
5470
5280
4990
4560
4475
4440
4200
3430
2230
1430
860
430
Gage Pressure (bar)
Temperat
ure
(oF)
< 100
200
300
400
500
600
650
700
750
800
850
900
950
1000
150
19.7
17.9
15.9
13.8
11.7
9.7
8.6
7.6
6.6
5.5
4.5
3.4
2.4
1.4
300
51.0
46.6
45.2
43.8
41.4
37.9
36.9
36.9
34.8
28.3
18.6
11.7
7.2
3.4
400
68.3
62.1
60.3
58.3
55.2
50.3
49.3
49.0
46.2
37.9
24.5
15.9
9.7
4.8
Flange Class
600
102.1
93.1
90.7
87.6
82.8
75.5
74.1
73.4
69.7
56.9
36.9
23.8
14.1
7.2
900
153.1
139.7
135.9
131.0
123.8
113.1
111.0
110.3
104.1
85.2
55.5
35.5
21.4
10.7
1500
255.5
232.8
226.2
218.6
206.6
188.6
185.2
183.8
173.8
142.1
92.4
59.3
35.5
17.9
2500
425.5
387.9
377.2
364.1
344.1
314.5
308.6
306.2
289.7
236.6
153.8
98.6
59.3
29.7
