1.

Formula To Find: Belt Length

Compressor Flywheel OD + Motor Pulley OD X 1.57 + 2 X Shaft's Center To Center
Distance In Inches

2. Formula To Find: Motor Pulley OD

Compressor Flywheel OD X Compressor Rpm's / Motor Rpm's

3. Formula To Find: Tank OD

Measure Circumference / 3.1416

4. Formula To Find: Volume Of Tank In Gallons

Tank OD X OD X .785 X Tank Length In Inches / 231

5. Formula To Find: PSIA Pressure

14.7 + Gauge Pressure

6. Formula To Find: Compressor CFM Using The Time Method

Tank Gallons X .536 X PSIG Increase / Total Seconds

7. Formula To Find: Motor Max AMP Draw Before Damage Begins

Motor Data Plate AMPS X Data Plate Service Factor

FORMULA SYMBOLS & DEFINITIONS:

/ = divide
X = multiply
+ = add

AMPS = Abbreviation of the plural for Ampere, a unit of electrical current

CFM or cfm = Abbreviation of Cubic feet per minute - a unit of measurement of the flow of a
air/gas or liquid that indicates how much volume in cubic feet pass by a stationary point in
one minute.

OD = Abbreviation for Outside diameter is a dimension commonly used to specify the size of
tubing or pipe.

PSIA or psia = Abbreviation for Pounds per square inch absolute (including atmospheric
pressure)
 COMPRESSED AIR FORMULAS

Electrical cost = HP x .746 x hours x Kw cost / motor efficiency

Example: 50 hp air compressor that runs 8 hours a day 5 days a week for a year with a $.06 Kw electric rate and a

90% efficient electric motor.

50 hp x .746 x 2080 hours x $.06 / .90 = $5,172.27 per year

Compressor RPM = motor pulley diameter x motor rpm / compressor pulley diameter.

Motor pulley diameter = compressor pulley diameter x compressor RPM / motor RPM

Compressor pulley diameter = motor pulley diameter x motor RPM / compressor RPM

Motor RPM = compressor pulley diameter x compressor RPM / motor pulley diameter

Gallons= cubic feet / .134

Cubic Feet = gallons x .134

Pump up time (minutes) =

V (tank size) x (final pressure – initial pressure)

7.48 x atmospheric pressure x pump delivery (cfm)

Example: 7.5 hp compressor rated at 24 cfm with an 80 gallon tank – unit starts at 100 psi and turns off at 150 psi.

80 gallons x (150 psi – 100 psi) 4,000 = 1.51 minutes

7.48 x 14.7 psi x 24 cfm 2,638

Pressure drop and horsepower: Every 1 psi of pressure drop equals 0.5% in horsepower

Heat and horsepower : Rejected heat from an air-cooled compressor is equal to total machine horsepower x 2,545

BTU per hour

Example: 50 hp compressor with 3 hp fan motor will produce…

53 hp x 2,545 = 134,885 BTU per hour

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FLUID POWER FORMULAS

Basic Formulas: Pressure (psi) = Force (pounds) / Area (in2)Force (pounds) = Area (in2) x Pressure (psi)Area (in2) =

Force (pounds) / Pressure (psi) Fluid Power Horsepower (hp) = Pressure (psi) x pump flow (gpm) / 1,714 Torque

(ft.lbs.) = Horsepower (hp) x 5,252 / Speed (rpm)Horsepower (hp) = Torque (ft.lbs.) x Speed (rpm) / 5,252Speed

(rpm) = Horsepower (hp) x 5,252 / Torques (ft.lbs.)Cylinder Formulas:Piston cylinder area (in2) = Diameter squared x

.7854

= 3.1416 x Radius squared

Rod-end cylinder area (in2) (Annulus end area)

= Cylinder area (in2) – Rod area (in2)

Cylinder force (pounds)

= Pressure (psi) x Area (in2)

Cylinder speed feet/minute)

(divide by 60 for feet/second)=19.25 x Flow rate (gpm) /Area (in2)

Cylinder time (seconds)

= Area (in2) x Cylinder stroke (in.) x .26 /Flow rate (gpm)

Cylinder flow rate (gpm) = 12 x 60 x Cylinder speed (ft./sec.) x Area (in2) / 231Cylinder volume capacity (gallons)=

3.1416 x Radius squared (in.) x Cylinder stroke / 231Hydraulic Motor Formulas:Fluid motor torque(in.lbs.) =

Pressure (psi) x Fluid motor displacement / 6.28

= Horsepower (hp) x 63,025 / Speed (rpm)

= Flow rate (gpm) x Pressure (psi) x 36.77 / Speed (rpm)Fluid motor speed (revs./min.)= 231 x Flow rate

(gpm) / Fluid motor displacement (in3/rev.)

Fluid motor power (hp output)

= Torque output (in.lbs.) x Speed (rpm) / 63,025

Fluid motor torque / 100 psi (in.lbs.)= Fluid motor displacement (in3/rev.) /

.0628 Fluid motor flow rate (gpm)= Motor speed (rpm) x Motor displacement(in3/rev.) / 231

Pump Formulas:

Pump outlet flow (gpm)

= Speed (rpm) x Pump displacement (in3/rev.) / 231 Pump speed (rpm)

= 231 x Pump flow rate (gpm) /

Pump displacement (in3/rev.)Pump input horsepower (hp)

= Flow rate output (gpm) x Pressure (psi) / 1,714 x Efficiency factor (overall %)

Pump Efficiency

(Overall in %)(Output horsepower / Input horsepower) x 100 Pump displacement (in3/rev.) = Flow rate (gpm) x 231

Pump speed (rpm) Pump torque (in.lbs.) = Horsepower (hp) x 63,025 /

Speed (rpm)

= Pressure (psi) x Pump displacement (in3/rev.) /6.28 Miscellaneous Formulas, Data and "Rules of Thumb":Reservoir

capacity (gallons) = Length (ins.) x width (ins.) x height (ins.) / 231 Reservoir cooling capacity(BTU/hr.)2 x

Temperature difference between reservoir walls and air (degrees F) x area of reservoir (ft2)

(Based on adequate air circulation)Heat radiating capacity of a steel reservoir expressed in horsepower

(hp)Horsepower (hp)= 0.001 x reservoir surface area (ft2) x temperature Difference (degrees F) between oil and
surrounding air Heat equivalent of fluid power(BTU/hr.) = Pressure (psi) x Flow (gpm) x 1.5

(Note: One horsepower = 2,545 BTU/hour)One British Thermal Unit (BTU) is the amount of heat required to raise the

temperature of one pound of water one degree Fahrenheit.Heating hydraulic fluid = 1 watt will raise the temperature

of 1 gallon of oil 1 degree Fahrenheit per hour Compressibility of hydraulic oil = Volume reduction is approximately

1/2% for every 1,000 psi of fluid pressure Compressibility of water = Volume reduction is about 1/3% for every 1,000

psi of fluid pressure Estimating pump drive horsepower (hp) = Approximately 1 hp of drive for every 1 gpm (flow) at

1,500 psi (pressure) Pump idling horsepower (hp) = Approximately 5% of a pumps full rated horsepower will be

required when a pump is running unloaded"Guidelines" for flow velocity in hydraulic lines: Pump suction lines 2 – 4

ft./sec. Pressure lines to 500 psi

10 – 15 ft./sec.

Pressure lines of 500 to 3,000 psi 15 – 20 ft./sec. Pressure lines over 3,000 psi 25 ft./sec. Fluid velocity of oil flow in a

pipe (ft./sec.)

= Flow rate (gpm) x 0.3208 / Inside area of pipe (in2)

Common Fluid Power Equivalents:One U.S. gallon = 231 in3

4 quarts or 8 pints

128 liquid ounces

128 liquid ounces

133.37 ounces in weight

8.3356 pounds

3.785 liters One imperial gallon =1.2 U.S. gallons One liter = 0.2642 U.S. gallons One cubic foot = 7.48 gallons

1728 cubic inches

62.4 pounds of water One Bar at sea level = 14.504 psi

0.98692 atmosphere

33.6 foot water column

41 foot oil column

Approximately ½ psi decrease for each 1,000 feet of elevation change

One inch mercury (hg.) = 0.490 psi

1.131 ft. water

One horsepower =

33,000 ft.lbs./min.

550 ft.lbs./sec.

42.4 BTU/min.

2,545 BTU/hour
746 watts or 0.746 kilowatts (kw)One psi = 2.0416 inches of mercury (hg.)

27.71 inches of water

0.0689 bar

One atmosphere =

1.013 bar

29.921 inches of mercury (hg.)

14.696 psi

760 mm of mercury (hg.)One foot water column = 0.432 psi One foot oil column = 0.354 psi

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LUBRICATION FORMULAS

Calculating Bearing Requirements for Oil Lubricants:

V=AxT

V = Volume in terms of lube-oil replacement rate in cubic inches per hour (in3/hr)A = Bearing surface area in square

inches (in2) (Sized differently based on bearing type)

T = Film thickness…generally .001 inch… but it may vary based on oil type and application

Calculating Bearing Requirements for Grease Lubricants: V = A x TV = Volume in terms of lube-grease

replacement as cubic inches per four hour (in3/4 hrs) A = Bearing surface area in square inches (in2) (Sized differently

based on bearing type)

T = Film thickness…generally .002 inches…but it may vary based on grease type and application

Note: Quite often requirements are expressed in metric terms.

To convert to metric, calculate volume requirements as noted above and simply multiply by 16.39 to convert to cubic

centimeters per hour...cc3/hr... (oil) or cubic centimeters per four hours...cc3/4 hrs... (grease).

Common Bearing Types:(Necessary to know for calculating areas.)Plain Bearings:

Area (in2) = 3.14 x Shaft diameter (ins.) x Length of bearing (ins.)Slides, Gibs and Ways:

Area (in2) = Area of largest contact surface Anti-Friction Bearings: Area (in2) = Shaft diameter squared x number of

rows

Gears:

Area (in2) = 3.14 x Pitch diameter of gear (ins.) x width of gear (ins.)

Sizing Example:Plain bearing with 6 inch shaft and 6 inch long bearing surface using oil.

Area (in2) = 3.14 x 6(ins.) x 6 (ins.) = 113.04 (in2)

Volume (in3/hr.) = 113.04 (in2) x .001 (in.)

= .113 (in3/hr.) lube oil replacement rate

Should this need to be converted to metric, the requirement for this single bearing application would be 1.85 cubic

centimeters per hour.

.113 (in3/hr.) x 16.39 = 1.85 (cc3/hr.)

Each and every bearing or lube point on a machine would be calculated in this fashion and when done, the

replacement rates for all points would be added together to determine the total system lubrication requirement.

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ELECTRICAL FORMULAS

Volts: (E)

Volts = Square root of (Watts x Ohms)

= Watts / Amperes

= Amperes x Ohms

Ohms: (R)

Ohms= Volts / Amperes

= Volts squared / Watts

= Watts / Amperes squared

Watts: (W)

Watts = Volts squared / Ohms

= Amperes squared x Ohms

= Volts x Amperes

Amperes: (I)

Amps = Volts / Ohms

= Watts / Volts

= Square root of (Watts / Ohms)

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PNEUMATIC FORMULAS

Air valves are sized for flow capacity (Cv) based on given cylinder piston size, stroke and travel time requirements. Cv

is actually a flow coefficient that measures the amount of air a device can pass. The following formula can be used for

air valve sizing:

Cv =Area (in2) x Length (ins.) x Compression factor

Pressure drop factor x Time (secs) x 29

Area = Effective cylinder piston area in square inches

(A = 3.1416 x radius2 – or – diameter2 x .7854)

Note: For the rod end (annulus end) of the cylinder, the same area formulas apply, but to calculate accurately, one

must take the cylinder area (in2) minus the rod area (in2) in using this valve sizing formula for determining return

stroke Cv rating.

Length = Simply the total cylinder stroke length in inches

Compression factor = Taken from the table based on supply pressure rating.

Pressure drop factor = Taken from the table....10 or 15 psi drop is a good guideline for using in this formula

Time = Required cylinder stroke time in seconds

Pressure Drop Factor PD for Various

Pressure Drops

Supply Compression
2 5 15 20
Pressure Factor 10

PSI
CF PSID

40 3.7 9.9 15.3 20.5 23.6 N/A

50 4.4 10.8 16.7 22.6 26.4 29

60 5.1 11.7 18.1 24.6 29 32

70 5.8 12.5 19.3 26.5 31.3 34.8

80 6.4 13.2 20.5 28.2 33.5 37.4

90 7.1 13.9 21.6 29.8 35.5 39.9

100 7.8 14.5 22.7 31.3 37.4 42.1

110 8.5 15.2 23.7 32.8 39.3 44.3

120 9.2 15.8 24.7 34.2 41.0 46.4

130 9.8 16.4 25.6 35.5 42.7 48.4

140 10.5 16.9 26.5 36.8 44.3 50.3

150 11.2 17.5 27.4 38.1 45.9 52.1

Sizing Example:

6 inch bore cylinder with 2 inch rod and 15 inch stroke.... 2 second travel time....100 psi supply pressure....and 15 psi

pressure drop factor will be used:

1. Calculate piston area in square inches

(A = 6 ins. x 6 ins. x .7854 = 28.2 in2)

Note that this is the cylinder extend area, to calculate the cylinder return area, the rod area must be subtracted from

(A = 2 ins. x 2 ins. x .7854 = 3.14 in2)

Cylinder return area is then 28.2 in2 – 3.14 in2 = 25.06 in2

2. Simply apply application variables to the Cv sizing formula:

Cv = 28.2 in2 x 15 ins. x 7.8 = 3,299 = 1.52 Cv

37.4 x 2 secs x 29 2,169

3. Select a valve that meets this 1.52 Cv rating.

Many fluid power engineering and data resources have flow charts to simplify this sizing process, but in absence of

those charts, this information should help to size pneumatic valve requirements.

Air Flow Rates

Standard Cubic Feet Per Minute (SCFM)

One cubic foot of gas (air) per minute at standard conditions of 68 degrees F, 14.69 psi and a relative humidity of

36%.

Cubic Feet Per Minute (CFM): One cubic foot of gas (air) per minute at actual conditions...ie: at actual temperature

and compressed or expanded pressure.

Free Air Flow: The volume of air at normal atmospheric conditions which enters a vacuum system due to the lower

pressure caused by the pump or vacuum in a tank.

Expanded Air Flow: Air flow inside a vacuum system, same as CFM.

SCFM and Compressor Horsepower Requirements: To calculate pneumatic cylinder air consumption in SCFM and

convert it to required air compressor horsepower, please request an RHM Fluid Power Data Book which includes quick

reference charts for these purposes.

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Note: This information is provided as a quick reference resource and is not intended to serve as a substitute for

qualified engineering assistance. While every effort has been made to ensure the accuracy of this information, errors

can occur. As such, neither RHM or its employees will assume any liability for damage, injury or misapplication tied to

the use of this information.

PSIG or psig = Abbreviation for Pounds per Square Inch Gauge

AIR MOISTURE CONTENT

Grains of water in one cubic foot of air at various

temperatures and percentages of saturation.

Rule of Thumb: For every 20 degrees Fahrenheit

temperature drop, we loose one half the water!
DEW POINT
CONVERSION CHART

EXPRESSING
PRESSURE
 COST OF COMPRESSED AIR:

I. 15% Fixed Charges: Compressor, Installation, Depreciation, Insurance, Repair

II. 15% Operating Charges: Attendance, Lubrication, Cooling-Water, Filters.
III. 70% Power: Electric Motor Driven (both energy & demand) at 6 cents/kW hr.

-Facts-

A. 20 cents per 1000 CF @ 100 PSIG: 200 HP = 1000 CFM X 60 min. X 24 hr. =
day.
B. Rule of Thumb: Cost $1.00 per HP per 24 hrs. at 6 cents per kW hour.
C. Cost of Air Leakage 1/4" leak = 2,920,000 cu. ft. per month = $684.00.

Electric Operating Cost

Full Load KVa Operating Cost Per Year (8760 hours) at Stated Cost p
Size HP @1800 RPM .03 .04 .05 .06 .07 .08
10 10.14 $ 2,665 $ 3,553 $ 4,441 $ 5,330 $ 6,218 $ 7,10
15 15.67 4,118 5,491 6,865 8,236 9,609 10,98
20 20.06 5,271 7,029 8,786 10,554 12,301 14,05
25 24.93 6,551 8,735 10,919 13,103 15,287 17,47
30 28.58 7,511 10,014 12,518 15,022 17,525 20,02
40 38.32 10,070 13,427 16,784 20,141 23,498 26,85
50 47.10 12,378 16,504 20,630 24,756 28,882 33,00
60 57.21 15,035 20,046 25,058 30,070 35,081 40,09
75 71.10 18,685 24,913 31,142 37,370 43,599 49,82
100 91.11 23,944 31,925 39,906 47,887 55,869 63,85
125 118.47 31,134 41,512 51,890 62,268 72,646 83,02
150 140.57 36,942 49,256 61,570 73,884 86,198 98,51
200 188.65 49,577 66,103 82,629 99,154 115,680 132,20

DISCHARGE, CUBIC FEET, FREE AIR PER MINUTE:

Gauge pressure DIAMETER OF ORIFICE in inches

 before Orifice PSIG 1/64 1/32 1/16 1/8 1/4 3/8 1/2 5/8 3/4
5 .062 .248 .993 3.97 15.9 35.7 63.5 99.3 143
15 .105 .420 1.68 6.72 26.9 60.5 108 168 242
20 .123 .491 1.96 7.86 31.4 70.7 126 196 283
25 .140 .562 2.25 8.98 35.9 80.9 144 225 323
30 .158 .633 2.53 10.1 40.5 91.1 162 253 365
35 .176 .703 2.81 11.3 45.0 101 180 281 405
40 .194 .774 3.10 12.4 49.6 112 198 310 446
45 .211 .845 3.38 13.5 54.1 122 216 338 487
50 .229 .916 3.66 14.7 58.6 132 235 366 528
60 .264 1.06 4.23 16.9 67.6 152 271 423 609
70 .300 1.20 4.79 19.2 76.7 173 307 479 690
80 .335 1.34 5.36 21.4 85.7 193 343 536 771 1
90 .370 1.48 5.92 23.7 94.8 213 379 592 853 1
100 .406 1.62 6.49 26.0 104 234 415 649 934 1
110 .441 1.76 7.05 28.2 113 254 452 705 1016 1
120 .476 1.91 7.62 30.5 122 274 488 762 1097 1
125 .494 1.98 7.90 31.6 126 284 506 790 1138 1

FRICTION OF AIR IN HOSE:

Hose Cubic foot of free air per minute passing through 50-ft. length
Gage
size 20 30 40 50 60 70 80 90 100 110
pressure
coupled
at line
each
(Lb.) Loss of pressure (PSI) in 50-ft. lengths of hose
end (in.)
50 1.8 5.0 10.1 18.1
60 1.3 4.0 8.4 14.8 23.4
70 1.0 3.4 7.0 12.4 20.0 28.4
1/2 80 0.9 2.8 6.0 10.8 17.4 25.2 34.6
90 0.8 2.4 5.4 9.5 14.8 22.0 30.5 41.0
100 0.7 2.3 4.8 8.4 13.3 19.3 27.2 36.6
110 0.6 2.0 4.3 7.6 12.0 17.6 24.6 33.3 44.5
50 0.4 0.8 1.5 2.4 3.5 4.4 6.5 8.5 11.4 14.2
60 0.3 0.6 1.2 1.9 2.8 3.8 5.2 6.8 8.6 11.2
70 0.2 0.5 0.9 1.5 2.3 3.2 4.2 5.5 7.0 8.8
3/4 80 0.2 0.5 0.8 1.3 1.9 2.8 3.6 4.7 5.8 7.2
90 0.2 0.4 0.7 1.1 1.6 2.3 3.1 4.0 5.0 6.2
100 0.2 0.4 0.6 1.0 1.4 2.0 2.7 3/5 4.4 5.4
110 0.1 0.3 0.5 0.9 1.3 1.8 2.4 3.1 3.9 4.9
 50 0.1 0.2 0.3 0.5 0.8 1.1 1.5 2.0 2.6 3.5
60 0.1 0.2 0.3 0.4 0.6 0.8 1.2 1.5 2.0 2.6
70 0.1 0.2 0.4 0.5 0.7 1.0 1.3 1.6 2.0
1 80 0.1 0.2 0.3 0.5 0.7 0.8 1.1 1.4 1.7
90 0.1 0.2 0.3 0.4 0.6 0.7 0.9 1.2 1.4
100 0.1 0.2 0.2 0.4 0.5 0.6 0.8 1.0 1.2
110 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.9 1.1

PIPE SIZE Volume Length of Run (Ft.)

RECOMMENDED Of Air 50-200 | 200-500 | 500-1000 | 1000-25
FOR Transmitted 3000
TRANSMISSION OF
COMPRESSED AIR
(CFM) Nominal Pipe Diameter (In.)
TO 80-125 P.S.I: 30-60 1 1 1-1/4 1-1/2
60-100 1 1-1/4 2-1/4
100-200 1-1/4 1-1/2 2 2-1/2
200-500 2 2-1/2 3 3-1/2
500-1000 2-1/2 3 3-12 4
1000-2000 2-1/2 4 4-1/2 5
2000-4000 3-12 5 6 8
4000-8000 6 8 8 10

SAND BLASTING NOZZLES: Nozzle Gage Press

Diameter 60 70 8
1/16 4 5 5
3/32 9 11 1
1/8 17 19 2
3/16 38 43 4
1/4 67 76 8
5/16 105 119 13
3/8 151 171 19
1/2 268 304 34
CFM CFM CF