2.5 NOISE LEVEL Noise is defined as unwanted sound, In the recent years, people's awareness for the need to control noise is increasing. In this section, we will briefly discuss the limits of noise exposure and some basic noise control measures that could be helpful when installation of the generator set is being carried out. Acceptable Limits Exposure to excessive noise causes permanent hearing damage and adversely affects working efficiency and comfort. ‘When a person’ daily noise exposure - designated D(8) - is composed of two or more periods of noise at different levels, the combined effect is calculated using this formula : D(8)= (C/T) + (C/T) +. + C/T) Where: C, = Duration of exposure at a specified sound level. T! = Total time of exposure permitted at a specified sound level (refer to Table 2) The noise exposure is acceptable when equal to or less than 1. Duration of Daily ‘Allowable Level Exposure Hours 8 (A) 8 90 6 92 4 95 3 . 97 2 100 1% 102 1 105 % 110 Yoorless 15 TABLE 2. DAILY ALLOWABLE NOISE LEVEL Common sound sources are qualified in the following chart. Table 3 relates sound pressure in decibels (4B) and pounds per square inch (psi). However, to measure the loudness of sound, frequency of the noise must be considered. Sound measurements ‘weighted to the human ear are referred to as the “A” scale. Figure 14 shows the difference between “A” scale and unfiltered measurements. Because it reflects the real impact on the human ear, the dB(A) scale is accepted worldwide. ‘Sound Power, w_| Sound Pressure, dB | Sound Pressure, psi | Common Sounds 10" 160 3x10" Jet Engine 10° 140 3x102 Riveting 1 120 3x107 Punch Press 102 100 3x 10+ City Trafic 10+ 80 3x 10+ Busy Office 10¢ 60 3x 10+ Normal Speech 107 40 3x107 Quiet Suburb 10” 20 3x10" ‘Whisper 10" 0 3x10* Threshold of Hearing TABLE 3. TYPICAL NOISE LEVELS20 50 100 200 500 1K 2K 5K 10K [FREQUENCY (12) FIGURE 14, ELECTRICAL FREQUENCY RESPONSE FOR THE ASA WEIGHTING CHARACTERISTICS OF “A” SCALE For noises of practical interest, differences in sound power levels are not large. Knowing that doubling sound pressure results in only 6 dB increase is also helpful. ‘The following charts (Figure 15 - 17 & Table 4) aid in predicting overall engine room noise. These levels are anechoic (free) field measurements which do not account for surrounding machines, floors and walls. The effect of distance on sound : doubling distance from source decreases sound 6 4B, halving distance from source increase measurement 6 dB. 4 a 2s INCREASE | e DECIBELS 38 ‘ADDED To 3 HIGHER 4 10 in, ooo ‘souNDs TO 4 | OBTAIN TOTAL ae 8 ol ° 0 2] 3 ate 7 Com eo; a ere etme ope NUMBER OF SOURCES DIFFERENCE BETWEEN TWO NOISES IN dB ADDITION OF EQUAL SOUNDS "ADDITION OF UNEQUAL SOUND FIGURE 15. AIDING CHART FIGURE 16, AIDING CHART ©[ATTENUATION IN DECIBELS aC 2828 28 & 8 OCTAVE BANDS IN CYCLES PER SECOND FIGURE 17. AIDING CHART Octave Bands in Cycles Per Second | 31.5 63 | 125 | 250 | 500 | 1000 | 2000 | 4000 | 8000 Highly Critical Hospital or 7 | 63 | 44 | 37 | 35 | 34 | 33 [a3 | 33 Residential Zone Night, Residential 73 | 69'| 52 | 44 | 39 | 98 | 38 | 38 | 98 Day, Residential 7% | 71 | 59 | 50 | 44 | 43 | 43 | 43 | 43 ‘Commercial ai | 75 | 65 | 58 | 54 | 50 | 47 | 44 | 43 Industrial-Commercial ai | 77 | 71 | 64 | 60 | 58 | 56 | 55 | 54 Industrial 87 | 85 | 81 | 75 | 71 | 70 | 68 | 66 | 66 Ear Damage Risk 112 | 108 | 100 | 95 | 94 | 94 | 94 | 94 | 94 TABLE 4. AIDING CHART Control - Mechanical Many techniques for isolating generator set vibrations are applicable to mechanical noise isolation. Modest noise reductions result from attention to noise sources, i.e., reducing fan speeds, coating casting areas and ducting air flows. But for attenuation over 10 dB(A), units must be totally isolated. One effective method utilizes conerete blocks filled with sand to house the generator set. In addition, the unit must incorporate vibration isolation techniques. A rough guide comparing various isolation methods is illustrated in Figure 18. ‘Completely enclosed engines are impractical due to openings required for pipes, ducts and ventilation. Enclosures with numerous openings rarely attain 20 dB(A) attenuation. Control - Exhaust Exhaust noise attentuation is commonly achieved by a quality muffler. Standard silencers typically reduce exhaust noise 15 dB(A) when measured 10 ft (3.3 m) perpendicular to exhaust outlet. Because the number of cylinders and engine speeds create varied exhaust frequencies, specific effects of mufflers must be predicted by the muffler manufacturer.IONS VIA DIFFERENCES IN INSTALLATIONS 18. NOISE LEVEL VARIATI FIGUREThis chapter looks into the operation of the Cumford-Turbo generator set after proper installation has been implemented. We will discuss the prestart requisites, the switchgear (control panel), some circuit protective devices and the various steps in the operational procedure.6.1 CONVERSION FACTORS Length Unit mm in ft ya ™ km mi mm 03937 0.08281 0.01084 0.01 ‘0.00001 = in 25.4 1 0.08333 0.02778 0.0254 0.00003 - ft 304.8 or 1 0.33933 0.3048 0.00030 - yd 9144 36 3 1 0.9144 0.00091 - m 1000 = 99.3701 3.28084 1.09961 1 0.001 0.00062 km 1000000 -99370.1 3208.84 1093.61 1000 1 0.62137 mi 1609340__63360 5280 1760 1609.34 __ 1.60934 1 Energy Btu Cal feb J Therm Keal British Thermal Unit 1 252 778 1055.05 0.00001 —~0.252 Calorie 0.00397 1 9.08866 4.185 0.002519 0,001 Foot-Pound 0.001285 0.923765 1 1.356 0000816 0.003089 Joule 0.000948 0.29895 (0.73745 1 0.01055 0.000239 Kilocalorie 3.96825 1000 gosg 41850 2.519 1 1 Therm = 100,000 Btu Btu per sq foot per min = 0.1220 watts per sq inch Btu per cu foot = 8.899 kg-cal/m* Btu per pound = .5556 kg-calkg Power Btwimin __ftb/min hp Jimin_Metrichp KW w Btu/min 1 7782 0.02358 —-*10550 0.02891 0.017584 17.5843 ftlb/min 0.00128 1 0.00003 1.9504 0.00003 0.00002 (0.0206 Horsepower 42.456 33000 1 44791 1.014. 0.74570 745.7 Joules/min 0.00095 0.7405-—0.0000223 1 0.000226 0.0000168 0.016668 Metrichp 41.827 «32550 (0.98632. «44127 1 0.73549 735.498 Kilowatt 56.8690 44250 «1.94102 59907 1.35962 1 1000 Watt 0.05687 4425 0.00134 59.9968 0.00136 _—_—0.001 1 Angle 1 quadrant = 90 degrees 1 degree = 60 minutes 1 quadrant = 1.57 radians 1 radian = 57.3 degrees 1 minute = 2.9 x 10" radianPressure and Head mmvhginfhg inH,O _ ftH,0 ‘Amospheres Umt__(0°C)__(0°C) (30°F) (90) thin? __kglem* —_bar__(14.7 psi) kPa mmng 1 0.08987 0.53626 _0.0446 0.01934 0.00136 0.00138 0001318 — itg 254 1 18.5955 1.13296 0.49115 0.03453 0.03986 0.03342 — inH.0 1.86827 0.07955 1.——0.08833 0.03613 0.00254 0.00049 0.00246 0.249 ftH0 224192 088265 12 1 0.49352 0.030479 0.02989 0.02950 2.989 lbjint 81.7149 2.09602 27.6807 2.3067 = 1—=S.07031 0.06895 0.06805 6.895. kolo? 795.559 28.959 393.71171 32.80931 14.2293 1.—=S=— 0.98067 0.96784 98.067 bar 750.062 29.590 401.4742 3345618 14.504 1.019721 0.98692 101.325 KPa 7.50062 0.29530 4.014742 0,3945618 0.145038 0.0101972 0.010000 0.00986920 1 Volume and Capacity Unit in? fe ye mm? m _US.gal_Impgal__litre in 1 0.0058 0.00002 16387.1 0.00002 0.00432 0.00361 0.01699 te 1728 1 0.09704 28.3168x106 0.02832 7.48052 6.22883 28,3169 ye 46656 ar 1 764554 0.76455 201.974 168.178 764.555 mm? 61x10 40x10" — 1 = 26x10? 2.2x1071.0x10* m 6128.7 95.3147 1.30795 1000000 1 264.172 219.969 1000 US. gal 231 0.19968 0.00495 3785410 0.00378 ~=ss«1—Ss( 83267 3.78541 Imp gal 277.419 0.16054 0.00595 4540090 0.00455 1.20095 1 454609 litre 61.0237 0.09531 0.00131 1000000 0.001 «0.26417 21997 4 acrett — — 49560161333 — 4233.48 925851271995 1 board-foot = 144 in? 1 bushel = 1.244 ft? 1 bushel = 4 pecks Weight ‘Ounces Pounds Tons Unit Kilograms Avoirdupois Avoirdupois _ Short_____Long Metric | 1 Kilogram 1 35.27 2.205 = = = 1 Ounce 0.02835 1 0.0625 - - = 1 Pound 0.4536 16 1 = S ig 1ShortTon 907.2 32,000 2,000 1 0.8929 0.9072 1 Long Ton 4,016 35,840 2,240 1.12 1 1.016 ‘Metric Ton 1,000 35,274 2,205 1.102 0.9842 1 grain = 0.064799 gramFlow Million’ Unit US. gallmin_US.gaday _ft'/s mm Us TUS. gpm 1 0.001440 0.00228 0.2270 (0.0631 1 Million gaVday 694.5 1 1.547 157.73 438 1ft%s 448.8 0.646 1 101.9 28.32 1mm 4.403, 0.00634 0.00981 1 02778 1Us 15.85 0.0228 0.0353, 3.60 1 MCFD = 1000 cubic feet per day MMCFD = 1000 000 cubic feet per day lbfohp-hr x 607.73 = g/KW-hr Area Unit mm? in? mm tt mm? 1 0.155 = 2s int 645.16 1 0.00064516 0.006944 m 10000 + 1550 1 10.764 fe 92900 144 0.0929 1 1/sq mile = 640 acres 1 acre = 4840 yd* 1 cir mil = 7.854 x 107 in? 1 cir mil = .7854 mils* 1 cir mil = 5.067 x 10* om? ‘TEMPERATURE ik CONVERSION SEER 8 oF =(1.8x°C) + 92 °C = 0.5555 (°F - $2) SSosuessssesssseses sess62 COOLING AT-Flow Relationship Heat Rejection (BTU/MIN. CF) = OTCF) = Fig (GPM) x Density (LEVGAL ) x Spec. Heat (BTUILB“F) Pure Water Sea Water S0/60Water—Giyco! Diesel Fuel Density (LB/GAL) aa 35 26 7A Specific Heat (BTU/LB+F) 10 094 os 04s aT eC) = Heat Rejection (kW) Flow (UMIN ) x Density (KGI/L) x Spec, Heat (KWeMIN KG"C PureWater ‘Sea Water _50/50Water—Glycol__ Diesel Fuel Density (KG/L) 0.98 1.02 1.03 0.85 Specific Heat (acu 071 0.086 0.06 0.032 Piping Design — Flow Relationships Recommended Coolant Velocities ‘Maximum Fresh Water Velocities for 3600 Engines Jacket Water: 2-8 FT/SEC. (0.6-2.5 M/SEC.) Pressurized Lines: 14.8 FT/SEC. (4 5 M/SEC.) Max. ‘Sea Water: 2-6 FT./SE.C (0.6-1.9 M/SEC.) ‘Suction Lines: 4.9 FT/SEC. (1.5 M/SEC.) Max. Pipe Dimensions Standard Iron Pipe Nominal Size Actual |.D. Actual 0.D. ft. per mper ft. per m per in. (mm) in. (mm) in. (mm) gal. Litre | cu.ft. m Te} 31s | 0270 | 686 | 0405 | 1029 | 336 | 270 | 2519 | 27,009 x | 695 | 0264 | 925 | 0540 | 1372 | 18 | 161 | 1369 | 14,986 x» | 953 | 049 | 1255 | 0675 | 1715 | 1004 | 93 | 751 | 8,083 ‘ee 12.7 0.623 15.82 0.840 21.34 63.1 5 472 5,080 Me 19.05 0.824 20.93 1,050 26.68 36.1 29 271 2,917, 1 25.4 1.048 26.62 1,315 33.4 22.3 19 166.8 1,795 an | 9175 | 1.980 | 35.05 | 1.660 | 4216 | 1285 | 1.09 | 961 | 1.034 1 | 961 | 1610 | 4089 | 1.900 | 4226 | 946 | 76 | 706 | 760 sos | 2067 | 522s | 2375 | 603 | 573 | 6 | 420 | 402 eas | 246a-| 6269 | 2875 | 7302 | soz | se | 901 | 324 762 | 3067 | 779 | 3500 | 089 | 260 | 21 | 195 | 210 88.9 3.548 90.12 4.000 101.6 1.94 16 14.51 156 4 | 1016 | 4026 | 10226 | 4500 | 1143 | 151 | 12 | 11.90 | 122 an | 1143 | 4508 | 1145 | 5.000 | 127 | 1205 | 097 | 901 | 97 5 127 5.045 | 128.14 | 5.563 141.3 0.961 077 7.19 7 6 | 1524 | 6065 | 154 | 6605 | 16028 | o6se | 054 | 498 | 54 7 | 17a | 7023 | 17838 | 7.625 | 19366 | 0496 | 04 | 971 | 40 8 | 2002 | 7982 | 200.74 | 625 | 21908 | 0364 | o31 | 267 | 31 9 228.6 8.937 227 9.625 | 244.48 | 0.307 025 2.30 25 254 | 10.019 | 254.5 | 10.750 | 273.05 | 0244 | 02 | 1.825 | 196 304.8 | 12.000 | 304.8 | 12.750 | 323.85 | 0204 | o16 | 1526 | 164 10 12Flow Restriction of Fittings Expressed as Equivalent Feet of Straight Pipe Size of Fitting 2 [aa] | |e |e | to" | 12" | 14" | 16" 90 Ell ss|e6s| 6 | 11 | 14 | 16 | 21 | 26 | a2 | 37 | 42 46 Ell 25| 3 |38| 5 |63|75| 10 | 19 | 15 | 17 | 19 Long Sweep Ell as|42|s2| 7 | 9 | 11] 14 | 17 | 20 | 24 | 27 Close Return Bend 13 | 15 | 18 | 24 | 31 | 37 | 51 | 61 | 74 | 85 | 100 Tee—Straight Run 3s|42]s2] 7 | 9 | 11 | 14 | 17 | 20 | 24 | 27 Tee—Side Inlet or Outlet. | 12 | 14 | 17 | 22 | 27 | 33 | 43 | 53 | 68 | 78 | 88 Globe Valve Open 85 | 67 | 82 | 110 | 140 ‘Angle Valve Open 27 | 33 | 41 | 53 | 70 Gate Valve FullyOpen | 12] 14|17|23|29|35/45|58]68| 8 | 9 Gate Valve Half Open 27 | 33 | 41 | 53 | 70 | 100 | 130 | 160 | 200 | 230 | 260 Check Valve 19 | 23 | 32 | 43 | 59 Strainers: ‘As a general rule of thumb, strainers should be of adequate capacity to create no more than 1.5-2.0psi (10- 14kPa) of pressure drop under clean strainer conditions at maximum flow.Typical Friction Losses of Water In Pipe (Old Pipe) (Nominal Pipe Diameter) Gallons Gallons per Head Loss in Feet of Water per 100 ft. of Pipe per Minute (m per 100 m) Minute pn 0 [Ram | Fee FEATS tm] 2 NB [RS = 334 | 10s | 925 | 084 | 040 | 016 | 005 |rmzm| 5 94 10 63 | 380 | 11.7 | 305 | 143 | 050 | 017 | 007 | 10 63 1s 95 | 800 | 250 | 650 | 305 | 107 | 057 | 015 | 15 95 20 126 | 1960 | 420 | 111 | 520 | 162 | 061 | 025 | 20 1.26 25 1.58 |riorsmn)| 640 | 166 | 785 | 273 | 092 | 098 | 25 1.58 30 19 | 013 | e90 | 230 | 110 | 384 | 129 | 054 | 30 19 3s 221 | o17 | 1190 | 312 | 147 | sao | 172 | o71 | 35 221 40 252 | 022 | 1520 | 400 | 188 | 660 | 220 | ost | 40 252 45 284 | 028 |sarmm| 500 | 232 | 820 | 276 | 116 | 45 284 50 315 | 034 | 011 | 600 | 284°| 990 | 3c2 | 138 | 50 315 60 379| o47 | o16 | #50 | 396 | 139 | 465 | 192 | 60 3.79 7 442 | 063 | 021 | 1130 | 530 | 184 | 620 | 257 | 70 442 75 473 | 072 | 024 | 1290 | 600 | 209 | 7.05 | 299 | 75 473 eo 50s | oat | 027 | 1450 | 680 | 237 | 7.90 | 328 | 80 505 90 568| 1.00 | 034 |eisnn| 840 | 294 | 960 | 408 | 90 5.68 100 631 | 122 | o41 | 0:17 | 1020 | 358 | 120 | 496 | 100 631 125 789 | 1.85 | 063 | 026 |rimenm| 540 | 176 | 755 | 125 7.89 150 946 | 260 | 087 | 036 | 017 | 760 | 257 | 105 | 150 9.46 175 11.05| 344 | 116 | 048 | 022 |eszmm| 340 | 141 | 175 11.05 200 1262| 440 | 148 | 061 | 028 | o15 | 431 | 178 | 200 1262 225 1420| 545 | 185 | 077 | 035 | o19 | 543 | 229 | 225 1420 250 15.77| 670 | 225 | 094 | 043 | 024 | 655 | 271 | 250 18.77 275 1735| 7.95 | 270 | 1.10 | 051 | 027 |epssmm) 323 | 275 17.95 300 1893| 990 | 314 | 1.30 | 060 | 092 | 018 | 380 | 300 18.93 32s 205| 108 | 365 | 151 | 068 | 097 | o21 | 441 | 925 205 350 22.08] 124 | 419 | 170 | 077 | 043 | 024 | 505 | 350 2208 37s 2366| 142 | 480 | 195 | 089 | 048 | 028 |r csm)| 375 23.86 400 2524| 160 | s4o | 220 | 1.01 | 055 | 031 | 0.19 | 400 25.24 425 2681| 179 | 610 | 247 | 114 | 061 | 035 | 021 | 425 2681 450 2839| 198 | 670 | 274 | 126 | 068 | 038 | 023 | 450 20.99 475 2997 740 | 282 | 146 | 075 | 042 | 026 | 475 29.97 500 31.55 ato | 290 | 154 | os2 | 046 | 028 | 500 31.55 750 47.32 709 | 323 | 1.76 | 098 | os9 | 750 47.92 1000 63.09 120 | 559 | 297 | 167 | 1.23 | 1000 63.09 1250 78.86 aso | 443 | 255 | 1.51 | 1250 786 1500 94.64 11.7 | 624 | 352 | 213 | 1500 9464 1750 110.41 74s | 470 | 280 | 1750 110.41 2000 126.18 to71 | 602 | 359 | 2000 126.18Boiling Point of Coolant at Varying Antifreeze Concentrations ‘Temperature at Which % Coolant with Ethylene Concentration Glycol Will Boil" 103°C (217°F) 104°C (219°F) 106°C (222°F) 108°C (226°F) 111°C(231°F) 298°F) assesses *At sea level. Protection Temperatures for Antifreeze Concentrations! Protection to: Concentration =15°C (5°F) 309% antifreeze, 70% water = 24°C ( 12°F) 40% antifreeze, 60% water = 37°C (-34°F), ‘50% antifreeze, 50% water = 52°C (- 62°F) 60% antifreeze, 40% water “Ethylene glycol-based antifreeze,6.3 EXHAUST Thermal Growth Allowance Exhaust Bellows Installation Limitations Thermal growth of exhaust piping must be plannedto avoid excessive load on supporting structures. Steel ‘exhaust pipe expands 0.0076 inches per foot of pipe for each 100°F rise of exhaust temperature (1.18mm per meter for each 100°C). This amounts to 0.65 in (16.5 mm) expansion for each 10 ft (3.05 m) of pipe from 100° to 950°F (35° to 510°C). {f bellows-type exhaust fitings are distorted beyond limits n table while engine is operating at full throttle, service life will be greatly reduced. Fanges must be parallel. Exhaust Bellows Installation eee B= Max Compression | C = Max Extension From Free Length | From Free Length in. (mm) in. (rm) 8 in. (200 mm) 1.50 38.1 1.00 25.4 and y + 0.90 229 0.50 127 10 in. (254 mm) 0.25 6.35 0.60 152 0.28 7A 0.38 9.65 0.40 102 0.20 5.08 170 Ibn 0.50 127 0.23 58 0 0 Spring Rate 0.75 19.4 0 0 0 o 0 0 1.50 38.1 1.00 25.4 12 in, (305 mm) 12 3.05 0.90 229 0.50 127 0.25 6.35 0.60 152 0.28 7m 194 Ib/in 0.38 9.65 0.40 10.2 0.10 5.08 Spring Rate 0.50 127 0.23 58 ° 0 0.75 19.1 0 0) 0 0 0 ° 3.90 99.06 2.08 5232 14 in. (356 mm) 0.12 3.05 2.85 72.39 2.08 52.32 0.25 6.35 4.70 43.18 2.06 52.92 100 tbyin 0.38 9.65 0.55 13.97 2.06 52.32 Spring Rate 0.44 11.2 0 0 2.06 52.92 0.50 127 ° 0 2.06 52.92 0.75 19.1 ° 0 2.06 52.32 0 0 6.30 160.0 3.28 83.31 18 in. (457 mm) 0.12 3.05 5.46 198.7 3.28 83.31 0.25 6.35 455 115.6 3.28 83.31 110 Ibn 0.38 9.65 3.64 92.46 3.28 83.31 Spring Rate 0.44 11.2 2.80 71.12 3.28 83.31 0.50 19.05 1.05 26.67 3.28 83.31 0.75 22.86 ° 0 3.28 83.31 606.4 HEAT RECOVERY Conversions : ‘One Boiler HP = 558 BTU/min = 33,475 BTU/hr = 9.8 KW ‘One Refrigeration Ton = 200 BTU/min = 12,000 BTU/hr = 5 KW Recoverable Exhaust Heat Heat recovery mufflers economically recover about hall the engine exhaust heat. Exhaust exit temperature above 300°F (149°C) discourages condensation in ducting. Recoverable heat can be estimated by: pM (T, -T,) Where: Q = Recoverable Heat (Btuh) Cp = Specific Heat (Btu/lb per °F) Diesel Engines - 0.258 Gas Engines - 0.279 T, = Exhaust Gas Stack Temperature °F Exhaust Gas Exit Temperature °F (30°F Minimum) Exhaust Mass Flow (Ib/h) Ma Exhaust Flow (cfm) x 60x 39.6 T, CF) + 460°F or Q = CpM(T,-T) Where: Q = Kih Cp = Diesel Engines - 1.081 Ku/kg per °C Gas Engines - 1.170 KJ/kg per °C M_ = Exhaust Mass Flow (kg/h) = _m°/min x 60 x 353.0 T, (0) + 273°C6.5 VENTILATION Diesel Engine Combustion Air Requirement 2.5 CFM (0.07 m*/min) per BHP Maximum Air Velocity to Avoid Excessive Noise and Flow Restriction 2000 fumin (610 m/min) Maximum Air Temperature at Air Cleaner 120°F (49°C) Air Velocity for Personnel Comfort Maintain at least 5 fV/sec (1.5 msec) in working areas adjacent to heat sources or where air temperature: exceeds 100°F (26°C) Engine Room Ventilation Requirements (For Stationary Generator Sets:) Engine room ventilation can be estimated by the fllowing formulaes, assuming 100°F (38°C) ambient ar temperature: ee I EE kad 0.070x024xAT — Combustion Air V (m?/min) = H + Engine 1.099 0.017 xAT Combustion Air V_ = Ventilating air (cfm) (m*/min). H_ = Heat radiation (Btu/min) (KW). Engine + Generator AT = Permissible temperature rise in engine room (°F) (°C). Density of air at 100°F = 0.071 Ib/ou ft (1.14 kg/m®).. seein fic heat of air = 0.24 Btulox FE Specific heat of ai (oor : )6.6 RULES OF THUMB & MISCELLANEOUS. Geometric Formulas ; TAN TS ree Circumference : Circle 2nr ‘Area : Circle xt Ellipse nab ‘Sphere 4nré Cylinder 2nr (+1) Triangle ‘/eab + Ellipsoid of revolution 4/3nb%a Sphere 4/3nr° Cylinder x bia Cone 22% Volume Trigonometric Relations ZA sino= 1 cos = r tano= Y x sin? O + cos? O e" = cos O + isin Law of Cosines n, a c xe Oca +b RULES OF THUMB Laws of Exponents Laws of Logarithms atxa’ » Ing) =xIny (aby = arxbs 2c ger In(ab) =Inatind rrr n(2) =Ina-inb Fuel Consumption— BHP: GPH fuel x15, GPH fuel x 9.5 cu fth fuel x Ve GPH fuel x 10 1/15 gal. per BHPsh 1/10 gal. per BHP+h 7 to 8 cu fYBHP+h 1/10 gale Gasoline Natural Gas* Diesel "100 Btu gas. Gas Compressor: BHP = 22 RevS Where : Re = Stage Compression Ratio V = Millon cu Uday ‘S = Number of Stages Cooling: Heat Exchanger Flow Rate Raw water to jacket water 1:1 to 2:1 ‘Submerged Pipe Cooling : '/ sq. ft. surface area per HP ‘With 85° F flowing water Electricity: Generator Capacity Required Motors : 1 kW per nameplate hp (motor running ‘coo! or warm to touch) 1" KW per nameplate hp (motor running hot to touch) Horsepower Requirements 1% BHP per kW of load or ve 0.746 x Gen. Eff Electric Sets: Motor Starting Requirements: Inrush kV*A (Code F motor) = 5.5 x BHP Inrush Current (Code F motor) = 6.2 x Full load rated currentON-SITE POWER REQUIREMENTS: Based on 100,000 sq. ft. of office bidg., etc., and 40° N. latitudes Electric Requirements : 600 KW continuous load (Air conditioning is absorption) Use three - 300 kW units (2 prime and 1 standby) Air Conditioning Compressor : 400 tons prime load Use two - 200 hp engines (No standby) REFRIGERATION: One ton refrigeration = 200 Btu/min = 12,000 Btu One boiler HP = 33,475 Btuh One ton compressor rating = One Engine hp ‘Auxiliary air conditioning equipment requires */« hp per ton of compressor rating Ice Plant : Complete power requires 4-5 hp per daily ton capacity AIR COMPRESSORS: hp = 1/4 X Cu ft per minute at 100 psi Increase BHP 10% for 125 psi Decrease BHP 10% for 80 psi CONVEYORS: 15 to 20° Incline. Hp = Vettcal ltt in x tons per hour 500 PUMPS: Deep Well BHP = Feetot it ost 1000 GPM Pipe Line BHP = Barrels per hour x psi x 0.00053 Any Liquid BHP. = GPM x lbigal (Liquid) x feet of head ‘33,000 x pump efficiency” “Efficiency : Centrigugal - Single impeller, double suction 65-80% Single impeller, side suction 55-75% Deep well turbine 65-80% Reciprocating 75% CENTRIFUGAL FANS AND PUMPS: Q= flow N= speed P = Static pressure or HP = HorsepowerFANS AND BLOWERS Oilfield Drilling Hoisting BHP = Weight x FPM (assume 100 is unknown) ‘33,000 x 0.85 (eff.) Mud Pumps BHP = ____GPMx Ib/gal x (feet of head) '33,000 x pump efficiency (see pumps) Dry Table [__Depthinfeet_| BHP Required ‘0 4000 75 ‘4000 - 8000 100 ‘8000- 12000 150 12000 - 16000 200 SAWMILL: 1" BHP per inch of saw diameter at 500 RPM. Increase or decrease in proportion to RPM ‘Swing Cut-Off Saw: 24-inch 3 BHP 36-inch 7'/ BHP 42.inch 10 BHP Table Trimmer 7'/ to 10 BHP Blower Fan, 12 foot sawdust 3 to 5 BHP Planer Mill 2 to 4 BHP per 100 board feet per hour, 24 to 30-inch planers 15 to 25 BHP Edgers : 2 saws 12 to 15 BHP 3 saws 15 to 25 BHP Slab Saw 10 BHP Jack Ladder 10 BHP ‘Approximate fuel consumption : Softwood 4 gal. per 1000 board feet Hardwood 1 gal. per 750 board feet BRAKE-MEAN EFFECTIVE PRESSURE BMEP psi (4-cycle) = BMEP psi = 159.8% Torque “Displacement ~ TORQUE: = Displacement x BMEP T (ib ft) 150.8 = -38000xhp_ _ 5252 xhp (ON) = Ox RPM. RPMMiscellaneous Relationships Mass (M) ‘Acceleration Due to Gravity 1 kg = 0.0685 Ib-s*/t, 1 Ib-s*/t = 14.6 kg 9 = 92.2 fs" or g = 9.81 mis* ‘Moment of inertia (We) Force (F): 1N=1 kgm/s? or N = 0.225 Ib Ibving? = Rotor Weight Diameter (tt 45 64.4 fis? 4 Torque (T) 1 Ibvin-s? = 0.113 kgm? 1. Nem = 1 kgm? or 1 Nem = 8.85 Ibv/in kVeA/kKW AMPERAGE CHART 80% POWER FACTOR KV*A_kW__208V_220V_240V_380V_400V_440V_460V 480V_600V_2400V 3300V_4160V] 63 5 175 165 152 96 91 63 81 76 641 94 75 261 247 226 143 136 123 12 113 94 125 10 34.7 33 901 192 182 166 162 151 12 187 15 52 495 45 288 273 249 244 225 18 25 20 695 66 602 384 364 332 924 301 2 6 44 31325 87 (825 755 48 455 445 405 378 30 75 55 375 30 104 99 903 576 546 498 487 452 36 91 66 50 40 139 132 120 77 73 665 65 60 48 121 88 625 50 173 165 152 96 18ST 76 115.1109 75 60 208 198 181 115 109 996 975 91 72 181 131 938 75 261 247 226 143 196 123 120 113 90 226 164 100 80 278 264 240 154146 133130120 96 24.1176 125 100 347 330 901 192 182 166 162 150 120 30 218 156 125 433 413 375 240 228 208 «204 188 150 38 27.3 187 150 520 495 450 268 273249244225 1804533, 219 175 608 S77 527 335 318 289 283 264 211 53 38 250 200 694 660 601 384 364 332 324 301 241 60 44 312 250 866825751 480455415 «4053769007555 375 300 1040 990 903 576 546 498 487 451 361 90 66 438 350 1220 1155 1053 672 637 581 568 527 422 105 77 500 400 1390 1320 1203770 730 665 650 602481 (120 88 625 S00 1735 1650 1504 960 910 630 810 752 602 150 109 750 600 2080 1980 1803 1150 1090 996 975 902 721 180 131 875 700 2430 2310 2104 1344 1274 1162 1196 1052 842 210 153121 1000 800 2780 2640 2405 1540 1460 1330 1300 1203 962 241 176 139 1125 900 3120 2970 2709 1730 1640 1495 1460 1354 1082 271 197 156 1250 1000 3470 3300 3009 1920 1820 1660 1620 1504 1202 301218 174 1563 1250 4350 4190 3765 2400 2260 2080 2040 1885 1503 976 273 218 1875 1500 5205 4950 4520 2880 2730 2490 2440 2260 1805 452 327 261 2188 1750 5280 _3350_3160 2890 2830 2640 2106 528 380 304 2500 2000 6020 3840 3640 3320 3240 3015 2405 602 496 348 2812 2250 6780 4320 4095 3735 3645 3400 2710 678 491 392 ‘3125 2500 7520 4800 _4560_4160 4080 3765 3005 752 546435 ‘3750 3000 9040 5760 5460 4980 4880 4525 3610 904 654 522 4375 3500 10550 6700 6360 5780 5660 5285 4220 1055 760 610 5000 4000 12040 7680 7280 6640 6480 6035 4810 1204 872 695ELECTRICAL FORMULAE Alternating Current To Obtain Single-Phase Three-Phase Direct Current Kitowatts Vxixpt 1.732xV x1 x pt (€q1) 7,000 4,000 kVA, Vxt 1.732xVx1 (42) 7,000 7,000 Horsepower Required KW. kW KW (43) To Drive Known kW “746 xEff. (Gen) 46x EH. (Gen) -746xEff.(Gen) Generator KW Input To a Motor hp x.746 hp x.746 hpx.746 (Eq) cof Known hp Eft. (Motor) Eft. (Motor) Eft. (Motor) Full Load Amperes hp x 746. x746 hpx746 —(Eq5) ‘When Motor Horse- Vx pixef. 1.782 x V x EM. xt Vxeff, power is Known ‘Amperes When kW kW x 1,000 KW x 1,000 (8) 1s Known Vxpr T732xVx ph ‘Amperes When kVA. —_KV*Ax 1,000 KV*A x 1,000 (a7) Is Known Vv 1.732xV ® Frequency (ops) Poles x pm_ Poles x pm E98) 120 120 Reactive KV*A (KV*AR)VxIxVIQ@IP 1.732 xVxIxVT= (pF (E99) 7,000 7,000 % Voltage Regulation 100 (VNu.- Vet) 100 (Vu = Veu) 100 (VNu- VFL) (Eq10) VEL VAL nak Where: V = Volts 1 = Line Current Amperes pf = Power FactorT Capscrew | Diameter and Ultimate Tensile To 1/2 - 69,000 PSI ‘Strength To 3/4 - 64,000 PSI To 3/4 - 120,000 PS! (PS!) To 1 - 55,000 PS To 1- 115,000 Psi oF 150,000 PSI SAE Grade Yor2 5 8 pune ys eetevyerk? apetgy fe Capscrew Feed Gs Markings ‘Capscrew Size (Inches) - Torque) Torque Torque@) (Thread) Ft-Lb (N-m) Ft-Lb (N-m) Ft-Lb (N-m) Dry Oiled Plated Dy Oiled Plated Dry Oiled Plated 114-20 5(7) 45 (6) 46) 8(11) 79) 6 (8) 12 (16) 11(15)—-10(14) 28 6 (8) 5.4 (7) 4.8(6) | 10(14) 9 (12) 8 (11) | 14(19) 13 (18) -11(15) 5/16-18 11(15) 10 (14) 9(12) | 17(23) —15(20)_-14(19) | 24(33)22,(30) 19 (26) 24 13(18) 12 (16) 10(14) | 19(26) 17(23) 15(20) | 27(37) 24 (83) 22 (30) 318-16 18 (24) 16 (22) 14(19) | 31(42) 28 (38) 25 (04) | 44 (60) 40 (54) 3547) 24 & (27) 18 (24) 16(22) | 35 (47) 32(43) 28 (98) | 4966) 44 (60) 39.(53) TNG-14 28 (38) 25 (34) 22(30) | 49(66) 44(60) 39 (53) | 70(95) 63/85) 56 (76) -20 90 (41), 27 (7) 24(93) | 55(75) 50(68) 44 (60) | 78(106) 70 (95) 62 (4) W213 3953) 35 (47) 31 (42) | 75(102) 68(92) 60 (81) | 105(142) 95(129) 84 (114) 20 41 (56) 37 (50) 33 (45) | 85(115) 77(104) 68 (92) | 120(163) 108 (146) 96 (130) 96-12 | 51 (69) 46,(62) “41 (66) |110(149) 99(134) 88 (119) | 155 (210) 140(190) 124 168) 18 ‘55 (75) 50(68) 44 (60) | 120 (163) 108 (146) 96 (130)| 170 (230) 153 (207) 136 (184) 518-11 | 83(113) 75(102) 66 (68) | 150(203) 195 (183) 120 (163) 210 (286) 189 (256) 168 (228) “18 95 (128) 86 (117) 76 (103) | 170(230) 153(207) 136 (184)| 240 (925) 216 (299) 192 (260) 4-10 105 (142) 95 (130) 84 (114) |270 (366) 243 (329) 216 (293)| 375 (508) 338 (458) 300 (407) 16 115 (156) 104 (141). 92 (125) | 295 (400) 266 (961) 296 (320)| 420 (669) 978 (513) 996 (456) 718-9 | 160 (217) 144,185) 128 (174) |995 (635) 356 (483) 316 (428)| 605 (820) 545 (739) 484 (656) 14 175 (237) 158 (214) 140(190) | 495 (580) 392 (531) 948 (472)| 675 (915) 608 (824) 540 (732) 18 235 (319) 212 (287) 188 (255) 590 (800) 531 (720) 472 (640) 910 (1234) 819 (1110) 728 (987) 14 250 (399) 225 (205) 200 (271) | 660 (895)_594 (805) 526 716)| 9901942) 891 (1208) 792 (1074) NOTES: @ Capscrews threaded into aluminum may require reductions in torque of 30% or more. TABLE 7. CAPSCREW TORQUE VALUES