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PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT 
Engineering-Book 
ENGINEERING FUNDAMENTALS AND HOW IT WORKS 
CONCEPTS, FORMULAS AND UNITS OF MEASUREMENT 
September 2014 
Supply Chain Manufacturing & DC Facilities Logistics Operations Planning Management 
Expertise in Process Engineering Optimization Solutions & Industrial Engineering Projects Management
Glossary 
HVAC (heating, ventilation, and air conditioning) The goal of HVAC design is to balance indoor 
environmental comfort with other factors such as installation cost, ease of maintenance, and 
energy efficiency 
air changes per hour The number of times per hour that the volume of a specific room or 
building is supplied or removed from that space by mechanical and natural ventilation 
air conditioner An appliance, system, or mechanism designed to dehumidify and extract 
heat from an area. Usually this term is reserved for smaller self contained units such as a 
residential system. 
air handling unit A central unit consisting of a blower, heating and cooling elements, filter 
racks or chamber, dampers, humidifier, and other central equipment in direct contact with 
the airflow. This does not include the ductwork through the building 
British thermal unit (BTU) Any of several units of energy (heat) in the HVAC industry, 
each slightly more than 1 kJ. One BTU is the energy required to raise one pound of 
water one degree Fahrenheit
Glossary 
The power of HVAC systems (the rate of cooling and dehumidifying or heating) is 
sometimes expressed in BTU/hour instead of watts The unit watt, is defined as one joule 
per second, and measures the rate of energy conversion or transfer 
Chiller A device that removes heat from a liquid via a vapor-compression or absorption 
refrigeration cycle 
This cooled liquid flows through pipes in a building and passes through coils in air 
handlers, fan-coil units, or other systems, cooling and usually dehumidifying the air in the 
building. 
Chillers are of two types; air-cooled or water-cooled. Air-cooled chillers are usually outside 
and consist of condenser coils cooled by fan-driven air. 
Water-cooled chillers are usually inside a building, and heat from these chillers is carried 
by re-circulating water to a heat sink such as an outdoor cooling tower
Glossary 
Coil Equipment that performs heat transfer to air when mounted inside an air handling unit 
or ductwork. It is heated or cooled by electrical means or by circulating liquid or steam 
within it. 
Condenser A component in the basic refrigeration cycle that ejects or removes heat from 
the system. 
The condenser is the hot side of an air conditioner or heat pump. Condensers are heat 
exchangers, and can transfer heat to air or to an intermediate fluid (such as water or an 
aqueous solution of ethylene glycol) to carry heat to a distant sink, such as ground (earth 
sink), a body of water, or air (as with cooling towers) 
Evaporator A component in the basic refrigeration cycle that absorbs or adds 
heat to the system. Evaporators can be used to absorb heat from air or from a 
liquid. The evaporator is the cold side of an air conditioner or heat pump
Glossary 
Damper A plate or gate placed in a duct to control air flow by increasing friction in the duct 
Economizer An HVAC component that uses outside air, under suitable climate conditions, 
to reduce required mechanical cooling. When the outside air’s enthalpy is less than the 
required supply air during a call for cooling, an economizer allows a building’s mechanical 
ventilation system to use up to the maximum amount of outside air 
Enthalpy For a given sample of air, a measure of the total heat content (the sum of the heat 
energy of the dry air and heat energy of the water vapor within it). It is typically used to 
determine the amount of fresh outside air that can be added to re-circulated air for the 
lowest cooling cost. 
fan coil unit A small terminal unit that is often composed of only a blower and a 
heating and/or cooling coil, as is often used in hotels, condominiums, or apartments 
Flow A transfer of fluid volume per unit time
Glossary 
fresh air intake An opening through which outside air is drawn into the building. This may 
be to replace air in the building that has been exhausted by the ventilation system, or to 
provide fresh air for combustion of fuel 
Grille A facing across a duct opening, often rectangular in shape, containing multiple 
parallel slots through which air may be delivered or withdrawn from a ventilated space. The 
grille directs the air flow in a particular direction and prevents the passage of large items 
heat gain / heat load / heat loss 
Terms for the amount of cooling (heat gain) or heating (heat loss) needed to maintain 
desired temperatures and humidity's in controlled air 
Regardless of how well-insulated and sealed a building is, buildings gain heat from 
sunlight, conduction through the walls, and internal heat sources such as people and 
electrical equipment 
Buildings lose heat through conduction during cold weather. Engineers use heat load 
calculations to determine the HVAC needs of the space being cooled or heated
Glossary 
intermediate fluid A liquid or gas used to transfer heat between two heat exchangers. 
An intermediate fluid is used when the hot and cold fluids are too bulky (such as air) or 
difficult to handle (such as halocarbon refrigerant) to directly transfer the heat 
makeup air unit An air handler that conditions 100% outside air. Typically used in industrial 
or commercial settings, or in "once-through" (blower sections that only blow air one-way 
into the building), "low flow" (air handling systems that blow air at a low flow rate), or 
"primary-secondary" (air handling systems that have an air handler or rooftop unit 
connected to an add-on makeup unit or hood) commercial HVAC systems 
Psychometric The study of the behavior of air-water vapor mixtures. Water vapor plays an 
important role in energy transfer and human comfort in HVAC design 
Radiation The transfer of heat directly from one surface to another (without heating the 
intermediate air acting as a transfer mechanism). 
Superheat The number of degrees a vapor is above its boiling point at a specific 
pressure
Glossary 
Sub-cooling The condition where liquid refrigerant is colder than the minimum temperature 
required to keep it from boiling which would change it from a liquid to a gas phase. 
Sub-cooling is the difference between its saturation temperature and the actual liquid 
refrigerant temperature 
terminal unit A small component that contains a heating coil, cooling coil, automatic 
damper, or some combination of the three. Used to control the temperature of a single 
room 
variable air volume An HVAC system that has a stable supply-air temperature, and 
varies the air flow rate to meet the temperature requirements 
Compared to constant air volume systems, these systems conserve energy through 
lower fan speeds during times of lower temperature control demand 
Most new commercial buildings have VAV systems. VAVs may be bypass type or 
pressure dependent. Pressure dependent type VAVs save energy while both types help 
in maintaining temperature of the zone that it feeds 
8 –
Glossary 
In thermodynamics, entropy (usual symbol S) is a measure of the number of specific 
ways in which a thermodynamic system may be arranged, often taken to be a measure of 
disorder, or a measure of progressing towards thermodynamic equilibrium 
The entropy of an isolated system never decreases, because isolated systems 
spontaneously evolve towards thermodynamic equilibrium, the maximum entropy 
Systems which are not isolated may decrease in entropy 
Since entropy is a state function, the change in the entropy of a system is the same 
whether a process going from one defined state to another is reversible or irreversible, 
but irreversible processes increase the entropy of the environment 
9 – 
The change in entropy (ΔS) was originally defined for a thermodynamically 
reversible process 
which is found from the uniform thermodynamic temperature (T) of a closed system 
dividing an incremental reversible transfer of heat into that system (dQ).
Glossary 
Enthalpy is a defined thermodynamic potential, designated by the letter "H", that consists 
of the internal energy of the system (U) plus the product of pressure (P) and volume (V) of 
the system 
The unit of measurement for enthalpy is the joule, but other historical, conventional units 
are still in use, such as the British thermal unit and the calorie. 
The total enthalpy, H, of a system cannot be measured directly 
The same situation exists in classical mechanics: only a change or difference in energy 
carries physical meaning 
Enthalpy itself is a thermodynamic potential, so in order to measure the enthalpy of a 
system, we must refer to a defined reference point; therefore what we measure is the 
change in enthalpy, ΔH 
The change ΔH is positive in endothermic reactions, and negative in heat-releasing 
exothermic processes. 
ΔH of a system is equal to the sum of non-mechanical work done on it and the heat 
supplied to it 
10 –
Glossary 
One of the fundamental thermodynamic equations is the description of thermodynamic 
work in analogy to mechanical work, or weight lifted through an elevation against gravity 
Power, is the elevation of a weight to a certain height. The product of the weight 
multiplied by the height to which it is raised.” With the inclusion of a unit of time 
The state of a thermodynamic system is specified by a number of extensive quantities, the 
most familiar of which are volume, internal energy, and the amount of each constituent 
particle (particle numbers). 
Extensive parameters are properties of the entire system, as contrasted with intensive 
parameters which can be defined at a single point, such as temperature and pressure 
The extensive parameters (except entropy) are generally conserved in some way as long 
as the system is "insulated" to changes to that parameter from the outside 
11 –
Glossary 
In the case of energy, the statement of the conservation of energy is known as the first 
law of thermodynamics, where is the infinitesimal increase in internal energy of the 
system. Is the infinitesimal heat flow into the system and is the infinitesimal work 
done by the system 
In physical chemistry, positive work is conventionally considered work done on the 
system rather than by the system, and the law is expressed as 
The concept which governs the path that a thermodynamic system traces in state space 
as it goes from one equilibrium state to another is that of entropy. The entropy is first 
viewed as an extensive function of all of the extensive thermodynamic parameters 
If we have a thermodynamic system in equilibrium, and we release some of the extensive 
constraints on the system, there are many equilibrium states that it could move to 
consistent with the conservation of energy, volume, etc. 
12 – 
.
Glossary 
The second law of thermodynamics specifies that the equilibrium state that it moves to is 
in fact the one with the greatest entropy. Once we know the entropy as a function of the 
extensive variables of the system, we will be able to predict the final equilibrium state. 
The entropy of an isolated system never decreases for an isolated system 
A process within a given isolated system is said to be reversible if throughout the process 
the entropy never increases (i.e. the entropy remains unchanged). 
The third law of thermodynamics states that at the absolute zero of temperature, the 
entropy is zero for a perfect crystalline structure when 
The zeroth law says that systems that are in thermodynamic equilibrium with each other 
have the same temperature. The law was actually the last of the laws to be formulated 
consider a system composed of a number of k different types of particles and has the 
volume as its only external variable. The fundamental thermodynamic relation may then 
be expressed in terms of the internal energy as 
13 – 
The thermodynamic space has k+2 dimensions 
The differential quantities (U, S, V, Ni) are all extensive 
quantities
Glossary 
Power in mechanical systems is the combination of forces and movement. In particular, 
power is the product of a force on an object and the object's velocity, or the product of a 
torque on a shaft and the shaft's angular velocity measured in radians per second 
In fluid power systems such as hydraulic actuators, power is given by 
where p is pressure in pascals, or N/m2 and Q is volumetric flow rate in m3/s in SI units 
The instantaneous electrical power P delivered to a component is given by 
P(t) is the instantaneous power, measured in watts (joules per second) 
V(t) is the potential difference (or voltage drop) across the component, measured in volts 
I(t) is the current through it, measured in amperes 
If the component is a resistor with time-invariant voltage to current ratio, then 
14 – 
is the resistance, measured in ohms
Glossary 
Electric power, like mechanical power, is the rate of doing work, measured in watts, and 
represented by the letter P. 
The term wattage is used colloquially to mean "electric power in watts." 
The electric power in watts produced by an electric current I consisting of a charge of Q 
coulombs every t seconds passing through an electric potential (voltage) difference of V is 
Q is electric charge in coulombs 
t is time in seconds 
I is electric current in amperes 
V is electric potential or voltage in volts 
In the case of resistive (Ohmic, or linear) loads, Joule's law can be combined with Ohm's 
law (V = I·R) to produce alternative expressions for the dissipated power 
15 – 
where R is the electrical resistance.
Glossary 
In alternating current circuits, energy storage elements such as inductance and 
capacitance may result in periodic reversals of the direction of energy flow 
The portion of power flow that, averaged over a complete cycle of the AC waveform, 
results in net transfer of energy in one direction is known as real power (also referred to as 
active power) 
That portion of power flow due to stored energy, that returns to the source in each cycle, is 
known as reactive power 
The real power P in watts consumed by a device is given by 
Vp is the peak voltage in volts 
Ip is the peak current in amperes 
Vrms is the root-mean-square voltage in volts 
Irms is the root-mean-square current in amperes 
θ is the phase angle between the current and voltage sine waves 
The ratio of real power to apparent power is a 
number between 0 and 1 
16 –
Glossary 
Classical mechanics is concerned with the set of physical laws describing the motion of 
bodies under the action of a system of forces 
The study of the motion of bodies is an ancient one, making classical mechanics one of the 
oldest and largest subjects in science, engineering and technology 
It is also widely known as Newtonian mechanics 
Isaac Newton proposed three laws of motion: the law of inertia, his second law of 
acceleration (mentioned above), and the law of action and reaction; and hence laid the 
foundations for classical mechanics 
Newton also enunciated the principles of conservation of momentum and angular 
momentum. In mechanics, Newton was also the first to provide the first correct scientific 
and mathematical formulation of gravity in Newton's law of universal gravitation. 
He demonstrated that these laws apply to everyday objects as well as to celestial objects. 
In particular, Newton obtained a theoretical explanation of Kepler's laws of motion of the 
planets. 
17 –
Glossary 
18 – 
. 
The velocity, or the rate of change of position with time, is 
defined as the derivative of the position with respect to time: 
The acceleration, or rate of change of velocity, is the 
derivative of the velocity with respect to time (the second 
derivative of the position with respect to time): 
Some physicists interpret Newton's second law of motion as a definition of force and mass 
The quantity mv is called the (canonical) momentum. The net force on a particle is thus 
equal to the rate of change of the momentum of the particle with time 
If a constant force F is applied to a particle that achieves a displacement Δr, the work 
done by the force is defined as the scalar product of the force and displacement vectors
Glossary 
The kinetic energy Ek of a particle of mass m travelling at speed v is given by 
19 – 
In special relativity, the momentum of a particle 
is given by 
where m is the particle's rest mass, v its 
velocity, and c is the speed of light. 
If v is very small compared to c, v2/c2 is 
approximately zero, and so 
Thus the Newtonian equation p = mv is an 
approximation of the relativistic equation for 
bodies moving with low speeds compared to 
•Statics, the study of equilibrium and its relation to forces the speed of light 
•Dynamics, the study of motion and its relation to forces 
•Kinematics, dealing with the implications of observed 
motions without regard for circumstances causing them
Glossary 
Derived kinematic quantities Derived dynamic quantities 
Velocity 
Acceleration 
Jerk 
Angular velocity 
Angular Acceleration 
Momentum 
Force 
Impulse 
Angular momentum 
about a position point 
r0, Most of the time we can set r0 = 0 if particles are orbiting about axes intersecting at a common point 
20 – 
Torque 
Angular 
impulse 
Mechanical work
Glossary 
Momentum is the "amount of translation" 
For a rotating rigid body: 
Angular momentum is the "amount of rotation": 
Torque τ is also called moment of a force, 
because it is the rotational analogue to force 
Resultant force acts on a system at the 
center of mass, equal to the rate of change 
of momentum 
Impulse is the change in momentum 
Angular impulse is the change in 
angular momentum 
21 – Title of the document or activity name – Month XX, 2012 – Insert tab > Header/Footer 
For constant force F: 
For constant torque τ: 
The work done W by an external agent which 
exerts a force F (at r) and torque τ on an object 
along a curved path C is Kinetic energy
Glossary 
A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel 
around which rope or chain wraps 
22 – 
"Chain hoist" also describes a 
hoist using a differential pulley 
A compound pulley with two 
different radii and teeth engage 
an endless chain, 
Allowing the exerted force to be 
multiplied according to the ratio 
of the radii.
Glossary 
Consider the set of pulleys that form the moving block and the parts of the rope that 
support this block 
If there are p of these parts of the rope supporting the load W, then a force balance on 
the moving block shows that the tension in each of the parts of the rope must be W/p 
This means the input force on the rope is T=W/p. Thus, the block and tackle reduces the 
input force by the factor p 
The mechanical advantage of a pulley system can be analyzed using free body diagrams 
which balance the tension force in the rope with the force of gravity on the load 
In this case, a force balance on a free body that includes the load, W, and n supporting 
sections of a rope with tension T, yields 
23 – 
the mechanical advantage of the system is equal to the 
number of sections of rope supporting the load
Glossary 
Differential pulley 
is used to manually lift very heavy objects like car engines. It is operated by pulling upon 
the slack section of a continuous chain that wraps around pulleys. The relative size of two 
connected pulleys determines the maximum weight that can be lifted by hand. 
It consists of two fixed pulleys of unequal radii that are attached to each other and 
rotate together, a single pulley bearing the load, and an endless rope looped 
around the pulleys. To avoid slippage, the rope is usually replaced by a chain, and 
the connected pulleys by sprockets. 
24 –
Glossary 
The two sections of chain carrying the single pulley exert opposing and unequal torques 
on the connected pulleys, such that only the difference of these torques has to be 
compensated manually by pulling the loose part of the chain. 
This leads to a mechanical advantage: the force needed to lift a load is only a fraction of 
the load's weight. 
At the same time, the distance the load is lifted is smaller than the length of chain pulled 
by the same factor. 
This factor (the mechanical advantage MA) depends on the relative difference of the radii 
r and R of the connected. The effect on the forces and distances is quantitatively 
The difference in radii can be made very small, making the mechanical advantage of this 
pulley system very large. In the extreme case of zero difference in radii, MA becomes 
infinite, thus no force (besides friction) is needed to move the chain, but moving the chain 
will no longer lift the load, when r is zero, the system becomes with a MA = 2 
25 –
Glossary 
A belt and pulley system is characterized by two or more pulleys in common to a belt. This 
allows for mechanical power, torque, and speed to be transmitted across axles. If the 
pulleys are of differing diameters, a mechanical advantage is realized 
A belt drive is analogous to that of a chain drive, however a belt sheave may be smooth 
(devoid of discrete interlocking members as would be found on a chain sprocket, spur 
gear, or timing belt) so that the mechanical advantage is approximately given by the ratio 
of the pitch diameter of the sheaves only, not fixed exactly by the ratio of teeth as with 
gears and sprockets. 
26 –
Glossary 
27 – 
The gear ratio of a gear train, also known as its speed 
ratio, is the ratio of the angular velocity of the input gear to 
the angular velocity of the output gear 
The gear ratio can be calculated directly from the 
numbers of teeth on the gears in the gear train 
The torque ratio of the gear train, also known as its 
mechanical advantage, is determined by the gear ratio 
The speed ratio and mechanical advantage are defined 
so they yield the same number in an ideal linkage
Glossary 
A gear train is formed by mounting gears on a frame so that the teeth of the gears engage 
Gear teeth are designed to ensure the pitch circles of engaging gears roll on each other 
without slipping, providing a smooth transmission of rotation from one gear to the next 
28 – 
Gear teeth are designed so that the number of teeth on a gear is 
proportional to the radius of its pitch circle, and so that the pitch 
circles of meshing gears roll on each other without slipping. 
The speed ratio for a pair of meshing gears can be computed from ratio of the radii of the 
pitch circles and the ratio of the number of teeth on each gear 
The velocity v of the point of contact on the pitch circles is the same on both gears, 
and is given by
Glossary 
where input gear A has radius rA and meshes with output gear B of radius rB 
where NA is the number of teeth on the input gear and NB on the output gear 
The mechanical advantage of a pair of meshing gears for which the input gear has NA 
teeth and the output gear has NB teeth is given by MA 
This shows that if the output gear GB has more teeth than the input gear GA, then the gear 
train amplifies the input torque 
And, if the output gear has fewer teeth than the input gear, then the gear train reduces 
the input torque 
If the output gear of a gear train rotates more slowly than the input gear, then the gear 
train is called a speed reducer 
In this case, because the output gear must have more teeth than the input gear, the 
speed reducer amplifies the input torque. 
29 –
Glossary 
Speed ratio. Gear teeth are distributed along the circumference of the pitch circle so that 
the thickness t of each tooth and the space between neighboring teeth are the same 
The pitch p of a gear, which is the distance between equivalent points on neighboring 
teeth along the pitch circle, is equal to twice the thickness of a tooth, 
The pitch of a gear GA can be computed from the number of teeth NA and the radius rA of 
its pitch circle 
In order to mesh smoothly two gears GA and GB must have the same sized teeth and 
therefore they must have the same pitch p, which means 
This equation shows that the ratio of the circumference, the diameters and the radii of 
two meshing gears is equal to the ratio of their number of teeth, 
The speed ratio of two gears rolling without slipping on their pitch circles is given by, 
30 –
Glosary 
Calculating power 
Watt determined that a horse could turn a mill wheel 144 times in an hour (or 2.4 times a 
minute). The wheel was 12 feet in radius; therefore, the horse travelled 2.4 × 2π × 12 
feet in one minute. Watt judged that the horse could pull with a force of 180 pounds. So: 
This was rounded to an even 33,000 ft·lbf/min. 
If torque and angular speed are known, the power may be calculated. The relationship 
when using a coherent system of units (such as SI) is simply 
The constant 5252 is the rounded value of (33,000 ft·lbf/min)/(2π rad/rev). 
When torque is in inch pounds: 
The constant 63,025 is the rounded value of (33,000 ft·lbf/min) × (12 in/ft)/(2π rad/rev). 
31 –
Glosary 
The following definitions have been widely used: 
Mechanical horsepower 
hp(I) ≡ 33,000 ft-lbf/min 
32 – 
= 550 ft·lbf/s 
≈ 17,696 lbm·ft2/s3 
= 745.69987158227022 W 
Metric horsepower 
hp(M) - also PS, ''cv, hk, pk, ks or ch 
≡ 75 kgf·m/s 
≡ 735.49875 W 
Electrical horsepower 
hp(E) ≡ 746 W 
Boiler horsepower 
hp(S) ≡ 33,475 BTU/h 
= 9,812.5 W 
Hydraulic horsepower 
= flow rate (US gal/min) × pressure (psi) × 7/12,000 = 550 ft·lbf/s 
= flow rate (US gal/min) × pressure (psi) / 1714 = 745.699 W
Glosary 
Torque converter is generally a type of fluid coupling (but also being able to 
33 – 
multiply torque) that is used to transfer rotating power from a 
prime mover, such as an internal combustion engine or electric 
motor, to a rotating driven load 
The torque converter normally takes the place of a mechanical 
clutch in a vehicle with an automatic transmission, allowing the 
load to be separated from the power source 
It is usually located between the engine's flexplate and the 
transmission. 
The key characteristic of a torque converter is its ability to 
multiply torque when there is a substantial difference between 
input and output rotational speed, thus providing the equivalent 
of a reduction gear
Glosary 
As with a basic fluid coupling the theoretical torque capacity of a converter is proportional to 
34 – 
where is the mass density of the fluid (kg/m³), 
and is the impeller speed (rpm), 
is the diameter(m) 
A torque converter cannot achieve 100 percent coupling efficiency. 
The classic three element torque converter has an efficiency curve that resembles ∩: 
zero efficiency at stall, generally increasing efficiency during the acceleration phase and 
low efficiency in the coupling phase 
Typical stall torque multiplication ratios range from 1.8:1 to 2.5:1 for most automotive 
applications 
Specialized converters designed for industrial, rail, or heavy marine power transmission 
systems are capable of as much as 5.0:1 multiplication
Glosary 
35 – 
Power 
Motor Velocity (rpm) 
3450 2000 1000 500 
Torque 
hp kW (in lbf) (ft lbf) (Nm) (in lbf) (ft lbf) (Nm) (in lbf) (ft lbf) (Nm) (in lbf) (ft lbf) (Nm) 
1 0.75 18 1.5 2.1 32 2.6 3.6 63 5.3 7.1 126 10.5 14.2 
1.5 1.1 27 2.3 3.1 47 3.9 5.3 95 7.9 10.7 189 15.8 21.4 
2 1.5 37 3.0 4.1 63 5.3 7.1 126 10.5 14.2 252 21.0 28.5 
3 2.2 55 4.6 6.2 95 7.9 10.7 189 15.8 21.4 378 31.5 42.7 
5 3.7 91 7.6 10 158 13.1 18 315 26.3 36 630 52.5 71 
7.5 5.6 137 11 15 236 20 27 473 39 53 945 79 107 
10 7.5 183 15 21 315 26 36 630 53 71 1260 105 142 
15 11 274 23 31 473 39 53 945 79 107 1891 158 214 
20 15 365 30 41 630 53 71 1260 105 142 2521 210 285 
25 19 457 38 52 788 66 89 1576 131 178 3151 263 356 
30 22 548 46 62 945 79 107 1891 158 214 3781 315 427 
40 30 731 61 83 1260 105 142 2521 210 285 5042 420 570 
50 37 913 76 103 1576 131 178 3151 263 356 6302 525 712 
60 45 1096 91 124 1891 158 214 3781 315 427 7563 630 855 
70 52 1279 107 145 2206 184 249 4412 368 499 8823 735 997 
80 60 1461 122 165 2521 210 285 5042 420 570 10084 840 1140 
90 67 1644 137 186 2836 236 321 5672 473 641 11344 945 1282 
100 75 1827 152 207 3151 263 356 6302 525 712 12605 1050 1425 
125 93 2283 190 258 3939 328 445 7878 657 891 15756 1313 1781 
Example - Electrical Motor 
Torque 
Torque from an electrical motor 
with 
100 hp and speed 1000 rpm 
can be calculated as 
T = (100 hp) 63025 / (1000 rpm) 
= 6303 (in lbf) 
To convert to foot pound-force - 
divide the torque by 12.
Glosary 
Electrical Motor Torque Equation 
Torque can be calculated in Imperial units as 
T = Php 63025 / n (1) 
where 
T = torque (in lbf) 
Php = horsepower delivered by the electric motor 
n = revolution per minute (rpm) 
Alternatively 
Tft = Php 5252 / n (1b) 
where 
Tft = torque (ft lbf) 
•1 ft lbf = 1.356 Nm 
Torque can be calculated in SI units as 
T = PW 9.554 / n (1) 
where 
T = torque (Nm) 
PW = power (watts) 
n = revolution per minute (rpm) 
36 –
Glosary 
Calculating Motor Speed: 
A squirrel cage induction motor is a constant speed device. It 
cannot operate for any length of time at speeds below those shown 
on the nameplate without danger of burning out. 
To Calculate the speed of a induction motor, apply this 
formula: 
Srpm = 120 x F 
37 – 
P 
Srpm = synchronous revolutions per minute. 
120 = constant 
F = supply frequency (in cycles/sec) 
P = number of motor winding poles 
Example: What is the synchronous of a motor having 4 poles 
connected to a 60 hz power supply? 
Srpm = 120 x F 
P 
Srpm = 120 x 60 
4 
Srpm = 7200 
4 
Srpm = 1800 rpm
Glosary 
Calculating Braking Torque: 
Full-load motor torque is calculated to determine the required 
braking torque of a motor. 
To Determine braking torque of a motor, apply this formula: 
T = 5252 x HP 
rpm 
T = full-load motor torque (in lb-ft) 
5252 = constant (33,000 divided by 3.14 x 2 = 5252) 
HP = motor horsepower 
rpm = speed of motor shaft 
Example: What is the braking torque of a 60 HP, 240V motor 
rotating at 1725 rpm? 
T = 5252 x HP 
rpm 
T = 5252 x 60 
1725 
T = 315,120 
1725 
T = 182.7 lb-ft 
38 –
Glosary 
Calculating Work: 
Work is applying a force over a distance. Force is any cause 
that changes the position, motion, direction, or shape of an 
object. Work is done when a force overcomes a resistance. 
Resistance is any force that tends to hinder the movement of 
an object.If an applied force does not cause motion the no 
work is produced. 
To calculate the amount of work produced, apply this formula: 
W = F x D 
W = work (in lb-ft) 
F = force (in lb) 
D = distance (in ft) 
Example: How much work is required to carry a 25 lb bag of 
groceries vertically from street level to the 4th floor of a 
building 30' above street level? 
W = F x D 
W = 25 x 30 
W = 750 -lb 
39 –
Glosary 
Calculating Torque: 
Torque is the force that produces rotation. It causes an object to rotate. Torque 
consist of a force acting on distance. Torque, like work, is measured is pound-feet 
(lb-ft). However, torque, unlike work, may exist even though no movement occurs. 
To calculate torque, apply this formula: 
T = F x D 
T = torque (in lb-ft) 
F = force (in lb) 
D = distance (in ft) 
Example: What is the torque produced by a 60 lb force pushing on a 3' lever arm? 
T = F x D 
T = 60 x 3 
T = 180 lb ft 
40 –
Glosary 
Calculating Full-load Torque: 
Full-load torque is the torque to produce the rated power at full speed of the motor. The amount of 
torque a motor produces at rated power and full speed can be found by using a horsepower-to-torque 
41 – 
conversion chart. When using the conversion chart, place a straight edge along the two 
known quantities and read the unknown quantity on the third line. 
To calculate motor full-load torque, apply this formula: 
T = HP x 5252 
rpm 
T = torque (in lb-ft) 
HP = horsepower 
5252 = constant 
rpm = revolutions per minute 
Example: What is the FLT (Full-load torque) of a 30HP motor operating at 1725 rpm? 
T = HP x 5252 
rpm 
T = 30 x 5252 
1725 
T = 157,560 
1725 
T = 91.34 lb-ft
Glosary 
Calculating Horsepower: 
Electrical power is rated in horsepower or watts. A horsepower is a unit of power equal to 746 watts or 
33,0000 lb-ft per minute (550 lb-ft per second). A watt is a unit of measure equal to the power 
produced by a current of 1 amp across the potential difference of 1 volt. It is 1/746 of 1 horsepower. 
The watt is the base unit of electrical power. Motor power is rated in horsepower and watts. 
Horsepower is used to measure the energy produced by an electric motor while doing work. 
To calculate the horsepower of a motor when current and efficiency, and voltage are known, 
apply this formula: 
HP = V x I x Eff 
42 – 
746 
HP = horsepower 
V = voltage 
I = curent (amps) 
Eff. = efficiency 
Example: What is the horsepower of a 230v motor pulling 4 amps and having 82% efficiency? 
HP = V x I x Eff 
746 
HP = 230 x 4 x .82 
746 
HP = 754.4 
746 
HP = 1 Hp 
Eff = efficiency / HP = horsepower / V = volts / A = amps / PF = power factor
Glosary 
43 – 
Horsepower Formulas 
To Find Use Formula 
Example 
Given Find Solution 
HP HP = I X E X Eff. 
746 
240V, 20A, 85% 
Eff. HP 
HP = 240V x 20A 
x 85% 
746 
HP=5.5 
I I = HP x 746 
E X Eff x PF 
10HP, 240V, 
90% Eff., 88% PF I 
I = 10HP x 746 
240V x 90% x 
88% 
I = 39 A 
To calculate the horsepower of a motor when the speed and torque are known, apply this formula: 
HP = rpm x T(torque) 
5252(constant) 
Example: What is the horsepower of a 1725 rpm motor with a FLT 3.1 lb-ft? 
HP = rpm x T 
5252 
HP = 1725 x 3.1 
5252 
HP = 5347.5 
5252 
HP = 1 hp
Glosary 
Calculating Synchronous Speed: 
AC motors are considered constant speed motors. This is because the synchronous speed of an 
induction motor is based on the supply frequency and the number of poles in the motor winding. 
Motor are designed for 60 hz use have synchronous speeds of 3600, 1800, 1200, 900, 720, 600, 514, 
and 450 rpm. 
To calculate synchronous speed of an induction motor, apply this formula: 
rpmsyn = 120 x f 
44 – 
Np 
rpmsyn = synchronous speed (in rpm) 
f = supply frequency in (cycles/sec) 
Np = number of motor poles 
Example: What is the synchronous speed of a four pole motor operating at 50 hz.? 
rpmsyn = 120 x f 
Np 
rpmsyn = 120 x 50 
4 
rpmsyn = 6000 
4 
rpmsyn = 1500 rpm
Glosary 
Torque in 
45 – 
lb.ft. = 
HP x 5250 
rpm 
HP = 
Torque x 
rpm 
5250 
rpm = 
120 x 
Frequency 
No. of Poles 
Rules Of Thumb (Approximation) 
At 1800 rpm, a motor develops a 3 lb.ft. per hp 
At 1200 rpm, a motor develops a 4.5 lb.ft. per hp 
At 575 volts, a 3-phase motor draws 1 amp per hp 
At 460 volts, a 3-phase motor draws 1.25 amp per hp 
At 230 volts a 3-phase motor draws 2.5 amp per hp 
At 230 volts, a single-phase motor draws 5 amp per hp 
At 115 volts, a single-phase motor draws 10 amp per hp 
Mechanical Formulas
Glosary 
Synchronous Speed, Frequency And Number Of Poles Of AC Motors 
Relation Between Horsepower, Torque, And Speed 
46 – 
t = 
High Inertia Loads 
WK2 x rpm 
308 x T av. 
WK2 = inertia in lb.ft.2 
t = accelerating time in sec. 
T = Av. accelerating torque lb.ft.. 
Temperature Conversion 
Deg C = (Deg F - 32) x 5/9 
Deg F = (Deg C x 9/5) + 32 
inertia reflected to motor = Load Inertia (Load rpm) 
Motor rpm 2 
ns = 
120 x f 
P 
f = 
P x ns 
120 
P = 
120 x f 
ns 
HP = T x n 
5250 T = 5250 HP 
n n = 5250 HP 
T 
% Slip = 
ns - n 
ns 
x 100 
Motor Slip
Glosary 
Code KVA/HP Code KVA/HP Code KVA/HP Code KVA/HP 
A 0-3.14 F 5.0 -5.59 L 9.0-9.99 S 16.0-17.99 
B 3.15-3.54 G 5.6 -6.29 M 10.0-11.19 T 18.0-19.99 
C 3.55-3.99 H 6.3 -7.09 N 11.2-12.49 U 20.0-22.39 
D 4.0 -4.49 I 7.1 -7.99 P 12.5-13.99 V 22.4 & Up 
E 4.5 -4.99 K 8.0 -8.99 R 14.0-15.99 
Symbols 
I = current in amperes 
E = voltage in volts 
KW = power in kilowatts 
KVA = apparent power in kilo-volt-amperes 
HP = output power in horsepower 
N = motor speed in revolutions per minute (RPM) 
Ns = synchronous speed in revolutions per minute (RPM) 
P = number of poles 
F = frequency in cycles per second (CPS) 
T = torque in pound-feet 
EFF = efficiency as a decimal 
PF = power factor as a decimal 
47 –
Glosary 
Equivalent Inertia 
In mechanical systems, all rotating parts do not usually operate at the same speed. Thus, we need to 
determine the "equivalent inertia" of each moving part at a particular speed of the prime mover 
The total equivalent WK2 for a system is the sum of the WK2 of each part, referenced to prime mover 
speed 
The equation says: 
WK2 
48 – 
EQ = WK2 
part 
(Npart) 2 
Nprime mover 
This equation becomes a common denominator on which other calculations can be based. For variable-speed 
devices, inertia should be calculated first at low speed 
Let's look at a simple system which has a prime mover (PM), a reducer and a load 
WK2 = 100 lb.ft.2 WK2 = 900 lb.ft.2 
(as seen at output shaft) WK2 = 27,000 lb.ft.2 
PRIME MOVER 3:1 GEAR REDUCER LOAD 
The formula states that the system WK2 equivalent is equal to the sum of WK2 
parts at the prime mover's RPM
Glosary 
or in this case: 
49 – 
WK2 
EQ = WK2 
pm + 
WK2 
Red. 
(Red. RPM) 
PM RPM 2 + WK2 
Load (Load RPM) 
PM RPM 2 
Note: reducer RPM = Load RPM 
EQ = WK2 
pm + WK2 
Red. (1) 
WK2 
Load (1) 
3 2 + WK2 
3 2 
The WK2 equivalent is equal to the WK2 of the prime mover, plus the WK2 of the load. This is equal to the WK2 of the 
prime mover, plus the WK2 of the reducer times (1/3)2, plus the WK2 of the load times (1/3)2 
This relationship of the reducer to the driven load is expressed by the formula given earlier: 
WK2 
EQ = WK2 
part 
(Npart) 
Nprime mover 
2 
In other words, when a part is rotating at a speed (N) different from the prime mover, the WK2 
EQ is equal to the WK2 of 
the part's speed ratio squared
Glosary 
In the example, the result can be obtained as follows: 
The WK2 equivalent is equal to: 
WK2 
Finally: 
50 – 
EQ = 100 lb.ft.2 + 900 lb.ft.2 (1) 
3 2 + 27,000 
lb.ft.2 
(1 
)32 
WK2 
EQ = lb.ft.2 
pm + 100 lb.ft.2 
Red + 3,000 lb.ft2 
Load 
WK2 
EQ = 3200 lb.ft.2 
The total WK2 equivalent is that WK2 seen by the prime mover at its speed.
Glosary 
51 – 
To Find 
Alternating Current 
Single-Phase Three-Phase 
Amperes when horsepower is known HP x 746 
E x Eff x pf 
HP x 746 
1.73 x E x Eff x pf 
Amperes when kilowatts are known Kw x 1000 
E x pf 
Kw x 1000 
1.73 x E x pf 
Amperes when kva are known Kva x 1000 
E 
Kva x 1000 
1.73 x E 
Kilowatts I x E x pf 
1000 
1.73 x I x E x pf 
1000 
Kva I x E 
1000 
1.73 x I x E 
1000 
Horsepower = (Output) I x E x Eff x pf 
746 
1.73 x I x E x Eff x pff 
746 
Electrical Formulas 
I = Amperes; E = Volts; Eff = Efficiency; pf = Power Factor; Kva = Kilovolt-amperes; Kw = Kilowatts
Glosary 
Locked Rotor Current (IL) From Nameplate Data 
Three Phase: IL = 577 x HP x KVA/HP 
Effect Of Line Voltage On Locked Rotor Current (IL) (Approx.) 
52 – 
E 
See: KVA/HP Chart 
Single Phase: IL = 1000 x HP x KVA/HP 
E 
EXAMPLE: Motor nameplate indicates 10 HP, 3 Phase, 460 Volts, Code F 
IL = 577 x 10 x (5.6 or 6.29) 
460 
IL = 70.25 or 78.9 Amperes (possible range) 
IL @ ELINE = IL @ EN/P 
x 
ELINE 
EN/P 
EXAMPLE: Motor has a locked rotor current (inrush of 100 Amperes (IL) at the rated nameplate voltage (EN/P) of 230 volts. 
What is IL with 245 volts (ELINE) applied to this motor? 
IL @ 245 V. = 100 x 254V/230V 
IL @ 245V. = 107 Amperes
Glosary 
Basic Horsepower Calculations 
Horsepower is work done per unit of time. One HP equals 33,000 ft-lb of work per minute. When work is 
done by a source of torque (T) to produce (M) rotations about an axis, the work done is: 
radius x 2 x rpm x lb. or 2 TM 
When rotation is at the rate N rpm, the HP delivered is: 
HP = radius x 2 x rpm x lb. 
Where: 
53 – 
33,000 = TN 
5,250 
For vertical or hoisting motion HP = W x S 
33,000 x E 
W = total weight in lbs. to be raised by motor 
S = hoisting speed in feet per minute 
E = overall mechanical efficiency of hoist and gearing. For purposes of estimating 
E = .65 for eff. of hoist and connected gear.
Glosary 
For fans and blowers: 
HP = Volume (cfm) x Head (inches of water) 
For purpose of estimating, the eff. of a fan or blower may be assumed to be 0.65. 
54 – 
6356 x Mechanical Efficiency of Fan 
Note: Air Capacity (cfm) varies directly with fan speed. Developed Pressure varies with square of fan speed. 
Hp varies with cube of fan speed. 
HP 
= 
Volume (cfm) x Pressure (lb. Per sq. ft.) 
3300 x Mechanical Efficiency of Fan 
HP = Volume (cfm) x Pressure (lb. Per sq. in.) 
229 x Mechanical Efficiency of Fan 
For pumps: HP = GPM x Pressure in lb. Per sq. in. x Specific Grav. 
1713 x Mechanical Efficiency of Pump 
HP = 
GPM x Total Dynamic Head in Feet x 
S.G. 
3960 x Mechanical Efficiency of Pump 
where Total Dynamic Head = Static Head + Friction Head 
For estimating, pump efficiency may be assumed at 0.70
Glosary 
Accelerating Torque 
The equivalent inertia of an adjustable speed drive indicates the energy required to keep the system running. 
However, starting or accelerating the system requires extra energy. 
The torque required to accelerate a body is equal to the WK2 of the body, times the change in RPM, divided by 308 
times the interval (in seconds) in which this acceleration takes place: 
ACCELERATING TORQUE 
55 – 
= 
WK2N (in lb.ft.) 
308t 
N = Change in RPM 
W = Weight in Lbs. 
K = Radius of gyration 
t = Time of acceleration (secs.) 
WK2 = Equivalent Inertia 
308 = Constant of proportionality 
Where: 
TAcc = WK2N 
308t 
The constant (308) is derived by transferring linear motion to angular motion, and considering acceleration due to 
gravity. If, for example, we have simply a prime mover and a load with no speed adjustment
Glosary 
Example 1 PRIME LOADER LOAD 
56 – 
WK2 = 200 lb.ft.2 WK2 = 800 lb.ft.2 The WK2 
EQ is determined as before: 
WK2 
EQ = WK2 
pm + WK2 
Load 
WK2 
EQ = 200 + 800 
WK2 
EQ = 1000 ft.lb.2 
If we want to accelerate this load to 1800 RPM in 1 minute, enough information is 
available to find the amount of torque necessary to accelerate the load. 
The formula states: 
TAcc = WK2 
EQN 
308t 
or 1000 x 1800 
308 x 60 or 1800000 
18480 
TAcc = 97.4 lb.ft 
In other words, 97.4 lb.ft. of torque must be applied to get this load turning at 1800 RPM, in 60 seconds. 
Note that TAcc is an average value of accelerating torque during the speed change under consideration. If a more 
accurate calculation is desired, the following example may be helpful. 
Example 2 
The time that it takes to accelerate an induction motor from one speed to another may be found from the following equation: 
t = WR2 x change in rpm 
308 x T 
T = Average value of accelerating torque during the speed change under consideration. 
t = Time the motor takes to accelerate from the initial speed to the final speed. 
WR2 = Flywheel effect, or moment of inertia, for the driven machinery plus the motor rotor in lb.ft.2 (WR2 of driven 
machinery must be referred to the motor shaft).
Glosary 
The Application of the above formula will now be considered by means of an example 
Figure A shows the speed-torque curves of a squirrel-cage induction motor and a blower which it drives. 
At any speed of the blower, the difference between the torque which the motor can deliver at its shaft 
and the torque required by the blower is the torque available for acceleration 
Reference to Figure A shows that the accelerating torque may vary greatly with speed. When the 
speed-torque curves for the motor and blower intersect there is no torque available for acceleration. 
The motor then drives the blower at constant speed and just delivers the torque required by the load 
In order to find the total time required to accelerate the motor and blower, the area between the motor 
speed-torque curve and the blower speed-torque curve is divided into strips, the ends of which 
approximate straight lines. Each strip corresponds to a speed increment which takes place within a 
definite time interval 
The solid horizontal lines in Figure A represent the boundaries of strips; the lengths of the broken lines 
the average accelerating torques for the selected speed intervals. In order to calculate the total 
acceleration time for the motor and the direct-coupled blower it is necessary to find the time required to 
accelerate the motor from the beginning of one speed interval to the beginning of the next interval and 
add up the incremental times for all intervals to arrive at the total acceleration time 
If the WR2 of the motor whose speed-torque curve is given in Figure A is 3.26 ft.lb.2 and the WR2 of the 
blower referred to the motor shaft is 15 ft.lb.2, the total WR2 is 15 + 3.26 = 18.26 ft.lb.2 
57 –
Glosary 
And the total time of acceleration is: 
WR2 
308 X [ 
58 – 
rpm1 
T1 
+ 
rpm2 
T2 
+ 
rpm3 
T3 
+ - - - - - 
- - - - + 
rpm9 
T9 
] 
t = 
18.2 
6 
308 
X [ 150 
46 + 150 
48 + 300 
47 + 300 
43.8 + 200 
39.8 + 200 
36.4 + 300 
32.8 + 100 
29.6 + 40 
11 ] 
t = 2.75 sec. Accelerating Torques 
T1 = 46 lb.ft. T4 = 43.8 lb.ft. T7 = 32.8 lb.ft. 
T2 = 48 lb.ft. T5 = 39.8 lb.ft. T8 = 29.6 lb.ft. 
T3 = 47 lb.ft. T6 = 36.4 lb.ft. T9 = 11 lb.ft. 
Curves used to determine time required to 
accelerate induction motor and blower
Glosary 
In order for a duty cycle to be checked out, the duty cycle information must include the following: 
Inertia reflected to the motor shaft. 
Torque load on the motor during all portions of the duty cycle including starts, running time, stops or 
reversals. 
Accurate timing of each portion of the cycle. 
Information on how each step of the cycle is accomplished. For example, a stop can be by coasting, 
mechanical braking, DC dynamic braking or plugging. A reversal can be accomplished by plugging, or 
the motor may be stopped by some means then re-started in the opposite direction. 
When the motor is multi-speed, the cycle for each speed must be completely defined, including the 
method of changing from one speed to another. 
Any special mechanical problems, features or limitations 
59 –
Glosary 
Duty cycle refers to the detailed description of a work cycle that repeats in a specific time period 
This cycle may include frequent starts, plugging stops, reversals or stalls 
These characteristics are usually involved in batch-type processes and may include tumbling barrels, 
certain cranes, shovels and draglines, dampers, gate- or plow-positioning drives, drawbridges, freight 
and personnel elevators, press-type extractors, some feeders,presses of certain types, hoists, 
indexers, boring machines,cinder block machines, keyseating, kneading, car-pulling, shakers (foundry 
or car), swaging and washing machines, and certain freight and passenger vehicles 
The list is not all-inclusive. The drives for these loads must be capable of absorbing the heat 
generated during the duty cycles 
Adequate thermal capacity would be required in slip couplings, clutches or motors to accelerate or 
plug-stop these drives or to withstand stalls 
It is the product of the slip speed and the torque absorbed by the load per unit of time which 
generates heat in these drive components 
All the events which occur during the duty cycle generate heat which the drive components must 
dissipate. 
60 –
Conversion Units 
61 –
Conversion Units 
62 –
Conversion Units 
63 –
Conversion Units 
64 –
Conversion Units 
65 –
Conversion Units 
66 – 
1 mile per hour (mph) 
≅ 
1.46666667 feet per second (fps) 
1 mile per hour (mph) = 1.609344 kilometers per hour 
1 knot 
≅ 
1.150779448 miles per hour 
1 foot per second 
≅ 
0.68181818 miles per hour (mph) 
1 kilometer per hour 
≅ 
0.62137119 miles per hour (mph) 
1 square foot = 144 square inches 
1 square foot = 929.0304 square centimeters 
1 square yard = 9 square feet 
1 square meter 
≅ 
10.7639104 square feet 
1 centimeter (cm) 
= 
10 millimeters (mm) 
1 inch 
= 
2.54 centimeters (cm) 
1 foot 
= 
0.3048 meters (m) 
1 foot 
= 
12 inches 
1 yard 
= 
3 feet 
1 meter (m) 
= 
100 centimeters (cm) 
1 meter (m) 
≅ 
3.280839895 feet 
1 furlong 
= 
660 feet 
1 kilometer (km) 
= 
1000 meters (m) 
1 kilometer (km) 
≅ 
0.62137119 miles 
1 mile 
= 
5280 ft 
1 mile 
= 
1.609344 kilometers (km) 
1 nautical mile 
= 
1.852 kilometers (km) 
1 pound (lb) 
= 
0.45359237 kilograms (kg)
Conversion Units 
67 – 
Some Formulas 
Area of Square Side Squared 
Area of Circle 3.1415927 x Radius Square 
Area of Sphere 4 x 3.1415927 x Radius Squared 
Area of Parallelogram Base x Height 
Circumference of Circle 2 x 3.1415927 x Radius 
Volume of Rectangular Box Length x Width x Height 
Volume of Cone 1/3 x 3.1415927 x Radius Squared x Height 
Volume of Cylinder 3.1415927 x Radius Squared x Height 
Volume of Sphere 4 x 3.1415927 x Radius Cubed ÷ 3 
Volume of Cube Side Cubed 
a = area 
c = circumference 
v = volume 
sq = square 
cu = cubic 
r = radius 
d = diameter 
l = length 
w = width 
h = height 
s = side 
Pi = 3.1415927 (approx)
Conversion Units 
68 – 
Given Multiply by To Find 
Length [L] 
Foot (ft) 0.304800 Meter (m) 
Inch (in) 25.4000 Millimeter (mm) 
Mile (mi) 1.609344 Kilometer (km) 
Area [L]2 
ft2 0.092903 m2 
in2 645.16 mm2 
in2 6.45160 cm2 
Volume [L]3 & Capacity 
in3 16.3871 cm3 
ft3 0.028317 m3 
ft3 7.4805 Gallon 
ft3 28.3168 Liter (l) 
Gallon 3.785412 Liter
Conversion Units 
69 – 
Energy, Work or Heat [M] [L]2 [t]-2 
Btu 1.05435 kJ 
Btu 0.251996 kcal 
Calories (cal) 4.184* Joules (J) 
ft-lbf 1.355818 J 
ft-lbf 0.138255 kgf-m 
hp-hr 2.6845 MJ 
KWH 3.600 MJ 
m-kgf 9.80665* J 
N-m 1. J 
Flow Rate [L]3 [t]-1 
ft3/min 7.4805 gal/min 
ft3/min 0.471934 l/s 
gal/min 0.063090 l/s
Conversion Units 
70 – 
Force or Weight [M] [L] [t]-2 
kgf 9.80665* Newton (N) 
lbf 4.44822 N 
lbf 0.453592 Kgf 
Fracture Toughness 
ksi sqr(in) 1.098800 MPa sqr(m) 
Heat Content 
Btu/lbm 0.555556 cal/g 
Btu/lbm 2.324444 J/g 
Btu/ft3 0.037234 MJ/m3 
Heat Flux 
Btu/hr-ft2 7.5346 E-5 cal/s-cm2 
Btu/hr-ft2 3.1525 W/m2 
cal/s-cm2 4.184* W/cm2
Conversion Units 
71 – 
Mass Density [M] [L]-3 
lbm/in3 27.68 g/cm3 
lbm/ft3 16.0184 kg/m3 
Power [M] [L]2 [t]-3 
Btu/hr 0.292875 Watt (W) 
ft-lbf/s 1.355818 W 
Horsepower (hp) 745.6999 W 
Horsepower 550.* ft-lbf/s 
Pressure (fluid) [M] [L]-1 [t]-2 
Atmosphere (atm) 14.696 lbf/in2 
atm 1.01325 E5* Pascal (Pa) 
lbf/ft2 47.88026 Pa 
lbf/in2 27.6807 in. H20 at 39.2°F
Conversion Units 
72 – 
Stress [M] [L]-1 [t]-2 
kgf/cm2 9.80665 E-2* MPa 
ksi 6.89476 MPa 
N/mm2 1. MPa 
kgf/mm2 1.42231 ksi 
Specific Heat 
Btu/lbm-°F 1. cal/g-°C 
Temperature* 
Fahrenheit (°F-32) /1.8 Celsius 
Fahrenheit °F+459.67 Rankine 
Celsius °C+273.16 Kelvin 
Rankine R/1.8 Kelvin
Conversion Units 
73 – 
Stress [M] [L]-1 [t]-2 
kgf/cm2 9.80665 E-2* MPa 
ksi 6.89476 MPa 
N/mm2 1. MPa 
kgf/mm2 1.42231 ksi 
Specific Heat 
Btu/lbm-°F 1. cal/g-°C 
Temperature* 
Fahrenheit (°F-32) /1.8 Celsius 
Fahrenheit °F+459.67 Rankine 
Celsius °C+273.16 Kelvin 
Rankine R/1.8 Kelvin 
Thermal Conductivity 
Btu-ft/hr-ft2-°F 14.8816 cal-cm/hr-cm2-°C
Conversion Units 
74 – 
pound TO g Multiply pound by 453.5924 
pound TO joule/cm Multiply pound by 0.04448 
pound TO joule/m (newton) Multiply pound by 4.448 
pound TO kg Multiply pound by 0.4536 
pound/ft TO kg/m Multiply pound/ft by 1.488 
pound/in TO gm/cm Multiply pound/in by 178.6 
pound/sq ft TO kg/sq m Multiply pound/sq ft 
by 4.882 
pound/sq ft TO pound/sq in Multiply pound/sq ft 
by 6.94E-03 
pound/sq in TO kg/sq m Multiply pound/sq in 
by 703.1 
pound/sq in TO pound/sq ft Multiply pound/sq in 
by 144 
radian/sec TO degree/sec Multiply radian/sec 
by 57.29578 
radian/sec TO revolution/min Multiply radian/sec 
by 9.549 
radian/sec TO revolution/sec Multiply radian/sec 
by 0.1592
Conversion Units 
75 – 
revolution TO degree Multiply revolution 
by 360 
revolution/min TO degree/sec Multiply 
revolution/min by 6 
revolution/min TO radian/sec Multiply 
revolution/min by 0.1047 
revolution/min TO revolution/sec Multiply 
revolution/min by 0.01667 
sq cm TO sq ft Multiply sq cm by 1.08E-03 
sq cm TO sq in Multiply sq cm by 0.155 
sq cm TO sq m Multiply sq cm by 0.0001 
sq cm TO sq mile Multiply sq cm by 3.86E-11 
sq cm TO sq mm Multiply sq cm by 100 
sq cm TO sq yard Multiply sq cm by 1.20E-04 
sq ft TO acre Multiply sq ft by 2.30E-05 
sq ft TO sq cm Multiply sq ft by 929
Conversion Units 
76 – 
sq ft TO sq in Multiply sq ft by 144 
sq ft TO sq m Multiply sq ft by 0.0929 
sq ft TO sq mm Multiply sq ft by 9.29E+04 
sq in TO sq cm Multiply sq in by 6.452 
sq in TO sq ft Multiply sq in by 6.94E-03 
sq in TO sq mm Multiply sq in by 645.2 
ton (metric) TO kg Multiply ton (metric) 
by 1000 
ton (metric) TO pound Multiply ton (metric) 
by 2205 
watt TO Btu/hr Multiply watt by 3.4129 
watt TO Btu/min Multiply watt by 0.05688 
watt TO ft-pound/min Multiply watt by 44.27 
watt TO ft-pound/sec Multiply watt by 0.7378 
watt TO hp Multiply watt by 1.34E-03 
watt-hr TO Btu Multiply watt-hr by 3.413 
watt-hr TO ft-pound Multiply watt-hr by 2656 
watt-hr TO hp-hr Multiply watt-hr by 1.34E-03 
watt-hr TO kg-m Multiply watt-hr by 367.2 
watt-hr TO kilowatt-hr Multiply watt-hr by 0.001
Conversion Units 
77 – 
To Convert From To Convert To Multiply By 
lbf/in2 (psi) pascal (Pa) 6894.757 
pascal (Pa) lbf/in2 (psi) 1.4504E-4 
g/cm3 lb/ft3 62.427974 
lb/ft3 kg/m3 16.01846 
lb/in3 kg/m3 27,679.90 
lb/ft3 g/cm3 0.01601846 
volts/mil kV/mm 0.039370 
mil (0.001 inch) cm 2.54E-3 
cm mil 393.70 
MPa(m1/2) psi(in1/2) 910.06
Conversion Units 
78 – 
J/(g-°C) BTU/(lb-°F) 0.239006 
BTU/(lb-°F) J/(g-°C) 4.184000 
joule (J) cal (thermochemical) 0.2390057 
cal (thermochemical) joule (J) 4.184000 
joule (J) BTU (thermochemical) 9.4845E-4 
BTU (thermochemical) joule 1054.350 
μm/(m-°C) μin/(in-°F) 0.55556 
μin/(in-°F) μm/(m-°C) 1.80 
cm3/Kg in3/lb 0.027680 
in3/lb cm3/kg 36.127 
W/(m K) BTU in /(hr ft2 F) 6.9334713 
BTU in /(hr ft2 F) W/(m K) 0.1441314 
(J m)/(min m2 C) W/(m-K) 0.016667 
W/(m-K) (J m)/(min m2 C) 60
Conversion Units 
79 – 
Millimeters x 0.0394 = Inches 
Centimeters x 0.3937 = Inches 
Inches x 25.4 = Millimeters 
Inches x 2.54 = Centimeters 
Feet x 30.48 = Centimeters 
Meters x 3.281 = Feet 
Square Inches x 6.45 = Square 
Centimeters 
Square 
Centimeters x 155 = Square Inches 
Square Meters x 10.76 = Square Feet 
Cubic 
Centimeters x .0610 = Cubic Inches 
Cubic Feet x 1728 = Cubic Inches 
Cubic Feet x 28.32 = Liters 
Cubic Inches x 0.004329 = Gallons
Conversion Units 
80 – 
Gallons of 
Water x 8.35 = Pounds of 
Water 
Pounds of 
Water x 27.65 = Cubic Inches 
Gallons x 231 = Cubic Inches 
Pounds x .45359 = Kilograms 
Kilograms x 2.2046 = Pounds 
Grams x 15.43 = Grains 
Watts x 0.001341 = Horsepower 
Amps x Volts = Watts 
Atmospheres x 14.7 = Lbs per square 
inch 
Horsepower x .7457 = Kilowatts 
British Thermal 
Units x 3.927 x 10-4 = Horsepower-hours 
British Thermal 
Units x 2.928 x 10-4 = Kilowatt-hours
L | C | LOGISTICS 
PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT 
Engineering-Book 
ENGINEERING FUNDAMENTALS AND HOW IT WORKS 
CONCEPTS, FORMULAS AND UNITS OF MEASUREMENT 
Thank You

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Engineering plant facilities 01 concepts formulas and uom

  • 1. L | C | LOGISTICS PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT Engineering-Book ENGINEERING FUNDAMENTALS AND HOW IT WORKS CONCEPTS, FORMULAS AND UNITS OF MEASUREMENT September 2014 Supply Chain Manufacturing & DC Facilities Logistics Operations Planning Management Expertise in Process Engineering Optimization Solutions & Industrial Engineering Projects Management
  • 2. Glossary HVAC (heating, ventilation, and air conditioning) The goal of HVAC design is to balance indoor environmental comfort with other factors such as installation cost, ease of maintenance, and energy efficiency air changes per hour The number of times per hour that the volume of a specific room or building is supplied or removed from that space by mechanical and natural ventilation air conditioner An appliance, system, or mechanism designed to dehumidify and extract heat from an area. Usually this term is reserved for smaller self contained units such as a residential system. air handling unit A central unit consisting of a blower, heating and cooling elements, filter racks or chamber, dampers, humidifier, and other central equipment in direct contact with the airflow. This does not include the ductwork through the building British thermal unit (BTU) Any of several units of energy (heat) in the HVAC industry, each slightly more than 1 kJ. One BTU is the energy required to raise one pound of water one degree Fahrenheit
  • 3. Glossary The power of HVAC systems (the rate of cooling and dehumidifying or heating) is sometimes expressed in BTU/hour instead of watts The unit watt, is defined as one joule per second, and measures the rate of energy conversion or transfer Chiller A device that removes heat from a liquid via a vapor-compression or absorption refrigeration cycle This cooled liquid flows through pipes in a building and passes through coils in air handlers, fan-coil units, or other systems, cooling and usually dehumidifying the air in the building. Chillers are of two types; air-cooled or water-cooled. Air-cooled chillers are usually outside and consist of condenser coils cooled by fan-driven air. Water-cooled chillers are usually inside a building, and heat from these chillers is carried by re-circulating water to a heat sink such as an outdoor cooling tower
  • 4. Glossary Coil Equipment that performs heat transfer to air when mounted inside an air handling unit or ductwork. It is heated or cooled by electrical means or by circulating liquid or steam within it. Condenser A component in the basic refrigeration cycle that ejects or removes heat from the system. The condenser is the hot side of an air conditioner or heat pump. Condensers are heat exchangers, and can transfer heat to air or to an intermediate fluid (such as water or an aqueous solution of ethylene glycol) to carry heat to a distant sink, such as ground (earth sink), a body of water, or air (as with cooling towers) Evaporator A component in the basic refrigeration cycle that absorbs or adds heat to the system. Evaporators can be used to absorb heat from air or from a liquid. The evaporator is the cold side of an air conditioner or heat pump
  • 5. Glossary Damper A plate or gate placed in a duct to control air flow by increasing friction in the duct Economizer An HVAC component that uses outside air, under suitable climate conditions, to reduce required mechanical cooling. When the outside air’s enthalpy is less than the required supply air during a call for cooling, an economizer allows a building’s mechanical ventilation system to use up to the maximum amount of outside air Enthalpy For a given sample of air, a measure of the total heat content (the sum of the heat energy of the dry air and heat energy of the water vapor within it). It is typically used to determine the amount of fresh outside air that can be added to re-circulated air for the lowest cooling cost. fan coil unit A small terminal unit that is often composed of only a blower and a heating and/or cooling coil, as is often used in hotels, condominiums, or apartments Flow A transfer of fluid volume per unit time
  • 6. Glossary fresh air intake An opening through which outside air is drawn into the building. This may be to replace air in the building that has been exhausted by the ventilation system, or to provide fresh air for combustion of fuel Grille A facing across a duct opening, often rectangular in shape, containing multiple parallel slots through which air may be delivered or withdrawn from a ventilated space. The grille directs the air flow in a particular direction and prevents the passage of large items heat gain / heat load / heat loss Terms for the amount of cooling (heat gain) or heating (heat loss) needed to maintain desired temperatures and humidity's in controlled air Regardless of how well-insulated and sealed a building is, buildings gain heat from sunlight, conduction through the walls, and internal heat sources such as people and electrical equipment Buildings lose heat through conduction during cold weather. Engineers use heat load calculations to determine the HVAC needs of the space being cooled or heated
  • 7. Glossary intermediate fluid A liquid or gas used to transfer heat between two heat exchangers. An intermediate fluid is used when the hot and cold fluids are too bulky (such as air) or difficult to handle (such as halocarbon refrigerant) to directly transfer the heat makeup air unit An air handler that conditions 100% outside air. Typically used in industrial or commercial settings, or in "once-through" (blower sections that only blow air one-way into the building), "low flow" (air handling systems that blow air at a low flow rate), or "primary-secondary" (air handling systems that have an air handler or rooftop unit connected to an add-on makeup unit or hood) commercial HVAC systems Psychometric The study of the behavior of air-water vapor mixtures. Water vapor plays an important role in energy transfer and human comfort in HVAC design Radiation The transfer of heat directly from one surface to another (without heating the intermediate air acting as a transfer mechanism). Superheat The number of degrees a vapor is above its boiling point at a specific pressure
  • 8. Glossary Sub-cooling The condition where liquid refrigerant is colder than the minimum temperature required to keep it from boiling which would change it from a liquid to a gas phase. Sub-cooling is the difference between its saturation temperature and the actual liquid refrigerant temperature terminal unit A small component that contains a heating coil, cooling coil, automatic damper, or some combination of the three. Used to control the temperature of a single room variable air volume An HVAC system that has a stable supply-air temperature, and varies the air flow rate to meet the temperature requirements Compared to constant air volume systems, these systems conserve energy through lower fan speeds during times of lower temperature control demand Most new commercial buildings have VAV systems. VAVs may be bypass type or pressure dependent. Pressure dependent type VAVs save energy while both types help in maintaining temperature of the zone that it feeds 8 –
  • 9. Glossary In thermodynamics, entropy (usual symbol S) is a measure of the number of specific ways in which a thermodynamic system may be arranged, often taken to be a measure of disorder, or a measure of progressing towards thermodynamic equilibrium The entropy of an isolated system never decreases, because isolated systems spontaneously evolve towards thermodynamic equilibrium, the maximum entropy Systems which are not isolated may decrease in entropy Since entropy is a state function, the change in the entropy of a system is the same whether a process going from one defined state to another is reversible or irreversible, but irreversible processes increase the entropy of the environment 9 – The change in entropy (ΔS) was originally defined for a thermodynamically reversible process which is found from the uniform thermodynamic temperature (T) of a closed system dividing an incremental reversible transfer of heat into that system (dQ).
  • 10. Glossary Enthalpy is a defined thermodynamic potential, designated by the letter "H", that consists of the internal energy of the system (U) plus the product of pressure (P) and volume (V) of the system The unit of measurement for enthalpy is the joule, but other historical, conventional units are still in use, such as the British thermal unit and the calorie. The total enthalpy, H, of a system cannot be measured directly The same situation exists in classical mechanics: only a change or difference in energy carries physical meaning Enthalpy itself is a thermodynamic potential, so in order to measure the enthalpy of a system, we must refer to a defined reference point; therefore what we measure is the change in enthalpy, ΔH The change ΔH is positive in endothermic reactions, and negative in heat-releasing exothermic processes. ΔH of a system is equal to the sum of non-mechanical work done on it and the heat supplied to it 10 –
  • 11. Glossary One of the fundamental thermodynamic equations is the description of thermodynamic work in analogy to mechanical work, or weight lifted through an elevation against gravity Power, is the elevation of a weight to a certain height. The product of the weight multiplied by the height to which it is raised.” With the inclusion of a unit of time The state of a thermodynamic system is specified by a number of extensive quantities, the most familiar of which are volume, internal energy, and the amount of each constituent particle (particle numbers). Extensive parameters are properties of the entire system, as contrasted with intensive parameters which can be defined at a single point, such as temperature and pressure The extensive parameters (except entropy) are generally conserved in some way as long as the system is "insulated" to changes to that parameter from the outside 11 –
  • 12. Glossary In the case of energy, the statement of the conservation of energy is known as the first law of thermodynamics, where is the infinitesimal increase in internal energy of the system. Is the infinitesimal heat flow into the system and is the infinitesimal work done by the system In physical chemistry, positive work is conventionally considered work done on the system rather than by the system, and the law is expressed as The concept which governs the path that a thermodynamic system traces in state space as it goes from one equilibrium state to another is that of entropy. The entropy is first viewed as an extensive function of all of the extensive thermodynamic parameters If we have a thermodynamic system in equilibrium, and we release some of the extensive constraints on the system, there are many equilibrium states that it could move to consistent with the conservation of energy, volume, etc. 12 – .
  • 13. Glossary The second law of thermodynamics specifies that the equilibrium state that it moves to is in fact the one with the greatest entropy. Once we know the entropy as a function of the extensive variables of the system, we will be able to predict the final equilibrium state. The entropy of an isolated system never decreases for an isolated system A process within a given isolated system is said to be reversible if throughout the process the entropy never increases (i.e. the entropy remains unchanged). The third law of thermodynamics states that at the absolute zero of temperature, the entropy is zero for a perfect crystalline structure when The zeroth law says that systems that are in thermodynamic equilibrium with each other have the same temperature. The law was actually the last of the laws to be formulated consider a system composed of a number of k different types of particles and has the volume as its only external variable. The fundamental thermodynamic relation may then be expressed in terms of the internal energy as 13 – The thermodynamic space has k+2 dimensions The differential quantities (U, S, V, Ni) are all extensive quantities
  • 14. Glossary Power in mechanical systems is the combination of forces and movement. In particular, power is the product of a force on an object and the object's velocity, or the product of a torque on a shaft and the shaft's angular velocity measured in radians per second In fluid power systems such as hydraulic actuators, power is given by where p is pressure in pascals, or N/m2 and Q is volumetric flow rate in m3/s in SI units The instantaneous electrical power P delivered to a component is given by P(t) is the instantaneous power, measured in watts (joules per second) V(t) is the potential difference (or voltage drop) across the component, measured in volts I(t) is the current through it, measured in amperes If the component is a resistor with time-invariant voltage to current ratio, then 14 – is the resistance, measured in ohms
  • 15. Glossary Electric power, like mechanical power, is the rate of doing work, measured in watts, and represented by the letter P. The term wattage is used colloquially to mean "electric power in watts." The electric power in watts produced by an electric current I consisting of a charge of Q coulombs every t seconds passing through an electric potential (voltage) difference of V is Q is electric charge in coulombs t is time in seconds I is electric current in amperes V is electric potential or voltage in volts In the case of resistive (Ohmic, or linear) loads, Joule's law can be combined with Ohm's law (V = I·R) to produce alternative expressions for the dissipated power 15 – where R is the electrical resistance.
  • 16. Glossary In alternating current circuits, energy storage elements such as inductance and capacitance may result in periodic reversals of the direction of energy flow The portion of power flow that, averaged over a complete cycle of the AC waveform, results in net transfer of energy in one direction is known as real power (also referred to as active power) That portion of power flow due to stored energy, that returns to the source in each cycle, is known as reactive power The real power P in watts consumed by a device is given by Vp is the peak voltage in volts Ip is the peak current in amperes Vrms is the root-mean-square voltage in volts Irms is the root-mean-square current in amperes θ is the phase angle between the current and voltage sine waves The ratio of real power to apparent power is a number between 0 and 1 16 –
  • 17. Glossary Classical mechanics is concerned with the set of physical laws describing the motion of bodies under the action of a system of forces The study of the motion of bodies is an ancient one, making classical mechanics one of the oldest and largest subjects in science, engineering and technology It is also widely known as Newtonian mechanics Isaac Newton proposed three laws of motion: the law of inertia, his second law of acceleration (mentioned above), and the law of action and reaction; and hence laid the foundations for classical mechanics Newton also enunciated the principles of conservation of momentum and angular momentum. In mechanics, Newton was also the first to provide the first correct scientific and mathematical formulation of gravity in Newton's law of universal gravitation. He demonstrated that these laws apply to everyday objects as well as to celestial objects. In particular, Newton obtained a theoretical explanation of Kepler's laws of motion of the planets. 17 –
  • 18. Glossary 18 – . The velocity, or the rate of change of position with time, is defined as the derivative of the position with respect to time: The acceleration, or rate of change of velocity, is the derivative of the velocity with respect to time (the second derivative of the position with respect to time): Some physicists interpret Newton's second law of motion as a definition of force and mass The quantity mv is called the (canonical) momentum. The net force on a particle is thus equal to the rate of change of the momentum of the particle with time If a constant force F is applied to a particle that achieves a displacement Δr, the work done by the force is defined as the scalar product of the force and displacement vectors
  • 19. Glossary The kinetic energy Ek of a particle of mass m travelling at speed v is given by 19 – In special relativity, the momentum of a particle is given by where m is the particle's rest mass, v its velocity, and c is the speed of light. If v is very small compared to c, v2/c2 is approximately zero, and so Thus the Newtonian equation p = mv is an approximation of the relativistic equation for bodies moving with low speeds compared to •Statics, the study of equilibrium and its relation to forces the speed of light •Dynamics, the study of motion and its relation to forces •Kinematics, dealing with the implications of observed motions without regard for circumstances causing them
  • 20. Glossary Derived kinematic quantities Derived dynamic quantities Velocity Acceleration Jerk Angular velocity Angular Acceleration Momentum Force Impulse Angular momentum about a position point r0, Most of the time we can set r0 = 0 if particles are orbiting about axes intersecting at a common point 20 – Torque Angular impulse Mechanical work
  • 21. Glossary Momentum is the "amount of translation" For a rotating rigid body: Angular momentum is the "amount of rotation": Torque τ is also called moment of a force, because it is the rotational analogue to force Resultant force acts on a system at the center of mass, equal to the rate of change of momentum Impulse is the change in momentum Angular impulse is the change in angular momentum 21 – Title of the document or activity name – Month XX, 2012 – Insert tab > Header/Footer For constant force F: For constant torque τ: The work done W by an external agent which exerts a force F (at r) and torque τ on an object along a curved path C is Kinetic energy
  • 22. Glossary A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps 22 – "Chain hoist" also describes a hoist using a differential pulley A compound pulley with two different radii and teeth engage an endless chain, Allowing the exerted force to be multiplied according to the ratio of the radii.
  • 23. Glossary Consider the set of pulleys that form the moving block and the parts of the rope that support this block If there are p of these parts of the rope supporting the load W, then a force balance on the moving block shows that the tension in each of the parts of the rope must be W/p This means the input force on the rope is T=W/p. Thus, the block and tackle reduces the input force by the factor p The mechanical advantage of a pulley system can be analyzed using free body diagrams which balance the tension force in the rope with the force of gravity on the load In this case, a force balance on a free body that includes the load, W, and n supporting sections of a rope with tension T, yields 23 – the mechanical advantage of the system is equal to the number of sections of rope supporting the load
  • 24. Glossary Differential pulley is used to manually lift very heavy objects like car engines. It is operated by pulling upon the slack section of a continuous chain that wraps around pulleys. The relative size of two connected pulleys determines the maximum weight that can be lifted by hand. It consists of two fixed pulleys of unequal radii that are attached to each other and rotate together, a single pulley bearing the load, and an endless rope looped around the pulleys. To avoid slippage, the rope is usually replaced by a chain, and the connected pulleys by sprockets. 24 –
  • 25. Glossary The two sections of chain carrying the single pulley exert opposing and unequal torques on the connected pulleys, such that only the difference of these torques has to be compensated manually by pulling the loose part of the chain. This leads to a mechanical advantage: the force needed to lift a load is only a fraction of the load's weight. At the same time, the distance the load is lifted is smaller than the length of chain pulled by the same factor. This factor (the mechanical advantage MA) depends on the relative difference of the radii r and R of the connected. The effect on the forces and distances is quantitatively The difference in radii can be made very small, making the mechanical advantage of this pulley system very large. In the extreme case of zero difference in radii, MA becomes infinite, thus no force (besides friction) is needed to move the chain, but moving the chain will no longer lift the load, when r is zero, the system becomes with a MA = 2 25 –
  • 26. Glossary A belt and pulley system is characterized by two or more pulleys in common to a belt. This allows for mechanical power, torque, and speed to be transmitted across axles. If the pulleys are of differing diameters, a mechanical advantage is realized A belt drive is analogous to that of a chain drive, however a belt sheave may be smooth (devoid of discrete interlocking members as would be found on a chain sprocket, spur gear, or timing belt) so that the mechanical advantage is approximately given by the ratio of the pitch diameter of the sheaves only, not fixed exactly by the ratio of teeth as with gears and sprockets. 26 –
  • 27. Glossary 27 – The gear ratio of a gear train, also known as its speed ratio, is the ratio of the angular velocity of the input gear to the angular velocity of the output gear The gear ratio can be calculated directly from the numbers of teeth on the gears in the gear train The torque ratio of the gear train, also known as its mechanical advantage, is determined by the gear ratio The speed ratio and mechanical advantage are defined so they yield the same number in an ideal linkage
  • 28. Glossary A gear train is formed by mounting gears on a frame so that the teeth of the gears engage Gear teeth are designed to ensure the pitch circles of engaging gears roll on each other without slipping, providing a smooth transmission of rotation from one gear to the next 28 – Gear teeth are designed so that the number of teeth on a gear is proportional to the radius of its pitch circle, and so that the pitch circles of meshing gears roll on each other without slipping. The speed ratio for a pair of meshing gears can be computed from ratio of the radii of the pitch circles and the ratio of the number of teeth on each gear The velocity v of the point of contact on the pitch circles is the same on both gears, and is given by
  • 29. Glossary where input gear A has radius rA and meshes with output gear B of radius rB where NA is the number of teeth on the input gear and NB on the output gear The mechanical advantage of a pair of meshing gears for which the input gear has NA teeth and the output gear has NB teeth is given by MA This shows that if the output gear GB has more teeth than the input gear GA, then the gear train amplifies the input torque And, if the output gear has fewer teeth than the input gear, then the gear train reduces the input torque If the output gear of a gear train rotates more slowly than the input gear, then the gear train is called a speed reducer In this case, because the output gear must have more teeth than the input gear, the speed reducer amplifies the input torque. 29 –
  • 30. Glossary Speed ratio. Gear teeth are distributed along the circumference of the pitch circle so that the thickness t of each tooth and the space between neighboring teeth are the same The pitch p of a gear, which is the distance between equivalent points on neighboring teeth along the pitch circle, is equal to twice the thickness of a tooth, The pitch of a gear GA can be computed from the number of teeth NA and the radius rA of its pitch circle In order to mesh smoothly two gears GA and GB must have the same sized teeth and therefore they must have the same pitch p, which means This equation shows that the ratio of the circumference, the diameters and the radii of two meshing gears is equal to the ratio of their number of teeth, The speed ratio of two gears rolling without slipping on their pitch circles is given by, 30 –
  • 31. Glosary Calculating power Watt determined that a horse could turn a mill wheel 144 times in an hour (or 2.4 times a minute). The wheel was 12 feet in radius; therefore, the horse travelled 2.4 × 2π × 12 feet in one minute. Watt judged that the horse could pull with a force of 180 pounds. So: This was rounded to an even 33,000 ft·lbf/min. If torque and angular speed are known, the power may be calculated. The relationship when using a coherent system of units (such as SI) is simply The constant 5252 is the rounded value of (33,000 ft·lbf/min)/(2π rad/rev). When torque is in inch pounds: The constant 63,025 is the rounded value of (33,000 ft·lbf/min) × (12 in/ft)/(2π rad/rev). 31 –
  • 32. Glosary The following definitions have been widely used: Mechanical horsepower hp(I) ≡ 33,000 ft-lbf/min 32 – = 550 ft·lbf/s ≈ 17,696 lbm·ft2/s3 = 745.69987158227022 W Metric horsepower hp(M) - also PS, ''cv, hk, pk, ks or ch ≡ 75 kgf·m/s ≡ 735.49875 W Electrical horsepower hp(E) ≡ 746 W Boiler horsepower hp(S) ≡ 33,475 BTU/h = 9,812.5 W Hydraulic horsepower = flow rate (US gal/min) × pressure (psi) × 7/12,000 = 550 ft·lbf/s = flow rate (US gal/min) × pressure (psi) / 1714 = 745.699 W
  • 33. Glosary Torque converter is generally a type of fluid coupling (but also being able to 33 – multiply torque) that is used to transfer rotating power from a prime mover, such as an internal combustion engine or electric motor, to a rotating driven load The torque converter normally takes the place of a mechanical clutch in a vehicle with an automatic transmission, allowing the load to be separated from the power source It is usually located between the engine's flexplate and the transmission. The key characteristic of a torque converter is its ability to multiply torque when there is a substantial difference between input and output rotational speed, thus providing the equivalent of a reduction gear
  • 34. Glosary As with a basic fluid coupling the theoretical torque capacity of a converter is proportional to 34 – where is the mass density of the fluid (kg/m³), and is the impeller speed (rpm), is the diameter(m) A torque converter cannot achieve 100 percent coupling efficiency. The classic three element torque converter has an efficiency curve that resembles ∩: zero efficiency at stall, generally increasing efficiency during the acceleration phase and low efficiency in the coupling phase Typical stall torque multiplication ratios range from 1.8:1 to 2.5:1 for most automotive applications Specialized converters designed for industrial, rail, or heavy marine power transmission systems are capable of as much as 5.0:1 multiplication
  • 35. Glosary 35 – Power Motor Velocity (rpm) 3450 2000 1000 500 Torque hp kW (in lbf) (ft lbf) (Nm) (in lbf) (ft lbf) (Nm) (in lbf) (ft lbf) (Nm) (in lbf) (ft lbf) (Nm) 1 0.75 18 1.5 2.1 32 2.6 3.6 63 5.3 7.1 126 10.5 14.2 1.5 1.1 27 2.3 3.1 47 3.9 5.3 95 7.9 10.7 189 15.8 21.4 2 1.5 37 3.0 4.1 63 5.3 7.1 126 10.5 14.2 252 21.0 28.5 3 2.2 55 4.6 6.2 95 7.9 10.7 189 15.8 21.4 378 31.5 42.7 5 3.7 91 7.6 10 158 13.1 18 315 26.3 36 630 52.5 71 7.5 5.6 137 11 15 236 20 27 473 39 53 945 79 107 10 7.5 183 15 21 315 26 36 630 53 71 1260 105 142 15 11 274 23 31 473 39 53 945 79 107 1891 158 214 20 15 365 30 41 630 53 71 1260 105 142 2521 210 285 25 19 457 38 52 788 66 89 1576 131 178 3151 263 356 30 22 548 46 62 945 79 107 1891 158 214 3781 315 427 40 30 731 61 83 1260 105 142 2521 210 285 5042 420 570 50 37 913 76 103 1576 131 178 3151 263 356 6302 525 712 60 45 1096 91 124 1891 158 214 3781 315 427 7563 630 855 70 52 1279 107 145 2206 184 249 4412 368 499 8823 735 997 80 60 1461 122 165 2521 210 285 5042 420 570 10084 840 1140 90 67 1644 137 186 2836 236 321 5672 473 641 11344 945 1282 100 75 1827 152 207 3151 263 356 6302 525 712 12605 1050 1425 125 93 2283 190 258 3939 328 445 7878 657 891 15756 1313 1781 Example - Electrical Motor Torque Torque from an electrical motor with 100 hp and speed 1000 rpm can be calculated as T = (100 hp) 63025 / (1000 rpm) = 6303 (in lbf) To convert to foot pound-force - divide the torque by 12.
  • 36. Glosary Electrical Motor Torque Equation Torque can be calculated in Imperial units as T = Php 63025 / n (1) where T = torque (in lbf) Php = horsepower delivered by the electric motor n = revolution per minute (rpm) Alternatively Tft = Php 5252 / n (1b) where Tft = torque (ft lbf) •1 ft lbf = 1.356 Nm Torque can be calculated in SI units as T = PW 9.554 / n (1) where T = torque (Nm) PW = power (watts) n = revolution per minute (rpm) 36 –
  • 37. Glosary Calculating Motor Speed: A squirrel cage induction motor is a constant speed device. It cannot operate for any length of time at speeds below those shown on the nameplate without danger of burning out. To Calculate the speed of a induction motor, apply this formula: Srpm = 120 x F 37 – P Srpm = synchronous revolutions per minute. 120 = constant F = supply frequency (in cycles/sec) P = number of motor winding poles Example: What is the synchronous of a motor having 4 poles connected to a 60 hz power supply? Srpm = 120 x F P Srpm = 120 x 60 4 Srpm = 7200 4 Srpm = 1800 rpm
  • 38. Glosary Calculating Braking Torque: Full-load motor torque is calculated to determine the required braking torque of a motor. To Determine braking torque of a motor, apply this formula: T = 5252 x HP rpm T = full-load motor torque (in lb-ft) 5252 = constant (33,000 divided by 3.14 x 2 = 5252) HP = motor horsepower rpm = speed of motor shaft Example: What is the braking torque of a 60 HP, 240V motor rotating at 1725 rpm? T = 5252 x HP rpm T = 5252 x 60 1725 T = 315,120 1725 T = 182.7 lb-ft 38 –
  • 39. Glosary Calculating Work: Work is applying a force over a distance. Force is any cause that changes the position, motion, direction, or shape of an object. Work is done when a force overcomes a resistance. Resistance is any force that tends to hinder the movement of an object.If an applied force does not cause motion the no work is produced. To calculate the amount of work produced, apply this formula: W = F x D W = work (in lb-ft) F = force (in lb) D = distance (in ft) Example: How much work is required to carry a 25 lb bag of groceries vertically from street level to the 4th floor of a building 30' above street level? W = F x D W = 25 x 30 W = 750 -lb 39 –
  • 40. Glosary Calculating Torque: Torque is the force that produces rotation. It causes an object to rotate. Torque consist of a force acting on distance. Torque, like work, is measured is pound-feet (lb-ft). However, torque, unlike work, may exist even though no movement occurs. To calculate torque, apply this formula: T = F x D T = torque (in lb-ft) F = force (in lb) D = distance (in ft) Example: What is the torque produced by a 60 lb force pushing on a 3' lever arm? T = F x D T = 60 x 3 T = 180 lb ft 40 –
  • 41. Glosary Calculating Full-load Torque: Full-load torque is the torque to produce the rated power at full speed of the motor. The amount of torque a motor produces at rated power and full speed can be found by using a horsepower-to-torque 41 – conversion chart. When using the conversion chart, place a straight edge along the two known quantities and read the unknown quantity on the third line. To calculate motor full-load torque, apply this formula: T = HP x 5252 rpm T = torque (in lb-ft) HP = horsepower 5252 = constant rpm = revolutions per minute Example: What is the FLT (Full-load torque) of a 30HP motor operating at 1725 rpm? T = HP x 5252 rpm T = 30 x 5252 1725 T = 157,560 1725 T = 91.34 lb-ft
  • 42. Glosary Calculating Horsepower: Electrical power is rated in horsepower or watts. A horsepower is a unit of power equal to 746 watts or 33,0000 lb-ft per minute (550 lb-ft per second). A watt is a unit of measure equal to the power produced by a current of 1 amp across the potential difference of 1 volt. It is 1/746 of 1 horsepower. The watt is the base unit of electrical power. Motor power is rated in horsepower and watts. Horsepower is used to measure the energy produced by an electric motor while doing work. To calculate the horsepower of a motor when current and efficiency, and voltage are known, apply this formula: HP = V x I x Eff 42 – 746 HP = horsepower V = voltage I = curent (amps) Eff. = efficiency Example: What is the horsepower of a 230v motor pulling 4 amps and having 82% efficiency? HP = V x I x Eff 746 HP = 230 x 4 x .82 746 HP = 754.4 746 HP = 1 Hp Eff = efficiency / HP = horsepower / V = volts / A = amps / PF = power factor
  • 43. Glosary 43 – Horsepower Formulas To Find Use Formula Example Given Find Solution HP HP = I X E X Eff. 746 240V, 20A, 85% Eff. HP HP = 240V x 20A x 85% 746 HP=5.5 I I = HP x 746 E X Eff x PF 10HP, 240V, 90% Eff., 88% PF I I = 10HP x 746 240V x 90% x 88% I = 39 A To calculate the horsepower of a motor when the speed and torque are known, apply this formula: HP = rpm x T(torque) 5252(constant) Example: What is the horsepower of a 1725 rpm motor with a FLT 3.1 lb-ft? HP = rpm x T 5252 HP = 1725 x 3.1 5252 HP = 5347.5 5252 HP = 1 hp
  • 44. Glosary Calculating Synchronous Speed: AC motors are considered constant speed motors. This is because the synchronous speed of an induction motor is based on the supply frequency and the number of poles in the motor winding. Motor are designed for 60 hz use have synchronous speeds of 3600, 1800, 1200, 900, 720, 600, 514, and 450 rpm. To calculate synchronous speed of an induction motor, apply this formula: rpmsyn = 120 x f 44 – Np rpmsyn = synchronous speed (in rpm) f = supply frequency in (cycles/sec) Np = number of motor poles Example: What is the synchronous speed of a four pole motor operating at 50 hz.? rpmsyn = 120 x f Np rpmsyn = 120 x 50 4 rpmsyn = 6000 4 rpmsyn = 1500 rpm
  • 45. Glosary Torque in 45 – lb.ft. = HP x 5250 rpm HP = Torque x rpm 5250 rpm = 120 x Frequency No. of Poles Rules Of Thumb (Approximation) At 1800 rpm, a motor develops a 3 lb.ft. per hp At 1200 rpm, a motor develops a 4.5 lb.ft. per hp At 575 volts, a 3-phase motor draws 1 amp per hp At 460 volts, a 3-phase motor draws 1.25 amp per hp At 230 volts a 3-phase motor draws 2.5 amp per hp At 230 volts, a single-phase motor draws 5 amp per hp At 115 volts, a single-phase motor draws 10 amp per hp Mechanical Formulas
  • 46. Glosary Synchronous Speed, Frequency And Number Of Poles Of AC Motors Relation Between Horsepower, Torque, And Speed 46 – t = High Inertia Loads WK2 x rpm 308 x T av. WK2 = inertia in lb.ft.2 t = accelerating time in sec. T = Av. accelerating torque lb.ft.. Temperature Conversion Deg C = (Deg F - 32) x 5/9 Deg F = (Deg C x 9/5) + 32 inertia reflected to motor = Load Inertia (Load rpm) Motor rpm 2 ns = 120 x f P f = P x ns 120 P = 120 x f ns HP = T x n 5250 T = 5250 HP n n = 5250 HP T % Slip = ns - n ns x 100 Motor Slip
  • 47. Glosary Code KVA/HP Code KVA/HP Code KVA/HP Code KVA/HP A 0-3.14 F 5.0 -5.59 L 9.0-9.99 S 16.0-17.99 B 3.15-3.54 G 5.6 -6.29 M 10.0-11.19 T 18.0-19.99 C 3.55-3.99 H 6.3 -7.09 N 11.2-12.49 U 20.0-22.39 D 4.0 -4.49 I 7.1 -7.99 P 12.5-13.99 V 22.4 & Up E 4.5 -4.99 K 8.0 -8.99 R 14.0-15.99 Symbols I = current in amperes E = voltage in volts KW = power in kilowatts KVA = apparent power in kilo-volt-amperes HP = output power in horsepower N = motor speed in revolutions per minute (RPM) Ns = synchronous speed in revolutions per minute (RPM) P = number of poles F = frequency in cycles per second (CPS) T = torque in pound-feet EFF = efficiency as a decimal PF = power factor as a decimal 47 –
  • 48. Glosary Equivalent Inertia In mechanical systems, all rotating parts do not usually operate at the same speed. Thus, we need to determine the "equivalent inertia" of each moving part at a particular speed of the prime mover The total equivalent WK2 for a system is the sum of the WK2 of each part, referenced to prime mover speed The equation says: WK2 48 – EQ = WK2 part (Npart) 2 Nprime mover This equation becomes a common denominator on which other calculations can be based. For variable-speed devices, inertia should be calculated first at low speed Let's look at a simple system which has a prime mover (PM), a reducer and a load WK2 = 100 lb.ft.2 WK2 = 900 lb.ft.2 (as seen at output shaft) WK2 = 27,000 lb.ft.2 PRIME MOVER 3:1 GEAR REDUCER LOAD The formula states that the system WK2 equivalent is equal to the sum of WK2 parts at the prime mover's RPM
  • 49. Glosary or in this case: 49 – WK2 EQ = WK2 pm + WK2 Red. (Red. RPM) PM RPM 2 + WK2 Load (Load RPM) PM RPM 2 Note: reducer RPM = Load RPM EQ = WK2 pm + WK2 Red. (1) WK2 Load (1) 3 2 + WK2 3 2 The WK2 equivalent is equal to the WK2 of the prime mover, plus the WK2 of the load. This is equal to the WK2 of the prime mover, plus the WK2 of the reducer times (1/3)2, plus the WK2 of the load times (1/3)2 This relationship of the reducer to the driven load is expressed by the formula given earlier: WK2 EQ = WK2 part (Npart) Nprime mover 2 In other words, when a part is rotating at a speed (N) different from the prime mover, the WK2 EQ is equal to the WK2 of the part's speed ratio squared
  • 50. Glosary In the example, the result can be obtained as follows: The WK2 equivalent is equal to: WK2 Finally: 50 – EQ = 100 lb.ft.2 + 900 lb.ft.2 (1) 3 2 + 27,000 lb.ft.2 (1 )32 WK2 EQ = lb.ft.2 pm + 100 lb.ft.2 Red + 3,000 lb.ft2 Load WK2 EQ = 3200 lb.ft.2 The total WK2 equivalent is that WK2 seen by the prime mover at its speed.
  • 51. Glosary 51 – To Find Alternating Current Single-Phase Three-Phase Amperes when horsepower is known HP x 746 E x Eff x pf HP x 746 1.73 x E x Eff x pf Amperes when kilowatts are known Kw x 1000 E x pf Kw x 1000 1.73 x E x pf Amperes when kva are known Kva x 1000 E Kva x 1000 1.73 x E Kilowatts I x E x pf 1000 1.73 x I x E x pf 1000 Kva I x E 1000 1.73 x I x E 1000 Horsepower = (Output) I x E x Eff x pf 746 1.73 x I x E x Eff x pff 746 Electrical Formulas I = Amperes; E = Volts; Eff = Efficiency; pf = Power Factor; Kva = Kilovolt-amperes; Kw = Kilowatts
  • 52. Glosary Locked Rotor Current (IL) From Nameplate Data Three Phase: IL = 577 x HP x KVA/HP Effect Of Line Voltage On Locked Rotor Current (IL) (Approx.) 52 – E See: KVA/HP Chart Single Phase: IL = 1000 x HP x KVA/HP E EXAMPLE: Motor nameplate indicates 10 HP, 3 Phase, 460 Volts, Code F IL = 577 x 10 x (5.6 or 6.29) 460 IL = 70.25 or 78.9 Amperes (possible range) IL @ ELINE = IL @ EN/P x ELINE EN/P EXAMPLE: Motor has a locked rotor current (inrush of 100 Amperes (IL) at the rated nameplate voltage (EN/P) of 230 volts. What is IL with 245 volts (ELINE) applied to this motor? IL @ 245 V. = 100 x 254V/230V IL @ 245V. = 107 Amperes
  • 53. Glosary Basic Horsepower Calculations Horsepower is work done per unit of time. One HP equals 33,000 ft-lb of work per minute. When work is done by a source of torque (T) to produce (M) rotations about an axis, the work done is: radius x 2 x rpm x lb. or 2 TM When rotation is at the rate N rpm, the HP delivered is: HP = radius x 2 x rpm x lb. Where: 53 – 33,000 = TN 5,250 For vertical or hoisting motion HP = W x S 33,000 x E W = total weight in lbs. to be raised by motor S = hoisting speed in feet per minute E = overall mechanical efficiency of hoist and gearing. For purposes of estimating E = .65 for eff. of hoist and connected gear.
  • 54. Glosary For fans and blowers: HP = Volume (cfm) x Head (inches of water) For purpose of estimating, the eff. of a fan or blower may be assumed to be 0.65. 54 – 6356 x Mechanical Efficiency of Fan Note: Air Capacity (cfm) varies directly with fan speed. Developed Pressure varies with square of fan speed. Hp varies with cube of fan speed. HP = Volume (cfm) x Pressure (lb. Per sq. ft.) 3300 x Mechanical Efficiency of Fan HP = Volume (cfm) x Pressure (lb. Per sq. in.) 229 x Mechanical Efficiency of Fan For pumps: HP = GPM x Pressure in lb. Per sq. in. x Specific Grav. 1713 x Mechanical Efficiency of Pump HP = GPM x Total Dynamic Head in Feet x S.G. 3960 x Mechanical Efficiency of Pump where Total Dynamic Head = Static Head + Friction Head For estimating, pump efficiency may be assumed at 0.70
  • 55. Glosary Accelerating Torque The equivalent inertia of an adjustable speed drive indicates the energy required to keep the system running. However, starting or accelerating the system requires extra energy. The torque required to accelerate a body is equal to the WK2 of the body, times the change in RPM, divided by 308 times the interval (in seconds) in which this acceleration takes place: ACCELERATING TORQUE 55 – = WK2N (in lb.ft.) 308t N = Change in RPM W = Weight in Lbs. K = Radius of gyration t = Time of acceleration (secs.) WK2 = Equivalent Inertia 308 = Constant of proportionality Where: TAcc = WK2N 308t The constant (308) is derived by transferring linear motion to angular motion, and considering acceleration due to gravity. If, for example, we have simply a prime mover and a load with no speed adjustment
  • 56. Glosary Example 1 PRIME LOADER LOAD 56 – WK2 = 200 lb.ft.2 WK2 = 800 lb.ft.2 The WK2 EQ is determined as before: WK2 EQ = WK2 pm + WK2 Load WK2 EQ = 200 + 800 WK2 EQ = 1000 ft.lb.2 If we want to accelerate this load to 1800 RPM in 1 minute, enough information is available to find the amount of torque necessary to accelerate the load. The formula states: TAcc = WK2 EQN 308t or 1000 x 1800 308 x 60 or 1800000 18480 TAcc = 97.4 lb.ft In other words, 97.4 lb.ft. of torque must be applied to get this load turning at 1800 RPM, in 60 seconds. Note that TAcc is an average value of accelerating torque during the speed change under consideration. If a more accurate calculation is desired, the following example may be helpful. Example 2 The time that it takes to accelerate an induction motor from one speed to another may be found from the following equation: t = WR2 x change in rpm 308 x T T = Average value of accelerating torque during the speed change under consideration. t = Time the motor takes to accelerate from the initial speed to the final speed. WR2 = Flywheel effect, or moment of inertia, for the driven machinery plus the motor rotor in lb.ft.2 (WR2 of driven machinery must be referred to the motor shaft).
  • 57. Glosary The Application of the above formula will now be considered by means of an example Figure A shows the speed-torque curves of a squirrel-cage induction motor and a blower which it drives. At any speed of the blower, the difference between the torque which the motor can deliver at its shaft and the torque required by the blower is the torque available for acceleration Reference to Figure A shows that the accelerating torque may vary greatly with speed. When the speed-torque curves for the motor and blower intersect there is no torque available for acceleration. The motor then drives the blower at constant speed and just delivers the torque required by the load In order to find the total time required to accelerate the motor and blower, the area between the motor speed-torque curve and the blower speed-torque curve is divided into strips, the ends of which approximate straight lines. Each strip corresponds to a speed increment which takes place within a definite time interval The solid horizontal lines in Figure A represent the boundaries of strips; the lengths of the broken lines the average accelerating torques for the selected speed intervals. In order to calculate the total acceleration time for the motor and the direct-coupled blower it is necessary to find the time required to accelerate the motor from the beginning of one speed interval to the beginning of the next interval and add up the incremental times for all intervals to arrive at the total acceleration time If the WR2 of the motor whose speed-torque curve is given in Figure A is 3.26 ft.lb.2 and the WR2 of the blower referred to the motor shaft is 15 ft.lb.2, the total WR2 is 15 + 3.26 = 18.26 ft.lb.2 57 –
  • 58. Glosary And the total time of acceleration is: WR2 308 X [ 58 – rpm1 T1 + rpm2 T2 + rpm3 T3 + - - - - - - - - - + rpm9 T9 ] t = 18.2 6 308 X [ 150 46 + 150 48 + 300 47 + 300 43.8 + 200 39.8 + 200 36.4 + 300 32.8 + 100 29.6 + 40 11 ] t = 2.75 sec. Accelerating Torques T1 = 46 lb.ft. T4 = 43.8 lb.ft. T7 = 32.8 lb.ft. T2 = 48 lb.ft. T5 = 39.8 lb.ft. T8 = 29.6 lb.ft. T3 = 47 lb.ft. T6 = 36.4 lb.ft. T9 = 11 lb.ft. Curves used to determine time required to accelerate induction motor and blower
  • 59. Glosary In order for a duty cycle to be checked out, the duty cycle information must include the following: Inertia reflected to the motor shaft. Torque load on the motor during all portions of the duty cycle including starts, running time, stops or reversals. Accurate timing of each portion of the cycle. Information on how each step of the cycle is accomplished. For example, a stop can be by coasting, mechanical braking, DC dynamic braking or plugging. A reversal can be accomplished by plugging, or the motor may be stopped by some means then re-started in the opposite direction. When the motor is multi-speed, the cycle for each speed must be completely defined, including the method of changing from one speed to another. Any special mechanical problems, features or limitations 59 –
  • 60. Glosary Duty cycle refers to the detailed description of a work cycle that repeats in a specific time period This cycle may include frequent starts, plugging stops, reversals or stalls These characteristics are usually involved in batch-type processes and may include tumbling barrels, certain cranes, shovels and draglines, dampers, gate- or plow-positioning drives, drawbridges, freight and personnel elevators, press-type extractors, some feeders,presses of certain types, hoists, indexers, boring machines,cinder block machines, keyseating, kneading, car-pulling, shakers (foundry or car), swaging and washing machines, and certain freight and passenger vehicles The list is not all-inclusive. The drives for these loads must be capable of absorbing the heat generated during the duty cycles Adequate thermal capacity would be required in slip couplings, clutches or motors to accelerate or plug-stop these drives or to withstand stalls It is the product of the slip speed and the torque absorbed by the load per unit of time which generates heat in these drive components All the events which occur during the duty cycle generate heat which the drive components must dissipate. 60 –
  • 66. Conversion Units 66 – 1 mile per hour (mph) ≅ 1.46666667 feet per second (fps) 1 mile per hour (mph) = 1.609344 kilometers per hour 1 knot ≅ 1.150779448 miles per hour 1 foot per second ≅ 0.68181818 miles per hour (mph) 1 kilometer per hour ≅ 0.62137119 miles per hour (mph) 1 square foot = 144 square inches 1 square foot = 929.0304 square centimeters 1 square yard = 9 square feet 1 square meter ≅ 10.7639104 square feet 1 centimeter (cm) = 10 millimeters (mm) 1 inch = 2.54 centimeters (cm) 1 foot = 0.3048 meters (m) 1 foot = 12 inches 1 yard = 3 feet 1 meter (m) = 100 centimeters (cm) 1 meter (m) ≅ 3.280839895 feet 1 furlong = 660 feet 1 kilometer (km) = 1000 meters (m) 1 kilometer (km) ≅ 0.62137119 miles 1 mile = 5280 ft 1 mile = 1.609344 kilometers (km) 1 nautical mile = 1.852 kilometers (km) 1 pound (lb) = 0.45359237 kilograms (kg)
  • 67. Conversion Units 67 – Some Formulas Area of Square Side Squared Area of Circle 3.1415927 x Radius Square Area of Sphere 4 x 3.1415927 x Radius Squared Area of Parallelogram Base x Height Circumference of Circle 2 x 3.1415927 x Radius Volume of Rectangular Box Length x Width x Height Volume of Cone 1/3 x 3.1415927 x Radius Squared x Height Volume of Cylinder 3.1415927 x Radius Squared x Height Volume of Sphere 4 x 3.1415927 x Radius Cubed ÷ 3 Volume of Cube Side Cubed a = area c = circumference v = volume sq = square cu = cubic r = radius d = diameter l = length w = width h = height s = side Pi = 3.1415927 (approx)
  • 68. Conversion Units 68 – Given Multiply by To Find Length [L] Foot (ft) 0.304800 Meter (m) Inch (in) 25.4000 Millimeter (mm) Mile (mi) 1.609344 Kilometer (km) Area [L]2 ft2 0.092903 m2 in2 645.16 mm2 in2 6.45160 cm2 Volume [L]3 & Capacity in3 16.3871 cm3 ft3 0.028317 m3 ft3 7.4805 Gallon ft3 28.3168 Liter (l) Gallon 3.785412 Liter
  • 69. Conversion Units 69 – Energy, Work or Heat [M] [L]2 [t]-2 Btu 1.05435 kJ Btu 0.251996 kcal Calories (cal) 4.184* Joules (J) ft-lbf 1.355818 J ft-lbf 0.138255 kgf-m hp-hr 2.6845 MJ KWH 3.600 MJ m-kgf 9.80665* J N-m 1. J Flow Rate [L]3 [t]-1 ft3/min 7.4805 gal/min ft3/min 0.471934 l/s gal/min 0.063090 l/s
  • 70. Conversion Units 70 – Force or Weight [M] [L] [t]-2 kgf 9.80665* Newton (N) lbf 4.44822 N lbf 0.453592 Kgf Fracture Toughness ksi sqr(in) 1.098800 MPa sqr(m) Heat Content Btu/lbm 0.555556 cal/g Btu/lbm 2.324444 J/g Btu/ft3 0.037234 MJ/m3 Heat Flux Btu/hr-ft2 7.5346 E-5 cal/s-cm2 Btu/hr-ft2 3.1525 W/m2 cal/s-cm2 4.184* W/cm2
  • 71. Conversion Units 71 – Mass Density [M] [L]-3 lbm/in3 27.68 g/cm3 lbm/ft3 16.0184 kg/m3 Power [M] [L]2 [t]-3 Btu/hr 0.292875 Watt (W) ft-lbf/s 1.355818 W Horsepower (hp) 745.6999 W Horsepower 550.* ft-lbf/s Pressure (fluid) [M] [L]-1 [t]-2 Atmosphere (atm) 14.696 lbf/in2 atm 1.01325 E5* Pascal (Pa) lbf/ft2 47.88026 Pa lbf/in2 27.6807 in. H20 at 39.2°F
  • 72. Conversion Units 72 – Stress [M] [L]-1 [t]-2 kgf/cm2 9.80665 E-2* MPa ksi 6.89476 MPa N/mm2 1. MPa kgf/mm2 1.42231 ksi Specific Heat Btu/lbm-°F 1. cal/g-°C Temperature* Fahrenheit (°F-32) /1.8 Celsius Fahrenheit °F+459.67 Rankine Celsius °C+273.16 Kelvin Rankine R/1.8 Kelvin
  • 73. Conversion Units 73 – Stress [M] [L]-1 [t]-2 kgf/cm2 9.80665 E-2* MPa ksi 6.89476 MPa N/mm2 1. MPa kgf/mm2 1.42231 ksi Specific Heat Btu/lbm-°F 1. cal/g-°C Temperature* Fahrenheit (°F-32) /1.8 Celsius Fahrenheit °F+459.67 Rankine Celsius °C+273.16 Kelvin Rankine R/1.8 Kelvin Thermal Conductivity Btu-ft/hr-ft2-°F 14.8816 cal-cm/hr-cm2-°C
  • 74. Conversion Units 74 – pound TO g Multiply pound by 453.5924 pound TO joule/cm Multiply pound by 0.04448 pound TO joule/m (newton) Multiply pound by 4.448 pound TO kg Multiply pound by 0.4536 pound/ft TO kg/m Multiply pound/ft by 1.488 pound/in TO gm/cm Multiply pound/in by 178.6 pound/sq ft TO kg/sq m Multiply pound/sq ft by 4.882 pound/sq ft TO pound/sq in Multiply pound/sq ft by 6.94E-03 pound/sq in TO kg/sq m Multiply pound/sq in by 703.1 pound/sq in TO pound/sq ft Multiply pound/sq in by 144 radian/sec TO degree/sec Multiply radian/sec by 57.29578 radian/sec TO revolution/min Multiply radian/sec by 9.549 radian/sec TO revolution/sec Multiply radian/sec by 0.1592
  • 75. Conversion Units 75 – revolution TO degree Multiply revolution by 360 revolution/min TO degree/sec Multiply revolution/min by 6 revolution/min TO radian/sec Multiply revolution/min by 0.1047 revolution/min TO revolution/sec Multiply revolution/min by 0.01667 sq cm TO sq ft Multiply sq cm by 1.08E-03 sq cm TO sq in Multiply sq cm by 0.155 sq cm TO sq m Multiply sq cm by 0.0001 sq cm TO sq mile Multiply sq cm by 3.86E-11 sq cm TO sq mm Multiply sq cm by 100 sq cm TO sq yard Multiply sq cm by 1.20E-04 sq ft TO acre Multiply sq ft by 2.30E-05 sq ft TO sq cm Multiply sq ft by 929
  • 76. Conversion Units 76 – sq ft TO sq in Multiply sq ft by 144 sq ft TO sq m Multiply sq ft by 0.0929 sq ft TO sq mm Multiply sq ft by 9.29E+04 sq in TO sq cm Multiply sq in by 6.452 sq in TO sq ft Multiply sq in by 6.94E-03 sq in TO sq mm Multiply sq in by 645.2 ton (metric) TO kg Multiply ton (metric) by 1000 ton (metric) TO pound Multiply ton (metric) by 2205 watt TO Btu/hr Multiply watt by 3.4129 watt TO Btu/min Multiply watt by 0.05688 watt TO ft-pound/min Multiply watt by 44.27 watt TO ft-pound/sec Multiply watt by 0.7378 watt TO hp Multiply watt by 1.34E-03 watt-hr TO Btu Multiply watt-hr by 3.413 watt-hr TO ft-pound Multiply watt-hr by 2656 watt-hr TO hp-hr Multiply watt-hr by 1.34E-03 watt-hr TO kg-m Multiply watt-hr by 367.2 watt-hr TO kilowatt-hr Multiply watt-hr by 0.001
  • 77. Conversion Units 77 – To Convert From To Convert To Multiply By lbf/in2 (psi) pascal (Pa) 6894.757 pascal (Pa) lbf/in2 (psi) 1.4504E-4 g/cm3 lb/ft3 62.427974 lb/ft3 kg/m3 16.01846 lb/in3 kg/m3 27,679.90 lb/ft3 g/cm3 0.01601846 volts/mil kV/mm 0.039370 mil (0.001 inch) cm 2.54E-3 cm mil 393.70 MPa(m1/2) psi(in1/2) 910.06
  • 78. Conversion Units 78 – J/(g-°C) BTU/(lb-°F) 0.239006 BTU/(lb-°F) J/(g-°C) 4.184000 joule (J) cal (thermochemical) 0.2390057 cal (thermochemical) joule (J) 4.184000 joule (J) BTU (thermochemical) 9.4845E-4 BTU (thermochemical) joule 1054.350 μm/(m-°C) μin/(in-°F) 0.55556 μin/(in-°F) μm/(m-°C) 1.80 cm3/Kg in3/lb 0.027680 in3/lb cm3/kg 36.127 W/(m K) BTU in /(hr ft2 F) 6.9334713 BTU in /(hr ft2 F) W/(m K) 0.1441314 (J m)/(min m2 C) W/(m-K) 0.016667 W/(m-K) (J m)/(min m2 C) 60
  • 79. Conversion Units 79 – Millimeters x 0.0394 = Inches Centimeters x 0.3937 = Inches Inches x 25.4 = Millimeters Inches x 2.54 = Centimeters Feet x 30.48 = Centimeters Meters x 3.281 = Feet Square Inches x 6.45 = Square Centimeters Square Centimeters x 155 = Square Inches Square Meters x 10.76 = Square Feet Cubic Centimeters x .0610 = Cubic Inches Cubic Feet x 1728 = Cubic Inches Cubic Feet x 28.32 = Liters Cubic Inches x 0.004329 = Gallons
  • 80. Conversion Units 80 – Gallons of Water x 8.35 = Pounds of Water Pounds of Water x 27.65 = Cubic Inches Gallons x 231 = Cubic Inches Pounds x .45359 = Kilograms Kilograms x 2.2046 = Pounds Grams x 15.43 = Grains Watts x 0.001341 = Horsepower Amps x Volts = Watts Atmospheres x 14.7 = Lbs per square inch Horsepower x .7457 = Kilowatts British Thermal Units x 3.927 x 10-4 = Horsepower-hours British Thermal Units x 2.928 x 10-4 = Kilowatt-hours
  • 81. L | C | LOGISTICS PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT Engineering-Book ENGINEERING FUNDAMENTALS AND HOW IT WORKS CONCEPTS, FORMULAS AND UNITS OF MEASUREMENT Thank You