INJECTION MOLDING

MATERIAL

LBS. / HR.
PER 1 TON

HDPE

30

LDPE

35

ACRYLIC

35

PP

35

PPO

40

NYLON 6, 66

40

POLYURETHANE

40

PET

40

PS

50

ABC

50

PC

50

CELCON

50

ACETAL

50

PVC

75

 

VACUUM FORMING

MATERIAL

LBS. / HR.
PER 1 TON

HDPE

70

LDPE

70

PP

70

PS

200

PVC

250

 

BLOWING MOLDING

MATERIAL

LBS. / HR.
PER 1 TON

HDPE

40

PET

40

PVC

70

 

EXTRUSION - PIPE PROFILE

MATERIAL

LBS. / HR.
PER 1 TON

HDPE

50

LDPE

50

PP

50

PET

50

ABS

70

PVC

65

PS

75

EXTRUSION - TROUGH, BATH, CHILL ROLL

POLYSTYRENE

60

ABS

60

 

BLOWN FILM COOLING LOAD

1.12 TONS

100 CFM @ 40 F AIR

35 F GLYCOL

1.03 TONS

100 CFM @ 45 F AIR

40 F GLYCOL

0.95

100 CFM @ 50 F AIR

45 F WATER

INCOMING AIR

95 F DRY BULB, 78 F WET BULB
15 F SENSIBLE FAN HEAT

AIR FLOW GUIDELINES

125 CFM PER 1" RING DIAMETER
3 CFM PER LB. / HOUR OF PLASTIC
IBC CFM (1/2 AIR RING CFM)

 

COOLING LOAD ESTIMATES

BARREL

1 TON PER INCH OF SCREW DIA.

SCREW

2 TON

THROAT COOLING

0.5 TONS FOR SCREWS UP TO 3"
1.0 TONS FOR SCREWS OVER 3" 

GEAR DRIVE

2.0 TONS

HYDRAULIC OIL COOLING

1 TON PER 10 HP HYDRAULIC OIL MOTOR

VACUUM PUMPS

1 TON PER 10 HP

WATER PUMPS

1 TON PER 5 HP PUMP MOTOR

AIR COMPRESSOR

1 TON PER 10 HP OIL COOLER
1 TON PER 10 HP AIR AFTERCOOLER
1 TON PER HP AIR DRYER
(WATER-COOLED)

COMPOUND MIXERS

TONS=LB./HR. X ? T + 0.2 X HP 12,000

 

GENERAL FORMULAE

TONS OF REFRIGERATION

(GPM X DELTA WATER TEMP) / 24

AIR-SENSIBLE HEAT (BTUH)

CFM X 1.085 X (DRY BULB 1 - DRY BULB 2)

AIR-LATENT HEAT (BTUH)

CFM X 0.68 X (GRAINS 1 - GRAINS 2)

AIR-TOTAL HEAT (BTUH)

CFM X 4.5 X (ENTHALPY 1 - ENTHALPY 2)

AIR-MOLD ROOM HVAC

80 SQ FT PER TON

HP - PUMP MOTORS

(US GPM X FT HD) /
(3960 X PUMP EFFICIENCY)

HP - FAN MOTOR

(CFM X INCHES S.P.) /
(6356 X STATIC EFFICIENCY)

TCU'S

LOAD + ( 0.5 TONS PER 3/4 HP ZONE)

RECTIFIERS

AMPS X VOLTS X 3.414 = BTUH

 

PUMP OPERATION AT 50 HZ

60 HERTZ

50 HERTZ OPERATION

GPM

X 0.833 (17%)

HEAD

X 0.694(31%)

B.H.P.

X 0.58 (43%)

3500 RPM

2900 RPM

1750 RPM

1450 RPM

 

ENERGY AND TEMPERATURE

1 TON REFRIGERATION

12,000 BTUH

1 TON COOLING TOWER

15,000 BTUH

 

0.293 WATTS

1 BTU

252 CALORIES

0.252 KG-CAL

-40 F

- 40 C

-30 F

-34.4 C

-20 F

-28.9 C

-10 F

-23.3 C

0 F

-17.8 C

10 F

-12.2 C

20 F

-6.7 C

30 F

-1.1 C

40 F

4.4 C

50 F

10 C

60 F

15.6 C

70 F

21.1 C

80 F

26.7 C

90 F

32.2 C

100 F

37.8 C

 

POWER

1 HP

2544 BTUH

746 WATTS

 

WATER PRESSURE

1 PSI

2.31 FT HD

6.895< 10ˉ² BAR

6.8947 KILOPASCALS

2.036 INCHES OF MERCURY

 

FLOW

1 US GPM

3.785 LITRES / MINUTE

227.1 LITRES / HOUR

0.2271 CU METRES / HOUR

 

VOLUME

1 CU FT

7.481 US GALLONS
0.0283 CU METRES

1 CU METRE

35.31 CU FT
264.2 US GALLONS

1 US GALLON

3.785 LITRES
0.833 IMPERIAL GALLONS

2" DIA. PIPE

0.163 US GALLONS PER FT

2 1/2" DIA. PIPE

0.255 US GALLONS PER FT

3" DIA. PIPE

0.367 US GALLONS PER FT

4" DIA. PIPE

0.653 US GALLONS PER FT

6" DIA. PIPE

1.47 US GALLONS PER FT

8" DIA. PIPE

2.61 US GALLONS PER FT

10" DIA. PIPE

4.1 US GALLONS PER FT

12" DIA. PIPE

5.9 US GALLONS PER FT

 

AREA

1 SQ FT

0.0929 SQ METRES

AREA OF A CIRCLE

(DIA X DIA) X 0.7854

CIRCUM OF A CYLINDER

DIAMETER X 3.1415

VOLUME OF A CYLINDER

(DIA X DIA) X
0.7854 X LENGTH

 

DISTANCE

1 INCH

2.54 CM

1 FOOT

30.48 CM

1 YARD

0.9144 METRES

1 MILE

1.609 KILOMETRES

 

PRESSURE DROP ACROSS CONTROL VALVES

PSI PRESS DROP = (DESIGN GPM / VALVE CV) SQUARED

 

ELEVATION ABOVE SEALEVEL

DERATE CONDENSER BY

2,000 FT

0.96

4,000 FT

0.91

6,000 FT

0.87

8,000 FT

0.83

 

PIPE SIZE GUIDE C = 100

PROCESS PIPING

TOWER RETURNS

PIPE
SIZE

FLOW
GPM

LOSSES
FT. PER
100 FT.

WATER
VELOCITY
FT./SEC.

FLOW
GPM

WATER
VELOCITY
FT./SEC.

1/2"

4

17

4.2

3/4"

9

19

5.4

1"

16

16.5

5.9

1 1/4"

26

10.3

5.6

1 1/2"

40

10.7

6.3

2"

75

10

7.2

2 1/2"

120

10

8

3"

210

9.7

9.1

90

3.9

4"

400

8.5

10.1

180

4.5

6"

960

5.7

10.7

510

5.7

8"

1800

4.8

11.6

900

5.8

10"

2700

3.3

11

1600

6.1

12"

3600

2.4

10.4

2400

6.9

14"

4500

2.3

10.7

3000

7.1

16"

5600

1.8

10.2

4000

7.3

 

FRICTION LOSSES IN PIPE FITTINGS IN TERMS OF
EQUIVALENT LENGTHS OF STRAIGHT PIPE

PIPE
SIZE

STD.
ELBOW

TEE
STRAIGHT
THRU

CHECK VALVE
PORT

BALL VALVE
(OPEN)

GATE VALVE
(OPEN)

1/2"

1.5

3

3.5

0.6

0.3

3/4"

2

4

5

0.8

0.5

1"

2.5

5.5

6

1

0.6

1 1/4"

3.5

7.5

9

1.2

0.8

1 1/2"

4.5

9

10

1.3

0.9

2"

5.5

12

13

1.5

1.1

2 1/2"

6.2

14

16

1.5

1.3

3"

8

16

20

2

1.6

4"

11

22

25

2.3

6"

16

32

40

3.5

8"

21

44

50

4.5

10"

26

55

65

6

12"

30

65

75

7

14"

35

80

90

8

16"

40

90

100

9

 

ETHYLENE GLYCOL

PROPYLENE GLYCOL

PERCENT
VOLUME

FREEZE
POINT

SPECIFIC
HEAT

PERCENT
VOLUME

FREEZE
POINT

SPECIFIC
HEAT

10%

23F

0.957

10%

26F

0.98

20%

14F

0.924

20%

18F

0.96

30%

2F

0.897

30%

7F

0.935

40%

-13F

0.849

40%

-8F

0.895

50%

-36F

0.809

50%

-29F

0.85

 

SIZING GUIDE LINES

NOMINAL DESIGN FLOW

COOLING TOWER

= 3 GPM PER TON

CHILLING

= 2.4 GPM PER TON

WEIGHED WATER TESTS 

GPM X ∆ T  = CHILLER TON

GPM X ∆ T   = TOWER TON

              24

        30

#MIN X ∆ T  = CHILLER TON

#MIN X ∆ T  = TOWER TON

              200

       250

FT.HD = P.S.I. X 2.3

CHILLER SIZING

INJECTION MOLDING SIZING GUIDE LINE

30#/HR POLYOLEFNS

= 1 TON

 50#/HR POLYSTYRENE

= 1 TON

45#/HR P.V.C.

= 1 TON

40#/HR P.E.T.

= 1 TON

EXTRUSION

50#/HR POLYOLEFINS

= 1 TON

75#/HR POLYSTYRENE

= 1 TON

65#/HR P.V.C.

= 1 TON

BLOWING MOLDING

40#/HR POLYOLEFINS

= 1 TON

OTHER EQUIPMENT

AIR COMP. W/AFT COOLER

= 0.2 TON/HP

VAC PUMP

= 0.1 TON/HP

HYDRAULIC COOLING

= 0.1 TON/HP

BARREL COOLING

= 1 TON/IN.
SCREW DIA.

MOLD ROOM HEATING= 25 BTU/FT²

NON-MOLD ROOM HEATING= 50 BTU/FT²

 (-10° F −+ 70° F) (16' CEILING)

MOLD ROOM AIR COND.=80FT²/TON

AIR COMP. 1 HP = 4 SCFM @ 100 P.S.I.G.

PIPE SIZING GUIDE Based on 10' HD loss/100' Pipe

½ =  2 GPM

2½ = 90 GPM

¾ =  5 GPM

3" = 160 GPM

1" = 10 GPM

4" = 320 GPM

1¼ = 20 GPM

5" = 600 GPM

1½ = 30 GPM

6" = 900 GPM

2" = 50 GPM

8" = 2000 GPM

 

COMMONLY USED FORMULAE AND CONSTANTS

TONS =

GPM X RISE

Nominal Tons

        24

Pipe

CHW

or

Size

or

TONS =

#/MIN X RISE

(Inches)

CTW

GPM

       200

  GPM

= GALLONS PER MINUTE

1

3

10

  1 GAL

= 8.3#

1 ½

10

30

1 CU FT

= 7.5 GALLONS

2

17

50

  1 TON

= 12000 BTU/HR

2 ½

30

90

EWT °F

= ENTERING WATER TEMP °F

3

53

160

LWT °F

= LEAVING WATER TEMP °F

4

107

320

RISE °F

= LWT ― EWT

5

200

600

6

300

900

 

TEMPERATURE

°F

°C

°F

°C

°F

°C

0

―17.8

7

―13.9

30

―1.1

1

―17.2

8

―13.3

35

1.7

2

―16.7

9

―12.8

40

4.4

3

―16.1

10

―12.2

45

7.2

4

―15.6

15

― 9.4

50

10.0

5

 15

20

― 6.7

55

12.8

6

―14.4

25

― 3.9

60

15.6

 

METRIC CONVERSION TABLE
To ConvertMultiplyTo ConvertMultiply
fromTo byfromToby
To ConvertPower
US gpmliters/min3.785ft-lb/secwatts1.356
US gpmliters/hr227.1hpwatts745.7
US gpmcu m/hr0.2271hpkw0.7457
cfmliters/min28.317hpcheval-vap1.0139
cfmcu m/min0.02832
cfmcu m/hr1.6992
Unit WeightHeat

lb/ft

kg/m1.4881Btugr-cal252

lb/sq in

gr/sq cm70.31Btukg-cal0.252

lb/sq in

kg/sq cm0.07031Btu/lbkg-cal/kg0.5556

lb/cu in

gr/cu cum27.68Btu/sq ftgr-cal/sq cm0.2713

lb/cu ft

kg/cu m16.018Btu/cu ftkg-cal/cu m8.899
LengthWeight
inchesmm25.40grainsgrams0.0648
inchescm2.540ouncesgrams28.350
inchesmeters0.0254ounceskg0.02835
feetmeters0.3048poundskg0.4536
feetkm0.0003048poundstonnes0.000454
yardsmeters0.9144US tonskg907.2
yardskm0.0009144US tonstonnes0.9072
mileskm1.609long tonskg1016
long tonstonnes1.0160
VolumeArea
cu inchescu cm16.387sq inchessq mm645.2
cu inches liters0.01639sq inchessq cm6.452
cu feetcu meters0.02832sq feetsq meters0.09290
cu feetliters28.317sq yardssq meters0.8361
cu yardscu meters0.7646sq milessq km2.590
fl ouncescu cum29.57acreshectare0.4047
US galcu meters0.003785
US galliters3.785