CONVERSION FACTORS

1 HP = 33,000 ft.lbs/min = 550 ft lbs/sec

1 HP = 746 Watts
1 HP = 42.4 BTU/Min.

Amps
Electric HP = --------------------------
746
(---------------------------- )
Volts x decimal efficiency

Amps
= -------- ( 120 V) @ 86 % efficiency
7.2

Amps
= -------- ( 240 V) @ 86 % efficiency
3.6

Amps
= -------- ( 550 V) @ 75 % efficiency
1.8

H2O = 62.4 lb/ft3 = 8.34 # / gal

1 Imp.Gal = 4.546 liters

1 lb grams
-------- = 1.64 ----------
3000 ft2 Meter2

F = ---- C + 32
9

C
5
= (F – 32) x -----
9

1
SANTOSH SWAR
BASIS WEIGHT CONVERSIONS
Offset (3300 ft2) x 1.48 = GSM
Bond (1300 ft2) x 3.76 = GSM
Liner (1000 ft2) x 4.89 = GSM
News (3000 ft2) x 1.63 = GSM

CONVERSION FACTORS

FROM TO OBTAIN MULTIPLY BY

lb kg 0.454
in mm 25.4
in cm 2.54
in m 0.0254
ft/min (fpm) m/min (mpm) 0.305
cfm m3/hr 0.589
cfm/in m3/hr/cm 0.232
cfm/in2 m3/hr/cm2 0.91
cfm/in2/1000 fpm m /hr/cm2/100 mpm
3
0.278
oz g 28.3
oz/ft2 g/m2 305.6

1) M/C PRODUCTION CALCULATION

Let M/c speed in mt/min
M/c Deckle in mt

SPEED x DECKLE x GSM x 60

(mt/min) (mt) 2
(Gm/mt ) (min/hr)
M/C PROD = ------------------------------------------------------
(Tons/Hr) 1000000
(Gm/Ton)

Speed x Deckle x GSM x 60

M/C PROD = ----------------------------------------
(Tons/hr) 106

EXAMPLE

Let M/c Speed = 200 mt/min

Deckle = 3.2 mt
GSM = 50

2
SANTOSH SWAR
 . 200 x 3.2 x 50 x 60
. . M/C PROD = -------------------------
106

1920000
= ------------
106

= 1.92 Tons/hr

M/C Production in kg units

Speed x Deckle x GSM x 60

M/C Prod. = -------------------------------------
(kg/hr) 103

200 x 3.2 x 50 x 60
= ---------------------------
103
1920000
= -----------
103
= 1920 kgs/hr

2) REAM WEIGHT CALCULATION

REAM WEIGHT = PAPER SIZE x GSM x NO.OF SHEETS
(Gm)
= Length x Width x GSM x 500 (Let)
(Mt) (Mt) GM
( ----- )
mt2

Length x Width x GSM x 500

(cm) (cm) GM
( ----- )
m2
REAM WEIGHT = ----------------------------------------------
(kg) 107

EXAMPLE : Let Paper size = 40 cm x 60 cm

GSM = 50
No.of sheets = 500

3
SANTOSH SWAR
 40 x 60 x 50 x 500
Ream Weight = --------------------------
107

60000000
= ----------------
107

= 6 kg

3) CALCULATION OF GSM
Any samples of any size can be expressed in terms of GSM.

10000 x W
GSM = -----------------
l x b

Where, W = Weight of paper in gms.

l = Length of paper in cms.
b = Width of paper in cms.

EXAMPLE :

Let a paper sample of dimensions

10 cm x 15 cm

That means l = 10 cm
B = 15 cm
Weight of this sample, W = 0.72 gm

10000 x 0.72
GSM = ---------------------
10 x 15

7200
= -------
150
= 48 GSM

Second Expression

10 cm x 15 cm size of paper has 0.72 gms

4
SANTOSH SWAR
 i.e. 10 cm x 15 cm = 0.72 gms

150 cm2 = 0.72 gms

0.72
1 cm2 = ------
150

= 0.0048 gms

1 cm2 = 0.0048 gms

1
---------- m2 = 0.0048 gms . . 1 m = 100 cm
10000 . 1 m2 = 10000 cm2
1
1 cm = ------ m2
2

10000
1 m2 = 48 gms

TEMPLET EXPRESSION 25 cm

20 cms

Area of templet size sample

= 2 x 25 cm x 20 cm
= 1000 cm2

Let weight of this sample is 5.8 gms

1000 cm2 = 5.8 gms

5.8
1 cm2 = -------- gms
1000
1 cm2 = 0.0058 gms
1
--- m2 = 0.0058 gms
104
1 m2 = 0.0058 x 104 gms
1 m2 = 58 gms

5
SANTOSH SWAR
4) THEORETICAL HEAD
2
V
-----
100
Theoretical Head = --------------
K

Where, V = Spouting velocity (fpm)

K = Constant (see table)

Head In of H2O Ft of H2O In of Hg Pressure PSIG

K 1.932 23.184 26.345 53.623

5) SPOUTING VELOCITY
V = k h

Where, V = Spouting velocity (fpm)

h = Theoretical head
k = Constant (see table)

Head In of H2O Ft of H2O In of Hg Pressure PSIG

K 139.2 481.5 513.3 732.3

6) HEAD CALCULATION
V2 = 2 gh

V2
h = -------
2g

Where, h = Height of stock in head box

V = Velocity (M/c speed in m/min)
g = Acceleration due to gravity
(9.81 m/sec2)

6
SANTOSH SWAR
EXAMPLE

Let M/c speed V = 200 m/min

V2
h = -------
2g
m2
200 x 200 ------
min 2
= -------------------------
2 x 9.81 m
------
Sec2
40000 m x sec 2
= ------- ------------
19.62 min2

m x sec2
= 2038.74 ------------- . . 1 min2
3600 sec2 . = 1 min x 1 min
= 60 sec x 60 sec
3600 sec2

2038.74
= ----------- m
3600

= 0.5663 m
= 56.63 cm

Short Method

200 x 200 m2 sec2

h = ------------- ------ x -------
2 x 9.81 min2 m

200 x 200 m x sec2

= ------------- -------------
2 x 9.81 min2

200 x 200 100 cm x sec2

= -------------- ------------------
2 x 9.81 3600 sec2

7
SANTOSH SWAR
 200 x 200 x 100
= ---------------------- cm
2 x 9.81 x 3600

200 x 200 100

= ----------- cm . . --------------------- = 706.32
706.32 . 2 x 9.81 x 3600

= 56.63 cms.

QUICK FORMULA

Speed x Speed Where h in cms

h = -------------------- Speed = in m/min.
(in cms) 706.32

EXAMPLE
M/c Speed
180 x 180
1) 180 M/min , h = -------------- = 45.87 cms
706.32

200 x 200
2) 200 M/min , h = ------------ = 56.63 cms
706.32

250 x 250
3) 250 M/min , h = ------------ = 88.49 cms
706.32

7) FORMING LENGTH GUIDELINES

Dwell time in seconds between head box slice and first flat box or dandy roll:

 Wire speed < 12 fpm : 1.5 – 2.0 seconds multiply forming length in feet by 40
(1.5 sec) or 30 (2 sec) to determine M/c speed that can be supported conventional


drainage table.
Wire speed > 1200 fpm : 1.0 seconds. Multiply forming length by 60 to obtain


M/c speed potential.
42 lb. Liner : 1.25 seconds. Multiply forming length by 48 to obtain M/c speed


potential.
Foodboard : 2 seconds. Multiply forming length by 30 to obtain M/c speed
potential.

8
SANTOSH SWAR
8) JET VELOCITY CALCULATION
(Stock speed at slice)

Jet Velocity

V = Cv  2 gh
______

Where, V = Stock speed at slice

Cv = Coefficient of velocity discharge
g = Acceleration due to gravity
h = Head of stock

If h is measured close to the slice and V is measured at the vena-contracta of

the Jet, Cv is approximately 1.0 for most slices.

V =  2 gh
______

Friction losses will reduce Cv possibly to around 0.98.

EXAMPLE

Let head of stock h = 57 cms

Then Jet Velocity

=  2 x 9.81 m x 57 cm
______________________
V
------
Sec2

=  2 x 9.81 x 57 m x cm
______________________

------
Sec2

=  57 x 2 x 9.81 m x 1/100 m
____________________________
V
--------------
1/3600 min2

1
( . . 100 cm = 1 m 1 cm = ------- M )
100

9
SANTOSH SWAR
Similarly 3600 sec2 = 1 min2
1
1 Sec2 = ------ min2
3600

=  57 x 2 x 9.81 x 3600 M2
______________________

------ ----
100 Min2

=  57 x 2 x 9.81 x 36 M2
______________________

----
Min2

=  57 x 706.32 M2
__________________

----
Min2

=  40260.24 M2
______________

----
Min2
M
= 200.6 ------
Min.

QUICK FORMULA

=  Head x 706.32
____________
Jet Velocity
(In m/min) (in cms)

EXAMPLE

V =  46 x 706.32
____________
1) h = 46 cms,

=  32490.72
_________

= 180.25 M/min

V =  89 x 706.32
___________
2) h = 89 cms,

=  62862.48
_________

= 250.72 M/min

10
SANTOSH SWAR
9) CRITICAL SPEED OF CALENDAR ROLL (fpm)

C.S. = 4.12 x 106 x -----  Ro2 + Ri2

Ro ___________

L2
Where,
C.S. = Critical speed (fpm)
Ro = Outside radius (inches)
Ri = Inside radius (inches)
L = Centerline to centerline bearing (inches)
(assume L = face + 40 inches)

10) RETENTION
Net consistency
1) Retention % = -------------------------- x 100
Head box consistency

Head box consistency - Tray consistency

2) Retention % = ----------------------------------------------------- x 100
Head box consistency

Filler in sheet
3) Overall Retention = ----------------------------- x 100 %
Filler added to furnish

Filler in Sheet
4) First – Pass Retention = ----------------------- x 100 %
Filler in head box

11) FLOW RATE OF SLICE

Q = Av V , Where Av = Area of cross section at
Vena-contracta
Av = Ca As
Ca = Coefficient of contraction
As = Areas of cross section at the
Slice opening.

Ca As Cv  2 g h
_____
=

Ca Cv As  2 g h
_____
=

 2 g h where, Cq = Coefficient of volume

_____
= Cq As
discharge.

Q = Cq As  2 g h
______

11
SANTOSH SWAR
12) FLUID VELOCITY
GPM x 0.321
Velocity = ------------------
A

Where, Velocity in fps

A = Area in (inches 2)

NOTE : This formula is for savealls and general paper flow, since there is no orifice
Coefficient included.

13) ROLL SPEED

3.82 ( V )
RPM = -------------
Do

Where, RPM = revolutions per minute

V = Speed (fpm)
Do = Roll outside diameter (inches)

14) FORMING BOARD SETTING

----------------- (  V2 Sin2 A + Zyh - V Sin A)

12 V COS A _______________
X =
g
_____________
= 0.37267 V COS A (V2 Sin2 A + 64.4 h - V Sin A)

Where,

X = Distance of slice to lead forming board blade

V = Initial Jet Velocity
A = Jet angle
g = 32.2 ft/S2
h = Jet to wire height

12
SANTOSH SWAR
15) WATER REMOVAL BY A TABLE ROLL
1st Method
DU K
q = --------
F2

Where,
q = Water removed by a table roll per unit time & width
D = Diameter of roll
U = Wire speed
F = A drainage factor (proportional to basis weight) determined by the Sag
of wire, air content, thickness and porosity of mat, stock freeness, head
box consistency, degree of flocculation and evenness of formation.
K = Exponent defining the effect of speed on drainage, characteristics of
type and quality of pulp (varies between 0.3 – 1.2).

Second Method

STOCK h

Wire A C
R Extracted water

Table Roll

(mechanism of water extraction)

According to Mr.Cowan, the quantity of water that is being removed from the wire
from A to B is equal to
4 K2 R gh
= -------------
V

Where K = Drainage coefficient (dependent on the sheet weight & type of

wire)
R = Radious of the roll
g = Acceleration due to gravity
h = Head of stock suspension above the wire
V = Velocity of the wire

13
SANTOSH SWAR
 16) VACUUM PUMP CAPACITY (CFM)

PV = nRT

Where,

P = Absolute pressure, lb.ft2 = (Psi gauge + 14.7) x 144

V = Total gas volume, ft3

 R = F + 460
n = Weight of gas, lbs

Gas constant, lbf x ft / (lbn x  R )

T = Absolute temperature
R =
Ra (air) = 53.3
Rw (water)vapour = 85.8

P1V1 = P2V2

29.92 - P1 (  Hg)
V2 = ----------------------- x V1 (CFM)
29.92 - P2 ( Hg)

or for temperature cooling effects :

P1V1 P2V2
------- = -------
T1 T2

17) DRYER SURFACE REQUIRED CALCULATION

For normal types of dryers, the following empirical formula can be used for obtaining
a rough value of dryer surface required.

(Exact value will depend on the quality of paper and constructional details etc.)

SWd
L = K -------
(t – 100)

Where,

L = Peripherial length in meters of dryers in contact with paper

During drying.

14
SANTOSH SWAR
 K = Constant value around 0.05
S = Speed of M/c in M/min
W = Basis weight of paper in gm
----
m2

Temperature of ingoing steam in C

d = Thickness of dryer shell in centimeters
t =

EXAMPLE

Let M/c speed S = 180 M/Min

GSM W = 50

150 C
Dryer shell thickness d = 2.2 cm
t =

0.05 x 180 x 50 x 2.2

L = ------------------------------
(150 – 100)

990
= ------
50

= 19.8 meters to be required for paper drying

18) HEAD BOX FLOW RATE (GPM/inch)

GPM / inch = S.O. x V x 0.052 x C

Where

V = Spouting velocity (fpm)

S.O. = Slice opening (inches)
C = Orifice coefficient
(see table for approximate values)

Type C
Nozzle 0.95
A 0.75
B 0.70

15
SANTOSH SWAR
 C 0.60

Type A) Low angle,

Converflo
ß

Type B) High angle

Type C) Straight

19) NO OF DRYERS REQUIRED CALCULATION

GIVEN DATA
(TPD, Sheet width, Dryer diameter)

Production Rate = 40 TPD

Sheet width (to dryer) in inches W = 200 inches

200
W = ----- = 16.67 foot
12

16
SANTOSH SWAR
 Dryer diameter, d = 60 inches
60
= ---- 5 foot
12
Moisture to dryer = 37 % dry
Moisture to reel = 94 % dry

400
Hourly production = ------ Tons/hr
24
400
Convert it into lb/hr, ------- x 2000 = 33333 lb/hr
24

( 1 US Ton = 2000 lbs)

Now water to be removed

94
__
33333 x ( ---- 1)
37

Dryer surface required @ 2.8 lb water/hr/ft2

Evaporation rate

Required dryer surface

51350
= -------- = 18339 ft2
2.8

Now Area of single dryer surface,  dw

22
= --- x 5 x 16.67 = 261.95 ft2
7 = 262 ft2/dryer

No.of dryer required

18339
-------- = 69.99 = 70 dryers
262

20) PRESS IMPULSE

5 x PLI

17
SANTOSH SWAR
 PI = ---------
Speed

Where, PI = Press impulse (Psi – Sec)

PLI = Nip pressure (Pli)
Speed = Nip speed (fpm)

21) TORQUE
Tq = Force x Radius

Where Tq = Torque (inch – pounds)

Force = in pounds
Radius = in inches

22) WR2 OF A ROLL

WR2 = (0.000682) (W) (L) (Do4 – Di4)

Where, WR2 = in (lbs – ft2)

W = Density (pounds/inches 3)
L = Length (inches)
Do = Outside diameter (inches)
Di = Inside diameter (inches)

23) STOCK FLOW THROUGH THE PIPE CALCULATION

 d2 x Vrc
1
Q = -----
4

4Q

 d2
Vrc = -----

Where, Vrc = Velocity of flow

Q = Total quantity
d = Pipe diameter

24) IDEAL DRAINAGE IN WIRE PART

a) Theoritically after forming board the drainage should be 80 to 85 % of stock
thickness ( i.e. Slice opening).

18
SANTOSH SWAR
 b) At half of the forming zone, it should be 40 % of slice stock thickness
c) Before dandy it should be 20 to 25 % of slice stock thickness

25) STOCK THICKNESS ON FORMING FABRIC

Basis weight
T = ------------------------------------
J
Consistency x R x ( ---- )
W

Where,

T = Thickness of stock on table in cm.

Basis weight in g/cm2
%
Consistency in ---
100
R = Retention from that point down the rest of the machine

J/W = Jet/Wire ratio = 1.0 except at slice

i.e., overall retention of a machine with slice opening of ½  making 50 gsm at 0.6 %
slurry and Jet/Wire ratio of 0.95.

0.0050
R = -------------------------------- = 73 %
( 0.0060 ) x 1.6 x 0.95

26) CALCULATION OF WIRE LENGTH


Ls = 2 l + ---- (D1 + D2) + K
2

Where, Ls = Length of wire (in mm)

l = Distance between center of breast roll to couch roll (in mm)
D1 = Diameter of breast roll (in mm)

K
D2 = Diameter of couch roll (in mm)
= A constant, 130 mm for fourdrinier wire part.
EXAMPLE

L = 12,500 mm
D1 = 450 mm

19
SANTOSH SWAR
 
D2 = 800 mm

Then Ls = 2 x 12500 + ----- (450 + 800) + 130

2
= 25000 + 1.571 (1250) + 130
= 25000 + 1963.75 + 130
= 27093.75 mm
= 27.093 mtr.

27 a) DRAG LOAD The term drag load resulted from the necessity of fabric
manufacturers to monitor the power used to drive the fabric. It is a
measure of the increase in tension ( T) of the fabric as a result of the
suction forces pulling the fabric against the foil surfaces, the iovac
surfaces & the hivac surfaces.

T+ T

T Suction Couch

Drive Power = VOLT x AMP

0.8 VA Kilonewtons
DRAG LOAD = ---------- ------- -----------------
1000 UW Meter
Where
V = Volt
A = AMP
U = Fabric speed (M/S)
W = Fabric width (M)

lb KN lb
{ To convert in ------ , ------- x 5.71 = -------- }
in M inch

b) DRAG LOAD - CONVENTIONAL

V x A x 0.8
DL = ------------------------ DL in Pli
0.0226 x U x W

Wehre,
V = Drive volts (V)

20
SANTOSH SWAR
 A = Drive AMPs (AMPS)
U = Nominal fabric speed (fpm)
W = Nominal fabric width (inches)

c) DRAG LOAD CALCULATION

Safe drag load is

10 – 12 HP/Meter width of the wire/100 m/min wire speed

If it is beyond 15 HP then it is alarming

VOLT x AMP x 49 (Constant)

DRAG LOAD = --------------------------------------------
(In kg/cm) WIRE WIDTH x WIRE SPEED
(in mm) (in m/min)

Volt x AMP = WATT

746 WATT = 1 HP

28) DRAG LOAD – BETWEEN COMPONENTS IN THE FABRIC

Vn
DL = (---- __ 1) (EM + Ts)
Vs
Where,
DL = Drag load (Pli)
Vn = Fabric speed at point n in fabric run (fpm)
Vs = Fabric speed on slack side of fabric run (fpm)
EM = Fabric elastic modulus (young) at temperature
T ~ EMr – KT
EMr = Elastic modulus at reference temperature r (Pli)

Modulus Pli
K = ------------------------- (----- )
Temperature constant ºF

Ts = Slack side tension (Pli)

21
SANTOSH SWAR
29) DANDY DIAMETER CALCULATION
1) Open type 2) Journal typs
15 – 20 % of wire width 10-15 % of wire width

Below 240 m/min dandy of diameter equal to 10 % wire width may be used. At higher
speed the diameters should be more because with very high number of revolutions it
throws water causing damage to the web.

For Wove Dandy

M/C Speed

 x Maximum number of revolutions

Dia of Dandy = --------------------------------------

n
D = --------

Where, D = Diameter in mm
V = M/c speed in m/min
n = Maximum number of revolution for a wove
Dandy & it should be taken as 150 rev/min.
V
D = ---------------
3.142 x 150

V
D = -------
477

EXAMPLE

Let M/c speed V = 400 m/min

400
D = ------- = 850 mm
477

Wire Speed (m/min) 80 150 250 300 400

Dia of dandy (in mm) 300 400 500 600 800-1000

22
SANTOSH SWAR
30) DANDY ROLL REVOLUTION PER MINUTE
Wire Speed (fpm)

 x Dandy roll diameter (ft)

RPM = ----------------------------------------

Where  = 3.142

RPM Target = 125 – 150 RPM

31) SIZE PRESS ROLL REVOLUTION PER MINUTE

Web Speed (fpm)

RPM = ----------------------------------------------
3.142 x Size press Roll diameter (ft)

Maximum 250 rpm

32) TONS PER DAY (T/D)

Capacity (gpm) x % Bone dry consistency

T/D = ------------------------------------------------------
16.65

33) CENTRICLEANER DESIGN CALCULATION

GIVEN DATA - FINISHING PROD = 30 TPD

M/C PROD = 33 TPD

Ton
33 --------- Convert it into kg/min
Day

33 x 1000 = 33000 kg
24 hrs x 60 min = 1440 min

23
SANTOSH SWAR
 33000 kg
33 TPD = ------------- = 22.9 kg/min
1440 min
100
Bs factor = 1.45 (68.9 wire retention ------- = 1.45)
68.9

Bs factor x prod.

22.9 x 1.45 = 33.22 kg/min

10 % reject = 3.32 kg/min
5 % vent reject= 1.66 kg/min
-----
38.20 kg/min

kg/min x 100 38.20 x 100

Now LPM = ------------------ = ------------------ = 4775 lpm
Consistency 0.8

Through put/leg = 500 lpm

4775
No of legs required = --------- = 9.55 = 10 legs
500

Primary legs = 10 Nos.

Secondary legs = 3 Nos. (30 % of primary legs)
Tertiary legs = 1 No. (30 % of secondary legs)

Pressure drop = 1.4 kg/cm2

34) WEIR FLOW – RECTANGULAR WEIR WITH END

CONTRACTIONS

Q (ft2 H2O/Sec) = 3.33 (L - 0.2 H) H 1.5

Where,

L = Length of weir opening in feet

(should be 4 – 8 times H)
H = Head on weir in feet ( ~ 6 ft back of weir opening)
a = at least 3 H (end contraction)

35) WEIR FLOW – TRIANGULAR NOTCH WEIR WITH END

CONTRACTIONS

24
SANTOSH SWAR
 Q = C ( -----) L H  2 gH
4 ______

15

Where L = Width of notch in ft at H distance above apex

H = Head of water above apex of notch in feet
C = 0.57
a = Should be not less than ¼ L (end contraction)

For 90 notch the formula is :

Q = 2.438 H 5/2

For 60 notch the formula is :

Q = 1.4076 H 5/2

36) WASTED VOLUME OF THE COUCH

∆P
Wv = DA x DW x U x t x ----------
P

Where, Wv = Wasted volume (in ft3/min. or m3/sec)

DA = Drilled Area (in %)
DW = Drilled width (in inch or M)
U = Machine speed (in ft/min. or M/minute)
t = Shell Thickness (in inch or cm)
∆P = Suction Pressure (couch vacuum) in inch Hg)
P = Pressure (in inch Hg)

EXAMPLE

DA = 50 % = 50/100 = 0.5
DW = 286 inch or 7.26 M
U = 300 fit/min or 914.6 M/min
t = 2.5 inch or 6.35 cm. Or 0.0635 M
∆P = 24 inch Hg or 81.3 K Pa
P = 30 inch Hg or 101.6 K Pa

Wv = DA x DW x U x t x ∆P
-----
P
24 inch Hg
= 0.5 x 286 inch x 3000 fit/min. x 2.5 inch x ----------------

25
SANTOSH SWAR
 30 inch Hg

286 2.5
= 0.5 x ----------- ft x 3000 ft/min x -------- fit x 0.8
12 12

= 5948 ft3/min
81.3 KPa
Wv = 0.5 x 7.26 M x 914.6 M/min x 6.35 cm x ----------
101.6 KPa

914.6 M 6.35
= 0.5 x 7.26 M x ------------ ------- x ---------- M x 0.8
60 Sec 100

= 2.81 m3/S

37) COUCH VACUUM EXPANSION VOLUME

CFM = (V) (b) (S) (E) (m)

Where,

V = M/c speed, fpm

b = Roll shell face width, feet
S = Hole depth, feet
E = % Open area of shell
0.9
P2
m = Expansion factor, ------ -1
P1

P2 = ambient pressure,  Hg absolute

P1 = Suction box vacuum, Hg absolute

26
SANTOSH SWAR
38) FORMATION – BLADE PULSE FREQUENCY
V
F = -------
5x

Where,

F = Formation – blade pulse frequency

(in cycle/sec)
V = Wire speed (fpm)

= blade spacing, tip to tip (inches)

Optimum frequency for formation improvement “

F > 60 cycle/sec

39) PAPER WEB DRAW

SF – S1
Draw (%) = -------------- x 100
S1

Where, SF = Final Speed, fpm

S1 = Initial Speed, fpm

40) EFFLEX RATIO CONCEPT

SLICE JET SPEED
ER = ------------------------
WIRE SPEED

Efflex ratio should be 0.9 – 1.0 for better runnability of M/C.

EXAMPLE :
Let M/c speed = 200 M/min
Head in the head box = 50 cms

 50 x 706.32
.
. . Slice jet speed =

 35316
= 187.9 = 188 M/min.

27
SANTOSH SWAR
 Slice Jet Speed
ER = -------------------
M/C Speed

188
= ---------
200

= 0.94

JET VELOCITY VS WIRE SPEED

IF Jet velocity > Wire speed Floading problem

IF Jet velocity < Wire speed GSM drastically changed
IF Jet velocity = Wire speed Real fiber orientation not occur

So Jet velocity is kept slightly less than M/c speed for real fiber orientation.

41) PAPER ON ROLL (feet)

 (OD2 – ID2)
Ft of paper = ----------------------
48 x Caliper
OD, ID and Caliper in inches.

42) PAPER CALIPER (inches)

Basis weight
Paper caliper = ------------------------
Area x 144 x Density

Where Caliper in inches

Basis weight (lbs/Area), Example : 30 lb/3000 ft2
Area (ft2)
Density (lbs/in3), see table below

Average paper density

Grade Density lb/ in3
Coated & supered 0.042
Coated only 0.038
News print 0.023

28
SANTOSH SWAR
 Fine paper 0.029
Liner board 0.024
Board (coated) 0.028

43) MASS OF PAPER ON REEL CALCULATION


Mass of paper = ------ (D2-d2) x W x Apparent Density
(in kg) 4

 GSM
2 2
Mass of paper = ------ (D -d ) x W x -----------
(in kg) 4 Thickness

Where, D = Parent roll dia (in m)

d = Empty spool dia (in m)
W = Reel width (deckle) (in m)
Thickness in mm

UNIT CALCULATION

 GSM
2 2
------ (D -d ) x W x -----------
4 Thickness

GM
-----
m2
= m2 x m x --------------
mm

0.001 kg . . 1 GM = .001 kg
m3 x --------------- 1 mm = .1 cm
m2 x .001 m = .001 m
Kg
3
m x -------- = kg
m3

EXAMPLE
Let a parent roll of deckle 3 meter.
GSM = 50
Thickness = 0.075 mm

29
SANTOSH SWAR
 . 50
. . AD = ------ = 666.67 kg/m3
0.075
(Apparent density)

Parent roll circumference  D = 3.82 m

3.82
D = --------- = 1.2157 m
3.142

D2 = 1.478 m2

Empty spool circumference  d = 1.11 m

1.11
d = --------- = 0.3533 m
3.142

d2 = 0.1248 m2

 GSM
2 2
Mass of the Roll = ------ (D -d ) x W x -----------
4 Thickness
3.142
= -------- (1.478 – 0.1248) x 3 x 666.67
4
= 0.7857 x 1.3532 x 3 x 666.67 = 2126.429 kg.

44) HORSE POWER

TN
HP = ---------------
63,000

Where, T = torque (inch – pounds)

N = speed (rpm)

45) TENSION HP
fpm x Pli x inches of width
Tension HP = -----------------------------------------
33,000

46) APPROXIMATION FOR VACUUM COMPONENT IN PLI WHEN

TAKING NIP IMPRESSIONS (Pliv).

30
SANTOSH SWAR
 Vacuum box width x Vacuum
Pliv = ---------------------------------------
3

Vacuum box width (inches)

Vacuum (inches of Hg)

47) KWH CALCULATION

TYPE OF METHODS

1. By taking 80 % efficiency
2. By Amp reading method

1st Method

Motor capacity = 10 KW
80 % efficiency, 10 x 80 % = 8 KWH

2nd Method
 3 V I COS 
KWH = -----------------------------
1000

Where V = Input voltage (in volt)

COS  =
I = Current (in Amp)
Power factor

EXAMPLE

If 10 KW motor taking load 12 Amp

COS 
Input voltage V = 410 V
= 0.95 (power factor)

 3 V I COS  1.732 x 410 x 12 x 0.95

KWH = --------------------- = -----------------------------
1000 1000

= 8.09  8 KWH

48) HYDRAULIC PUMP HORSE POWER (HP)

Hydraulic Pump HP = 583 x PSI x GPM x 10-6

31
SANTOSH SWAR
 In centrifugal pumps or blowers

A) Capacity varies directly with speed

B) Head varies as the square of speed
C) Horse power varies as the cube of speed.

49) STANDARD HEAD BOX FLOW RATE (GPM/inch)

( B.D. Ton/24 hr/in) (16.76) (1.5 – Tray Consistency)
GPM/inch = ---- -------------------------------------------------------------
1.5 x Net consistency

Where,
Net consistency = Head box consistency - Tray consistency

50) TISSUE HEAD BOX FLOW RATE (GPM/inch)

T.O x V
GPM/inch = ----------- = T.O. x V x 0.0052
19.25

T.O. = Throat opening (inches)

V = Spouting velocity (fpm)

51) CALCULATION OF LENGTH OF BELT

The percentage of power transmission through pulley and belt largely depends
on the length of belts. If the belt is tight the pulley will also run tightly. Its bush
bearings shall also worn out easily. On the other hand if length of a belt is in excess of
the need, it will slip frequently and result in loss of power. In order to determine the
right length of belt, the following formula are applied.

Indications

L= Requisite length of the belt

C= Distance from the center
D= Diameter of the larger pulley
d= Diameter of the smaller pulley

Length of Open Belt

32
SANTOSH SWAR
 1) For pulley of equal diameter

L =  D + 2C

2) For pulley of different diameter


L = ----- (D+d) + 2  C2 + D - d 2
_________________

2 --------
2
Length of Cross Belt

1) For pulley of equal diameter

L =  D + 2  D2 + C2
________

2) For pulley of different diameter


L = ----- (D+d) + 2  C2 + D + d) 2
_________________

2 --------
2

52) TANK SIZING AND CAPACITY

# / ft3 x volume
Tons = ----------------------
2000

% B.D. x Volume
= -----------------------
1.6 x 2000

Volume = 3200 x # tons/% B.D.

US Gallons = Volume / 7.4805

Where
# / ft3 = Weight of dry stock at % consistency
Volume = Volume of tank in cubic feet
1 US Gallon = 2.31 Cu.inches
% B.D. = Percent consistency of stock

33
SANTOSH SWAR
53) LOAD FACTOR OF WIRE
Ph
K = -------
F

Ph
K = ------- (. . F = b.L. )
b.L .

Where,

Ph = Production of paper/hr (in kg/hr)

F = Working surface of paper m/c wire
b = Working width of paper web on the wire (in m)
L = Distance from the axis of breast roll to the axis of couch roll
(in m) (working length of Wire).

54) INTERPRETING THE NIP IMPRESSION

(Ne2 – Nc2) (D1 + D2)
C = --------------------------------
2 D1D2
Where,

C = Change in total crown of two rolls (inches)

Ne = Nip width at the ends (inches)
Nc = Nip width at the center (inches)
D1 = Top roll diameter (inches)
D2 = Bottom roll diameter (inches)

OR if rolls have equal diameters

Ne2 - Nc2
C = --------------
D

NOTE : If C is minus, then the nip is over crowned.

EXAMPLE

Let us assume that we have two 30 inch (762 mm) diameter rolls and we find
that the nip widths are 0.9 inches (22.9 mm) on the ends and 0.7 inches (17.8 mm) at
the center under the loading which we desire to run the rolls.

34
SANTOSH SWAR
 Then Nc = 0.7 inches (17.8 mm)
Ne = 0.9 inches (22.9 mm)
D = 30 inches (762 mm)

(0.9)2 - (0.7)2 0.81 - 0.49 0.32

C = ------------------- = ------------------ = ------
30 30 30

= 0.011 inch (2.8 mm)

55) HEAD LOSS IN STOCK PIPES

Pressure drop in pipes conveying 2 % - 6 % consistency stock is given by

K x 0.0915 x C 1.89 x Q 0.364 x L

H = -------------------------------------------------
D 2.06
Where,
H = Head loss in feet of water / feet of pipe
K = A constant depending of the type of stock
(for bleached sulphite = 0.9
unbleached sulphite = 1.0
Cooked ground wood & kraft ground wood
= 1.4 oven dry cy %.
Q = Flow of stock
L = Pipe length
D = Pipe diameter (in inch)

For pipes made of 2 or more section of different diameter and length, the
pressure drop is given as

L1 L2
H = K x 0.0915 x C 1.89 x Q 0.364 x --------- + ---------
D1 2.06 D2 2.06

56) VACUUM PLI K N/M (SUCTION ROLLS)

Suction rolls present a problem in that part of the core bending or distortion
load is the result of the application of vacuum. This can be addressed either by
increasing the PLI KN/M to compensate for the vacuum or by sealing off the section
box area with plastic and applying an amount of vacuum equal to that normally run in
the roll. If the increased PLI KN/M method is used, the original equipment supplier
should be contacted to obtain the correct amount to be used. If this information is not
readily available, the incremental PLI KN/M addition can be approximated by using
the following formula :

35
SANTOSH SWAR
 Vacuum PLI KN/M = 0.4912 x W x V x F

Where W = The width, in inches (mm) of the vacuum box.

V = The vacuum level, in inches (mm) of mercury.
F = Box seal efficiency factor
( F = 0.9 for most suction rolls).

Only 70-75 % of the vacuum PLI KN/M is used as an addition to the applied loading.

57) BELT WIDTH IN FLAT PULLEY

P x C2 x C3 x 1000
bo = ----------------------------
FUN x V

Where, bo = Belt width

P = Kilowatt of motor
C2 = Over load factor
(50 % of normal load of motor)
For paper Industry C2 = 1.2 (constant factor)
C3 = Ratio between both pulley
FUN = Belt type i.e. 40
(40 means 1 cm of belt take 40 kg load)
V = Belt speed
d1 x n1
V = ----------- m/sec
19100

d1 = pulley dia
n1 = Motor rpm

(For cone pulley C3 is not required)

58) % WEAROUT OF WIRE

1) For single layer synthetic wire

Original caliper - Average used caliper

0.7 x Weft 
% Wear = --------------------------------------------------- x 100

2) For double layer synthetic wire

Original caliper - Average used caliper

% Wear = --------------------------------------------------- x 100

36
SANTOSH SWAR
 0.85 x Weft 

3) For Metal wire

Original caliper - Average used caliper

0.7 x Wrap 
% Wear = --------------------------------------------------- x 100

NOTE :- Synthetic wire is weft runner so weft  is taken for calculation & metal
wire is wrap runner so wrap  is taken for calculation.

EXAMPLE

Single layer synthetic wire

Original caliper = 0.565 mm

Weft 
Average used caliper = 0.4 mm
= 0.28 mm

0.565 – 0.4
% Wear = --------------------- x 100
0.7 x 0.28

= 84 %

59) PRODUCTION RATE (Off Machine)

Production (lbs/hr) = Factor x speed x Deckle x Basis weight

Where, Production = lbs/hour

Factor = From table
Speed = Feet/minute
Deckle = inches at reel
Basis weight = lbs/ream

Grade Ream size No.of sheets Ft2/Ream Factor

Liner board 1000 0.005
Bond 17 x 22 500 1300 0.00385

25 ½  x 30 ½
Cover 20 x 26 500 1805 0.00277
Index 500 2700 0.00185
Bristol 22 ½ x 28 ½ 500 2110 0.00225
Offset 25 x 38 500 3300 0.00152
Manuscript 18 x 31 500 1948 0.00258
Wrapper 24 x 36 480 2880 0.00174
News print 24 x 36 500 3000 0.00167

37
SANTOSH SWAR
60) M/C EFFICIENCY CALCULATION

Total Actual Prod. (MT)

M/C Efficiency = ---------------------------------- x 100
(%) Total theoretical prod. (MT)

Actual Production (MT) x 106

= -------------------------------------------------------- x 100
GSM x Speed x Deckle x Total running hours
(M/Min) (M) (in min)

Actual Production (MT) x 108

M/C Efficiency = ---------------------------------------------------------------
GSM x Speed x Deckle x Total running hours
(M/Min) (M) (in min)

EXAMPLE

Actual GSM Speed Deckle Total Running Efficiency

Production Time (in min.) (%)
(T)
2T 54 170 3.04 1.15’ = 75’ 95.55
11.3 T 65 155 3.05 6.10’ = 370’ 99.39
5.4 T 60 160 3.08 3.05’ = 185’ 98.72
12.7 T 50 180 3.04 9.00’ = 540’ 85.56

61) CALCULATION OF NIP LOAD ON PRESS

Area of Intensity Lever Edge x No.of  Roll weight

Cylinder x pressure x sides (kg)
(cm2) (kg/cm2)
Nip Load on Press = ---------------------------------------------------------------------------------
(kg/cm) Face length (in cm)

38
SANTOSH SWAR
  
Area of Cylinder

This is D ----- or (D – d ) -----

2 2 2

4 4

1)

Fulcrum
Air for
Loading


Here Area of cylinder is (D2 – d2) ------
4

2)


Air for Here Area of

2
Loading cylinder is D ---
4

39
SANTOSH SWAR
3)

Air for Loading


Here Area of cylinder is (D2 – d2) = -----
4

Intensity Pressure

Intensity pressure can be found from pressure gauge reading.

Lever Edge (It is only ratio)

Y X

1000 500

Y ( 1000) = X (500)

40
SANTOSH SWAR
 X 1000
= ------ = ------- = 2
Y 500
2)

Y X

26 
14

(14  + 26 )

Y (14  + 26 ) = X (26)

X 40
---- = ----- = 1.538
Y 26

Roll Weight

If the loading role is lower side then the role weight to be subtracted & if it is on
upper side the role weight to be added.

1) 2)

Here loading roll is on lower side, Here loading roll is on upper side,
So roll weight is -ve. So roll weight is +ve.

EXAMPLE

41
SANTOSH SWAR
Y X

(14 + 26)

Given Data

Roll weight = 2 T = 2000 kg

Intensity pressure = 5 kg/cm2
Face length = 220 cms
Cylinder bore (in cms) D = 25 cm

Distance from roll center to fulcrum = 26 

Piston rod dia (in cms) d = 5 cm

Distance from loading edge to fulcrum = 40


Now Area of cylinder is

(D – d ) -----
2 2

4
3.142
= (252 – 52) -----------
4
= 600 x 0.7855

= 471.3 cm2

Lever edge

Y (14 + 26) = X (26)

X 40
--- = ---- = 1.538
Y 26

Unit load on roll

42
SANTOSH SWAR
 Area of x Intensity x Lever x No.of  Roll weight
Cylinder pressure edge sides
= ------------------------------------------------------------------------------
Face length

471.3 cm2 x 5 kg/cm2 x 1.538 x 2 - 2000 kg

= ---------------------------------------------------------------
220 cm

7248 kg - 2000 kg
= -------------------------------
220 cm

5248
= ------ kg/cm
220

= 23.8 kg/cm

2)

Y |
1000 500

Given Data

Roll weight = 2 T (2000 kg)

Face length = 320 cms
Intensity pressure = 6 kg/cm2
Cylinder bore = 10 inch = 25.4 cm
Distance between loading edge to fulcrum = 1000 cms

43
SANTOSH SWAR
 
Distance between fulcrum to roll center = 500 cms

Are of cylinder D2 -----

4
3.142
2
= (25.4 cm) x ------------
4
= 645.16 x 0.7855 cm2
= 506.8 cm2

Lever edge

Y (1000) = X (500)

X 1000
---- = ------ = 2
Y 500

Nip load on press

Area of x Intensity x Lever x No.of  Roll weight

Cylinder pressure edge sides
= ------------------------------------------------------------------------------
Face length

506.8 x 6 x 2 x 2 + 2000
= ---------------------------------------------------------------
320

12163.2 + 2000
= ---------------------------------------
320

14163.2
= ---------- = 44.26 kg/cm
320

44
SANTOSH SWAR
62) MAXIMUM SPEED OF COUCH
Required Data

1) Dia of couch (d) (in metres)

Couch gear box pulley  ( Max. (in mm), Min. (in mm)
2) Couch gear box teeth details (ratio)

Line shaft couch cone pulley  ( Max. (in mm), Min. (in mm)
3)

Main motor pulley  (in mm)

4)
5)

Line shaft pulley  ( in mm)

6) Main motor RPM
7)

EXAMPLE

Main motor pulley  = 360 mm

Line shaft pulley  =

Main motor RPM = 1500
840 mm

360 x 1500
. . Line shaft pulley RPM = ----------------
840

= 642.8

Couch Gear Box pulley  Maximum = 760 mm Mean = 735 mm

Minimum = 710 mm

Shaft Couch Cone Pulley  , Max. = 460 mm Mean = 435 mm

Min. = 410 mm

 1.7
735
. . Ratio = -------- = 1.68
435

642.8
Hence gear box pulley RPM = ---------------- = 378.1
1.7
62
Gear box teeth details 62 & 19 i.e. -------- = 3.263
19
378.1
Gear box out put RPM = ---------- = 116 RPM
3.263

. . Speed of couch =  d x RPM

Now Dia of couch = 0.66 metres

45
SANTOSH SWAR
 = 3. 142 x 0.66 x 116
= 240 M/min.

63) WATER EVAPORATED AT DRYER

Final Dryness
Water evaporated at Dryer = -------------------- -1 Production
Initial Dryness

EXAMPLE

Let Final dryness = 95 %

Paper web entering the dryer
Section of dryness = 38 %
Production = 1200 kg/hr
95
Water evaporated at = ( ---- - 1) x 1200
Dryer/hr 38

= 1.5 x 1200
= 1800 kg
.
. . 1800 kg water evaporated at dryer Section for produce 1200 kg paper
in 1 hour.

64) FOURDRINIER SHAKE

Amplitude x (Frequency)2
Shake Number = --------------------------------
Wire speed

Where, Amplitude in inches

Frequency in strokes/minute
Wire speed in feet/minute

Optimum shake number is generally over 30 – 60

65) HEAD BOX APPROACH SYSTEM STOCK VELOCITIES

Stock flow (gpm)
V (fps) = -------------------- x 0.0007092
Pipe Radius (ft) 2

Stock flow (gpm)

46
SANTOSH SWAR
 = --------------------- x 0.321
Area of pipe (in2)

Acceptable Range 7 – 14 fps

66) “ L ” FACTOR (lbs. Paper / ft2 dryer surface /hour)

SW
“ L” Factor = -----------------
(“C” Value) N

Where,

L = # paper /ft2 dryer surface/hr

S = M/c speed (fpm)
W = Basis weight (lbs./3000 ft2)
N = Number of dryers

“C” Value
4 ft 628.3
5 ft 785.4
6ft 942.5

67) EVAPORATION RATE (lbs H2O/ft2 dryer surface/hour)

BD Out - BD In
Evaporation Rate (Ev) = L ( ---------------------------) BD Out
BD Out x BD In

Where,

Evaporation = # H2O /ft2 dryer surface / hr

BD = Percent bone dry

68) DEFLECTION OF A ROLL – OVER FACE

(Normally used for crown calculations)

47
SANTOSH SWAR
 | B |
| |
| |
| |
| |
| |
| F |
| | | |
| |
| |

WF3 (12 B – 7F)

d = ---------------------------
384 E I

Where,
d = deflection (inches) overface
W = Resultant unit load of shell (pounds/inch)
F = Shell face (inches)
B = Centerline to centerline bearings (inches)
E = Modulus of elasticity (lb/in2)
I = Moment of inertia (inches 4)
= 0.0491 ( Do4 - Di 4)
Do = Outside diameter (inches)
Di = Inside diameter (inches)

69) APPROXIMATE CRITICAL SPEED OF A ROLL

55.37 Do (0.9)
C.S. = -------------------

 d
_____

48
SANTOSH SWAR
 Where,

C.S. = Critical speed (fpm)

Do = Out side diameter of roll (inches)
d = Roll deflection (inches) over face due to roll weight only
(not to include externally applied forces)
(See previous formula)

70) RIMMING SPEED (5’ & 6’ dryers)

2160
Remming speed (fpm) = ( 5720 - -------- ) L 1/3
D

30000
0.33
Rimming speed (M/min) = (260 - -----------) L
D
Where D in mm
L in mm

Where, D = Inside diameter of roll (feet)

L = Condensate film thickness (feet)

71) NATURAL FREQUENCY OF SINGLE DEGREE OF FREEDOM

SYSTEM
3.127
F = ----------

 d
_____

Where F = Natural frequency (cycles/second)

d = Static deflection due only to weight of body
(No externally applied forces)

Wt.of dry material

72) Consistency = ------------------------------- x 100 %
Wt. of Suspension

49
SANTOSH SWAR
50
SANTOSH SWAR