CALCULATION FOR PLUG SCREW 100 TPD

Date: 15/12/06
Project Plug Screw 100
System Capacity TPD 105 Screw Deflection calculation
Equip Tag Plug Screw No. of flights 9
Material handled Pulp Stock Thickness of flights mm 10
Consistency % 30% 30% Weight of flights Kgs 50.64041171
Density Kg/cum 768 48 lbs/cuf Weight of pipe Kgs 61.5563586
Reqd capacity T TPH 4.375 2.92 TPH End shaft length mm 700
Reqd capacity-vol Q CuM/hr 14.583 540.0208333 cuft/hr End shaft dia mm 114
Screw diameter d mm 330 12.99212598 inch End shaft weight Kgs 57.15939338
Screw pitch p mm 240 9.448818898 inch Unit weight of Screw Kg/mm 0.081627228
Filling efficiency e % 90 50 % Pipe moment of inertia 6308301.522
Screw speed n RPM 94 10 6308301.522
Screw inclination I Deg. 0 0 Deflection mm 0.475766697
Inclination factor Fi 1 1
Screw length L mm 2775 9.25 FEET HANGAR BEARING NOT REQD !
Height of lift mm 0.0 0.0
Hollow shaft OD d1 mm 141.3 5.562992126 inch
Hollow shaft ID d2 mm 128.2 5.05 inch Deflection with hangar bearing
Calculated volume CuM/H 85.0927 3004.62166 cuft
Calculated capacity TPH 65.3629 1153.98124 Length of unsupported span 2500
Marrgin on capacity % 483.4925 No. of flights 14
POWER CALCULATION Thickness of flights mm 10
Weight of flights Kgs 78.23070499
Conveyor factor Fd 78 235 Weight of pipe Kgs 55.45617892
No. of hangar bearings 1 1 End shaft length mm 700
Hangar bearing factor Fb 1 4.4 End shaft dia mm 114
Flight factor Ff 1 1.2 End shaft weight Kgs 57.15939338
Material factor Fm 1 1 Coupling shaft length mm 575
Paddle factor Fp 2 2.2 Coupling shaft weight Kgs 46.95235884
Frictional HP HPf 0.293727 0.09565 Unit weight of Screw Kg/mm 0.095119454
Material HP HPm 2.619009 0.63229 Pipe moment of inertia 6308301.522
Lift HP HPl 0.000000 0.00000
Total HP HPt 2.912736 0.72794 Deflection mm 0.365204758
Overload factor Fo 1.50 1.50000
Calculated motor HP HP 4.37 1.16160
Selected motor KW 18.50

a 5 mm
b 5 mm
t 5 mm b
c 170 mm
g / feeder pipe dia 340 mm c
Area1 1.48205 M2
Area2 0.9435 M2
Weight of trough 97.6282 Kgs a a d2
Cover plate thickness 2.5 mm
Weight of cover plate 24.975 Kgs

Gear motor 37
Motor speed 1440 d1
Gear box ratio 56 d
Gear box output speed 25.7143 RPM g
Screw speed required 94 RPM (min.)
V.Pulley r. Ratio 2.2
Gear box pulley 330
Motor pulley 150

Note: Add weights for stiffeners, end plates, inlet & outlet nozzles, etc.

Page 1
For Stock only

Consistency 30%
Sample 1000 kgs
Stock 300 kgs
Water 990 kgs
Stock B D 962 kgs/CuM
Water Density 1000 kgs/CuM
Stock volume 0.312 Cu. M
Water volume 0.99 Cu. M
Total volume 1.302 Cu. M
Total weight 1000 Kgs
Bulk density of sample 768 Kg/CuM

Tube ID 0.355
Shaft OD 0.141
Cross Area 0.042
Volume 0.167

Velocity 5.836
Retn. Time 0.685

Page 2
Item : Inline Helical Gear Box
Model : AS 60 P12.6 P180 B5 B3
Input Power : 18.5 kW
Input Speed : 1400 RPM
Output : 111 RPM
Speed
Output : 970 NM
Torque
Output / : Solid Shaft
Input Shaft

Page 3
 Standard screw sizes and approximate capacities

Cap in CuM/hr @ 1 RPM @ 100 % filling CuM/hr at CuM/hr at

Screw size ERW shaft pipe sizes (NB) Max max RPM max RPM
Dia Pitch 65 80 100 125 150 200 250 RPM at 100% at 30%

250 250 0.654 0.632 0.571 - - - - 90 58.86 17.658

315 315 - 1.336 1.259 1.163 - - - 85 113.56 34.068
400 400 - - 2.729 2.606 2.465 - - 80 218.32 65.496
500 500 - - - 5.363 5.186 4.703 - 70 375.41 112.623
630 630 - - - - 10.87 10.26 - 56 608.72 182.616
800 800 - - - - - 22.15 21 36 797.4 239.22
1000 800 - - - - - 35.89 35 36 1243.44 373.032

Inclination factor for Maximum allowable spans

Inclined screw units for standard screw units
Angle of Correction Factor Screw Pipe Max Calculated
Inclination Fi Dia Size Span HP
mm mm NB M 0.25
0 Deg 1 65 4 0.5
2.5 Deg 0.95 250 80 4.5 0.75
5 Deg 0.9 100 5.5 1
7.5 Deg 0.85 80 4 1.5
10 Deg 0.8 315 100 5 2
12.5 Deg 0.75 125 5.5 2.5
15 Deg 0.7 400 100 5.25 3
20 Deg 0.65 125 6 3.5
25 Deg 0.6 500 125 5.75 4
150 6.5 4.5
Bearing Factor, Fb 125 5.5 >5
Ball 1 630 150 6
Babbit 1.7 200 7
Bronze 1.7 150 5
Oil-impregnated wood 1.7 800 200 6.5
Plastic 2 250 8
Nylon 2 ### 200 6
Hard iron 4.4 250 7

Screw diameter factor, Fd Flight factor Ff

Screw Dia Fd Flight Conveyor loading
(inch) type 15% 30% 45% 95%
6 18 Standard 1 1 1 1
9 31 Cut 1.1 1.15 1.2 1.3
12 55 Cut & fold - 1.5 1.7 2.2
14 78 Ribbon 1.05 1.15 1.2 -
16 106
18 135 Conveyor Frictional Material Max HP
20 165 size HP/M/RPM HP/M/RPM for std
24 235 mm HPf HPm @100% internals

250 5.33E-04 4.71E-03 10.9

Paddle factor Fp 315 7.94E-04 9.64E-03 17
Paddles per pitch set at 400 1.53E-03 1.96E-02 35
45 degrees reverse pitch 500 2.38E-03 0.038 49
None 1 2 3 4 630 4.62E-03 0.0784 76.1
Fp 1 1.3 1.6 1.9 2.2 800 6.35E-03 0.1598 182
1000 9.53E-03 0.2492 292

Page 4
 Dimensions & Weights of standard Pipes

Sch 10S Sch 20 Sch 40 Sch 80

Size O.D. Thk ID Weight Thk ID Weight Thk ID Weight Thk
mm NB mm mm mm Kg / M mm mm Kg / M mm mm Kg / M mm

15 21.3 2.11 17.08 1.00 2.77 15.76 1.27 3.73

20 26.7 2.11 22.48 1.29 2.87 20.96 1.69 3.91
25 33.4 2.77 27.86 2.09 3.38 26.64 2.5 4.55
32 42.2 2.77 36.66 2.69 3.56 35.08 3.39 4.85
40 48.3 2.77 42.76 3.11 3.69 40.92 4.05 5.08
50 60.3 2.77 54.76 3.98 3.91 52.48 5.44 5.54
65 73 3.05 66.9 5.26 5.16 62.68 8.61 7.01
80 88.9 3.05 82.8 6.45 5.49 77.92 11.29 7.62
90 101.6 3.05 95.5 7.41 5.74 90.12 11.57 8.08
100 114.3 3.05 108.2 8.37 6.02 102.26 16.07 8.56
125 141.3 3.4 134.5 11.56 6.55 128.2 21.77 9.53
Overload 150 168.3 3.4 161.5 13.82 7.11 154.08 28.26 10.97
Factor Fo 200 219.1 3.76 211.58 19.56 6.35 206.4 33.31 8.18 202.74 42.55 12.7
2.9 250 273.1 4.19 264.72 27.78 6.35 260.4 41.77 9.27 254.56 60.31 15.09
2.45 300 323.9 4.57 314.76 35.98 6.35 311.2 49.73 10.3 303.3 79.73 17.48
2.2 350 355.6 4.77 346.06 41.27 7.92 339.76 67.9 11.13 333.34 94.55 19.05
2.05 400 406.4 4.77 396.86 47.34 7.92 390.56 77.83 12.7 381 127.3 21.44
1.78 450 457 4.77 447.46 53.31 7.92 441.16 87.71 14.27 428.46 155.89 23.83
1.6 500 508 5.54 496.92 68.89 9.53 488.94 117.15 15.09 477.82 181.47 26.19
1.46 550 559 5.54 547.92 75.88 9.53 539.94 129.88 15.88 527.24 212.69 28.58
1.35 600 610 6.35 597.3 94.53 9.53 590.94 141.12 17.48 575.04 255.41 30.96
1.25
1.18
1.1 Standard motor ratings (KW)
1.1 Kw HP Kw HP Kw HP
0.12 0.16 3.7 5 55 75
0.18 0.25 5.5 7.5 75 100
0.25 0.33 7.5 10 90 125
0.37 0.5 11 15 110 150
0.75 1 15 20 132 180
1.1 1.5 22 30 160 220
1.5 2 30 40 200 270
2.2 3 37 50 250 340
3 4 45 60

Non- standard ratings (KW)

9.3 12.5 67 89.812
13 17.5 82 109.92
17 22.5 93 124.66
26 35 100 134
60 80.429 187 250.67
63 84.45 205 274.8

Page 5
Sch 80
ID Weight
mm Kg / M

13.84 1.62
18.88 2.2
24.3 3.24
32.5 4.47
38.14 5.41
49.22 7.48
58.98 11.41
73.66 15.27
85.44 18.63
97.18 22.32
122.24 30.97
146.36 42.56
193.7 64.64
242.92 96.01
288.94 132.08
317.5 158.1
363.52 203.53
409.34 254.55
455.62 311.17
501.84 373.83
548.08 442.08

Page 6
 FlightDev

Flight OD D 225 300

Pipe OD d 60.3 73.03 490
Pitch p 225 300 323.85
Q PI()*d 189.438037 229.4305115 300
S PI()*D 706.8583471 942.4777961 1017.40478087
z SQRT(p^2+Q^2) 294.13 377.67 1539.38040026
y SQRT(p^2+s^2) 741.804 989.072 1060.71
x (D-d)/2 82.35 113.485 1568.341
r1 (z*x)/(y-z) 54.11 70.1 83.075
R1 r1+x 136.46 183.59 173.59
d1 r1*2 108.21 140.2 256.66
D1 d1+2x 272.9101088 367.174815 347.18
D1 R1*2 272.9101088 367.174815 513.328898411
Angle a Deg. 48.526 51.32 513.328898411
9.896

Page 7
 FlightDev

D1

d1

Page 8
 PIPE SCHEDULE & WALL THICKNE
ANSI B 36 .10 - for carbon & alloy stee
ANSI B 36. 9 - for stainlees steel pip
NOM OUTSID SCH SCH SCH SCH SCH
PIPE DIA 5S 10S 10 20 30
SIZE thk wt/mtr thk wt/mtr thk wt/mtr thk wt/mtr thk wt/mtr
6 10.3 1.24
8 13.7 1.65
10 17.1 1.55
15 21.3 1.65 0.8 2.11 1 2.11 1
20 26.7 1.65 1.02 2.11 1.28 2.11 1.28
25 33.4 1.65 1.03 2.77 2.09 2.77 2.09
32 42.2 1.65 1.65 2.77 2.69 2.77 2.69
40 48.3 1.65 1.9 2.77 3.1 2.77 3.1
50 60.3 1.65 2.39 2.77 3.92 3.05 3.92
65 73 2.11 3.05 5.27 3.05 5.27
80 88.9 2.11 4.51 3.05 6.45 3.05 6.45
90 101.6 2.11 5.25 3.05 7.4 3.05 7.4
100 114.3 2.11 5.92 3.05 8.35 3.4 8.35
125 141.3 2.77 9.6 3.4 11.56 3.4 11.56
150 168.3 2.77 11.47 3.4 14.04 3.76 14.04
200 219.1 2.77 14.99 3.26 20.26 4.19 20.26 6.35 7.04
250 273 3.4 22.97 4.19 28.2 4.57 28.2 6.35 42.38 7.8 51.1
300 323.8 3.96 33.53 4.57 36.53 4.78 36.53 6.35 50.45 8.38 65.29
350 355.8 3.96 4.78 41.41 6.35 54.77 7.92 68.01 9.52 81.46
400 406.4 4.19 4.78 47.41 6.35 62.74 7.92 77.95 9.52 93.41
450 457.2 4.19 4.78 53.41 6.35 70.71 7.92 87.88 11.12 122.6
500 508 4.73 5.54 68.75 6.35 78.68 9.53 117.3 12.7 155.4
600 609.6 5.54 6.35 6.35 86.64 9.53 129.3 12.7 171.3

BLACK STEEL TUBES TO IS: 1239

LIGHT - CLASS "A" MEDIUM - CLASS "B" HEAVY - CLASS "C"

NOM OUTSID THK INSIDE Weight OUTSID THK INSIDE Weight OUTSID
PIPE DIA DIA Plain Scr/Soc DIA DIA Plain Scr/Soc DIA
SIZE End End End End
6 10.1 1.8 6.50 0.361 0.364 10.6 2 6.60 0.407 0.41 10.6
8 13.6 1.8 10.00 0.517 0.521 14 2.35 9.30 0.65 0.654 14
10 17.1 1.8 13.50 0.674 0.68 17.5 2.35 12.80 0.852 0.858 17.5
15 21.4 2 17.40 0.952 0.961 21.8 2.65 16.50 1.22 1.23 21.8
20 26.9 2.35 22.20 1.41 1.42 27.3 2.65 22.00 1.58 1.59 27.3
25 33.8 2.65 28.50 2.01 2.03 34.2 3.25 27.70 2.44 2.46 34.2
32 42.5 2.65 37.20 2.58 2.61 42.9 3.25 36.40 3.14 3.17 42.9
40 48.4 2.9 42.60 3.25 3.29 48.8 3.25 42.30 3.61 3.65 48.8
50 60.2 2.9 54.40 4.11 4.18 60.8 3.65 53.50 5.1 5.17 60.8
 65 76 3.25 69.50 5.8 5.92 76.6 3.65 69.30 6.51 6.63 76.6
80 88.7 3.25 82.20 6.81 6.98 89.5 4.05 81.40 8.47 8.64 89.5
100 113.9 3.65 106.60 9.89 10.2 115 4.5 106.00 12.1 12.4 115
125 140.8 4.85 131.10 16.2 16.7 140.8
150 166.5 4.85 156.80 19.2 19.8 166.5
CHEDULE & WALL THICKNESS
6 .10 - for carbon & alloy steel pipe
B 36. 9 - for stainlees steel pipe
SCH SCH SCH SCH SCH SCH
40S 40 60 80 80S 100
thk wt/mtr thk wt/mtr thk wt/mtr thk wt/mtr thk wt/mtr thk wt/mtr
1.73 1.73 2.41 2.41
2.24 2.24 3.02 3.02
2.31 2.31 3.2 3.2
2.77 1.27 2.77 1.27 3.73 1.62 3.73 1.62
2.87 1.68 2.87 1.68. 3.91 2.19 3.91 2.19
3.38 2.5 3.38 2.5 4.55 3.23 4.55 3.23
3.56 3.38 3.56 3.38 4.85 4.46 4.85 4.46
3.68 4.04 3.68 4.04 5.08 5.4 5.08 5.4
3.91 5.44 3.91 5.44 5.54 7.47 5.54 7.47
5.16 8.65 5.16 8.65 7.01 11.43 7.01 11.43
5.49 11.27 5.49 11.27 7.62 15.25 7.62 15.25
5.74 13.55 5.74 13.55 8.07 18.6 8.07 18.6
6.02 16.06 6.02 16.06 8.55 22.29 8.55 22.29
6.55 21.75 6.55 21.75 9.53 30.92 9.53 30.92
7.11 28.23 7.11 28.23 10.97 42.51 10.97 42.51
8.18 42.48 8.18 42.48 10.31 53.16 12.7 64.56 12.7 64.56 15.06 75.89
9.27 61.2 9.27 61.2 12.7 81.66 15.06 95.96 15.06 81.66 21.41 114.8
9.53 74.92 10.31 79.84 14.27 109.1 17.45 132.1 17.45 97.16 21.41 159.5
9.53 81.46 11.13 94.69 15.06 126.7 19.05 158.4 19.05 107.6 23.8 195.1
9.53 93.41 12.2 123.5 16.66 160.4 21.41 203.6 21.4 123.5 26.19 246
9.53 105.4 14.27 156.1 19.05 206.2 23.8 254.8 23.8 139.4 29.36 310.3
9.53 117.3 15.06 183.4 20.62 248.2 26.19 311.7 26.19 155.4 32.54 382.1
9.53 129.3 17.45 255.2 22.22 294.2 28.57 374.2 30.94 171.3 38.89 451.9

HEAVY - CLASS "C"

THK INSIDE Weight
DIA Plain Scr/Soc
End End
2.65 5.30 0.493 0.496
2.9 8.20 0.769 0.773
2.9 11.70 1.02 1.03
3.25 15.30 1.45 1.46
3.25 20.80 1.9 1.91
4.05 26.10 2.97 2.99
4.05 34.80 3.84 3.87
4.05 40.70 4.43 4.47
4.5 51.80 6.17 6.24
 4.5 67.60 7.9 8.02
4.85 79.80 10.1 10.3
5.4 104.20 14.4 14.7
5.4 130.00 17.8 18.3
5.4 155.70 21.2 21.8
SCH SCH SCH XXS
120 140 160 STRONG
thk wt/mtr thk wt/mtr thk wt/mtr thk wt/mtr

4.75 1.94 7.47 2.55

5.54 2.88 7.82 3.64
6.35 4.23 9.09 5.46
6.35 5.6 9.7 7.78
7.14 7.23 10.16 8.03
8.71 11.07 11.07 13.43
9.52 14.94 14.02 20.43
11.12 21.31 15.24 28.13
16.15 34.08
11.12 28.36 13.49 33.49 17.12 41.09
12.7 40.34 15.88 49.19 19.05 57.52
14.27 54.28 18.24 68.58 21.95 79.33
18.24 90.48 20.62 101.1 23.01 111.4 22.23 108.1
21.41 130.1 25.4 155.4 25.58 172.6 25.4
25.4 187.2 28.58 208.4 33.32 239.1 25.4
27.76 224.8 31.75 254 35.71 282.2
30.94 286.9 36.53 333.7 40.46 365.7
34.92 364.3 39.67 409.1 45.24 460.3
33.1 388.3 44.45 508.9 49.99 565.5
41.27 527.6 52.37 601.3 53.97 733.8
pipe sch qty(mts) wt/mtr tot wt. cost/mtr tot cost
100 40 140 16.06 2248.4 400 56000
 STEAM FLOW REQUIREMENT

SIZE SELECTION BASED ON WATER LIKE PRODUCT FLOW

Steam flow required QX T X0.43 lb/hr

14.58333 M^3/hr
Q Liquid flow 38.65 USGPM 0.243056 M^3/min
Rise in temperature 131 F 55 C
2177.155 lb/hr
987.8196 Kg/hr 987.81
16.46366 Kg/min 0.43
2297.233
steam @ header 1.5 bar 2800 kg/hr as approved by DGM
branches 8 nos

steam pipe sizeing from engineering power tools

as approved by DGM