CONVERSION FACTORS

1 HP =
1 HP =
1 HP =

33,000 ft.lbs/min
746 Watts
42.4 BTU/Min.

550 ft lbs/sec

Amps
-------------------------746
(---------------------------- )
Volts x decimal efficiency

Electric HP =

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
-------3000 ft2

F
C

grams
1.64 ---------Meter2

9
= ---- C + 32
5
5
= (F 32) x ----9

1
SANTOSH SWAR

BASIS WEIGHT CONVERSIONS

Offset (3300 ft2) x 1.48
Bond (1300 ft2) x 3.76
Liner (1000 ft2) x 4.89
News (3000 ft2) x 1.63

=
=
=
=

GSM
GSM
GSM
GSM

CONVERSION FACTORS
FROM
lb
in
in
in
ft/min (fpm)
cfm
cfm/in
cfm/in2
cfm/in2/1000 fpm
oz
oz/ft2

TO OBTAIN
kg
mm
cm
m
m/min (mpm)
m3/hr
m3/hr/cm
m3/hr/cm2
3
m /hr/cm2/100 mpm
g
g/m2

MULTIPLY BY
0.454
25.4
2.54
0.0254
0.305
0.589
0.232
0.91
0.278
28.3
305.6

1) M/C PRODUCTION CALCULATION

Let

M/c
M/c

speed in
Deckle in

mt/min
mt

SPEED x DECKLE x GSM x

60
2
(mt/min)
(mt)
(Gm/mt ) (min/hr)
M/C PROD = -----------------------------------------------------(Tons/Hr)
1000000
(Gm/Ton)

M/C PROD
(Tons/hr)

Speed x Deckle x GSM x 60

---------------------------------------106

EXAMPLE
Let

M/c Speed
Deckle
GSM

=
=
=

200 mt/min
3.2 mt
50

2
SANTOSH SWAR

.
. . M/C PROD =

200 x 3.2 x 50 x 60
------------------------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
GSM
No.of sheets

=
=
=

40 cm x 60 cm
50
500

3
SANTOSH SWAR

Ream Weight

40 x 60 x 50 x 500
-------------------------107

60000000
= ---------------107
= 6 kg

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

GSM =

Where,

W
l
b

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

Weight of paper in gms.

Length of paper in cms.
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

GSM =

10000 x 0.72
--------------------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

1 cm2

0.72
-----150

0.0048 gms

0.0048 gms

0.0048 gms

1 cm2

1
---------- m2
10000

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

1 cm2
1
--- m2
104
1 m2
1 m2

5.8
-------- gms
1000
0.0058 gms

0.0058 gms

=
=

0.0058 x 104 gms

58 gms

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SANTOSH SWAR

4) THEORETICAL HEAD
V
----100
-------------K

Theoretical Head =

Where, V
K
Head
K

5)

Spouting velocity (fpm)

Constant (see table)

In of H2O
1.932

Ft of H2O
23.184

In of Hg
26.345

Pressure PSIG
53.623

In of Hg
513.3

Pressure PSIG
732.3

SPOUTING VELOCITY
V
Where, V
h
k
Head
K

6)

=
=

= k
=
=
=

h
Spouting velocity (fpm)
Theoretical head
Constant (see table)

In of H2O
139.2

Ft of H2O
481.5

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 ------------3600 sec2

2038.74
----------3600

=
=

0.5663 m
56.63 cm

. .
1 min2
. = 1 min x 1 min
= 60 sec x 60 sec
3600 sec2

Short Method
200 x 200
------------2 x 9.81

m2
------ x
min2

200 x 200
------------2 x 9.81

m x sec2
------------min2

200 x 200
-------------2 x 9.81

100 cm x sec2
-----------------3600 sec2

h =

sec2
------m

7
SANTOSH SWAR

200 x 200 x 100

---------------------- cm
2 x 9.81 x 3600

200 x 200
----------- cm
706.32

.
.

100
. --------------------- = 706.32
2 x 9.81 x 3600

56.63 cms.

QUICK FORMULA
Speed x Speed
h = -------------------(in cms)
706.32

Where h in cms
Speed = in m/min.

EXAMPLE
M/c Speed
1) 180 M/min ,

180 x 180
h = -------------- = 45.87 cms
706.32

2) 200 M/min ,

h =

200 x 200
------------ = 56.63 cms
706.32

3) 250 M/min ,

h =

250 x 250
------------ = 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.

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SANTOSH SWAR

8) JET VELOCITY CALCULATION

(Stock speed at slice)
Jet Velocity
______
V = Cv 2 gh
Where, V
Cv
g
h

=
=
=
=

Stock speed at slice

Coefficient of velocity discharge
Acceleration due to gravity
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

V

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

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

( . . 100 cm = 1 m

1
1 cm = ------- M )
100

9
SANTOSH SWAR

Similarly 3600 sec2 = 1 min2

1 Sec2 =

1
------ 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

Jet Velocity
(In m/min)

____________
= Head x 706.32
(in cms)

EXAMPLE
1) h = 46 cms,

2) h = 89 cms,

____________
V = 46 x 706.32
_________
= 32490.72
= 180.25 M/min
___________
V = 89 x 706.32
_________
= 62862.48
= 250.72 M/min

10
SANTOSH SWAR

9) CRITICAL SPEED OF CALENDAR ROLL (fpm)

Ro
___________
C.S. = 4.12 x 106 x ----- Ro2 + Ri2
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
1)

Net consistency
Retention % = -------------------------- x 100
Head box consistency

Head box consistency - Tray consistency

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

3) Overall Retention =

Filler in sheet
----------------------------- 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
_____
Cq As
2 g h where, Cq = Coefficient of volume
discharge.
______
Q = Cq As 2 g h
11
SANTOSH SWAR

12) FLUID VELOCITY

Velocity =

GPM x 0.321
-----------------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

RPM =

Where,

3.82 ( V )
------------Do

RPM =
V
=
Do
=

revolutions per minute

Speed (fpm)
Roll outside diameter (inches)

14) FORMING BOARD SETTING

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

X =

Where,
X
V
A
g
h

=
=
=
=
=

Distance of slice to lead forming board blade

Initial Jet Velocity
Jet angle
32.2 ft/S2
Jet to wire height

12
SANTOSH SWAR

15) WATER REMOVAL BY A TABLE ROLL

1st Method
DU K
q = -------F2
Where,
q
=
D
=
U
=
F
=

Water removed by a table roll per unit time & width

Diameter of roll
Wire speed
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.
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
B

Wire

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

R
g
h
V

=
=
=
=

Drainage coefficient (dependent on the sheet weight & type of

wire)
Radious of the roll
Acceleration due to gravity
Head of stock suspension above the wire
Velocity of the wire

13
SANTOSH SWAR

16)

VACUUM PUMP CAPACITY (CFM)

PV

nRT

Where,
P
V
n
T
R

=
=
=
=
=

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

Total gas volume, ft3
Weight of gas, lbs
Absolute temperature
R = F + 460
Gas constant, lbf x ft / (lbn x R )
Ra (air)
=
53.3
Rw (water)vapour
=
85.8

P1V1

P2V2

V2

29.92 - P1 ( Hg)
----------------------- x V1 (CFM)
29.92 - P2 ( Hg)

or for temperature cooling effects :

P1V1
------T1

P2V2
------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
= K ------(t 100)

Where,
L

Peripherial length in meters of dryers in contact with paper

During drying.
14
SANTOSH SWAR

K
S
W

=
=
=

d
t

=
=

Constant value around 0.05

Speed of M/c in M/min
Basis weight of paper in gm
---m2
Thickness of dryer shell in centimeters
Temperature of ingoing steam in C

EXAMPLE
Let

M/c speed
S
=
180 M/Min
GSM W
=
50
Dryer shell thickness d = 2.2 cm
t
=
150 C

L =

0.05 x 180 x 50 x 2.2

-----------------------------(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
S.O.
C

=
=
=

Spouting velocity (fpm)

Slice opening (inches)
Orifice coefficient
(see table for approximate values)

Type
Nozzle
A
B

C
0.95
0.75
0.70
15
SANTOSH SWAR

Type

0.60

A) Low angle,
Converflo

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
----- = 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

Hourly production

400
-----24

Tons/hr

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 ( ---37

__

1)

Dryer surface required @ 2.8 lb water/hr/ft2

Evaporation rate
Required dryer surface

51350
-------2.8

= 18339 ft2

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
-------262

= 69.99 = 70 dryers

20) PRESS IMPULSE

5 x PLI
17
SANTOSH SWAR

PI = --------Speed
Where, PI
=
PLI
=
Speed =

Press impulse (Psi Sec)

Nip pressure (Pli)
Nip speed (fpm)

21) TORQUE
Tq = Force x Radius
Where Tq
=
Force =
Radius =

Torque (inch pounds)

in pounds
in inches

22) WR2 OF A ROLL

WR2 = (0.000682) (W) (L) (Do4 Di4)
Where, WR2
W
L
Do
Di

=
=
=
=
=

in (lbs ft2)
Density (pounds/inches 3)
Length (inches)
Outside diameter (inches)
Inside diameter (inches)

23) STOCK FLOW THROUGH THE PIPE CALCULATION

Q

Vrc

Where, Vrc
Q
d

24)

=
=
=

1
----4

d2 x Vrc

4Q
---- d2

Velocity of flow
Total quantity
Pipe diameter

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
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 making 50 gsm at 0.6 %
slurry and Jet/Wire ratio of 0.95.

R =

0.0050
-------------------------------( 0.0060 ) x 1.6 x 0.95

= 73 %

26) CALCULATION OF WIRE LENGTH

Ls = 2 l +

Where, Ls
l
D1
D2
K
EXAMPLE
L
D1

---- (D1 + D2) + K

2

=
=
=
=
=

Length of wire (in mm)

Distance between center of breast roll to couch roll (in mm)
Diameter of breast roll (in mm)
Diameter of couch roll (in mm)
A constant, 130 mm for fourdrinier wire part.

=
=

12,500 mm
450 mm
19
SANTOSH SWAR

D2

Then Ls

800 mm
=
=
=
=
=

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

Suction Couch
Drive Power = VOLT x AMP

DRAG LOAD =

0.8
---------1000

VA
------UW

Kilonewtons
----------------Meter

Where
V
A
U
W

=
=
=
=

Volt
AMP
Fabric speed (M/S)
Fabric width (M)

lb
{ To convert in ------ ,
in

KN
------- x 5.71
M

lb
-------- }
inch

b) DRAG LOAD - CONVENTIONAL

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

DL in Pli

Wehre,
V

Drive volts (V)

20
SANTOSH SWAR

A
U
W

c)

=
=
=

Drive AMPs (AMPS)

Nominal fabric speed (fpm)
Nominal fabric width (inches)

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 = (---Vs

__

1)

(EM + Ts)

Where,
DL
Vn
Vs
EM

=
=
=
=

Drag load (Pli)

Fabric speed at point n in fabric run (fpm)
Fabric speed on slack side of fabric run (fpm)
Fabric elastic modulus (young) at temperature

EMr

T ~ EMr KT
Elastic modulus at reference temperature r (Pli)

Modulus
------------------------Temperature constant

Ts

Slack side tension (Pli)

Pli
(----- )
F

21
SANTOSH SWAR

29) DANDY DIAMETER CALCULATION

1) Open type
15 20 % of wire width

2) Journal typs
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 =

V
D = -------n
Where,

D
V
n

=
=
=

Diameter in mm
M/c speed in m/min
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
400
D = ------477
Wire Speed (m/min)
Dia of dandy (in mm)

V = 400 m/min

= 850 mm

80
300

150
400

250
500

300
600

400
800-1000

22
SANTOSH SWAR

30) DANDY ROLL REVOLUTION PER MINUTE

Wire Speed (fpm)
RPM = --------------------------------------- x Dandy roll diameter (ft)
Where = 3.142
RPM Target = 125 150 RPM

31) SIZE PRESS ROLL REVOLUTION PER MINUTE

RPM =

Web Speed (fpm)

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

Maximum 250 rpm

32)

TONS PER DAY (T/D)

T/D =

Capacity (gpm) x % Bone dry consistency

-----------------------------------------------------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 = ------------1440 min

= 22.9 kg/min

Bs factor = 1.45 (68.9 wire retention

100
------68.9

= 1.45)

Bs factor x prod.
22.9 x 1.45 =
10 % reject =
5 % vent reject=

33.22
3.32
1.66
----38.20

kg/min
kg/min
kg/min
kg/min

kg/min x 100
38.20 x 100
Now LPM = ------------------ = ------------------ = 4775 lpm
Consistency
0.8
Through put/leg

= 500 lpm

No of legs required

Primary legs
Secondary legs
Tertiary legs

4775
--------500
=
=
=

= 9.55 = 10 legs

10 Nos.
3 Nos. (30 % of primary legs)
1 No. (30 % of secondary legs)

Pressure drop = 1.4 kg/cm2

WEIR FLOW
CONTRACTIONS

34)

RECTANGULAR

WEIR

WITH

END

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

Where,

35)

H
a

=
=

Length of weir opening in feet

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

WEIR FLOW TRIANGULAR NOTCH WEIR WITH END

CONTRACTIONS
24
SANTOSH SWAR

4
______
Q = C ( -----) L H 2 gH
15
Where L
H
C
a

=
=
=
=

Width of notch in ft at H distance above apex

Head of water above apex of notch in feet
0.57
Should be not less than 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
DA
DW
U
t
P
P

=
=
=
=
=
=
=

Wasted volume (in ft3/min. or m3/sec)

Drilled Area (in %)
Drilled width (in inch or M)
Machine speed (in ft/min. or M/minute)
Shell Thickness (in inch or cm)
Suction Pressure (couch vacuum) in inch Hg)
Pressure (in inch Hg)

EXAMPLE

Wv

DA
DW
U
t
P
P

= 50 %
= 286 inch
= 300 fit/min
= 2.5 inch
= 24 inch Hg
= 30 inch Hg

=
or
or
or
or
or

DA x DW x U x t

50/100
= 0.5
7.26 M
914.6 M/min
6.35 cm. Or 0.0635 M
81.3 K Pa
101.6 K Pa
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
= 0.5 x 7.26 M x ------------ ------- x
60
Sec

6.35
---------- M x 0.8
100

= 2.81 m3/S

37) COUCH VACUUM EXPANSION VOLUME

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

=
=
=
=

P2
P1

=
=

M/c speed, fpm

Roll shell face width, feet
Hole depth, feet
% Open area of shell
P2
Expansion factor, -----P1

0.9

-1

ambient pressure, Hg absolute

Suction box vacuum, Hg absolute
26
SANTOSH SWAR

38)

FORMATION BLADE PULSE FREQUENCY

F

V
------5x

Where,
F
V

= Formation blade pulse frequency

(in cycle/sec)
= Wire speed (fpm)
= blade spacing, tip to tip (inches)

Optimum frequency for formation improvement

F > 60 cycle/sec

39) PAPER WEB DRAW

Draw (%) =

Where, SF
S1

SF S1
-------------- x 100
S1

=
=

Final Speed, fpm

Initial Speed, fpm

40) EFFLEX RATIO CONCEPT

ER

SLICE JET SPEED

-----------------------WIRE SPEED

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

EXAMPLE :
Let M/c speed
Head in the head box
.
. .

Slice jet speed

=
=

200 M/min
50 cms

50 x 706.32

35316
187.9 = 188 M/min.

27
SANTOSH SWAR

ER

Slice Jet Speed

------------------M/C Speed
188
--------200

0.94

JET VELOCITY VS WIRE SPEED

IF
IF
IF

Jet velocity > Wire speed

Jet velocity < Wire speed
Jet velocity = Wire speed

Floading problem
GSM drastically changed
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
Coated & supered
Coated only
News print

Density lb/ in3

0.042
0.038
0.023
28
SANTOSH SWAR

Fine paper
Liner board
Board (coated)

0.029
0.024
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
-------------mm

m2

m3

0.001 kg
--------------m2 x .001 m

Kg
m x -------m3
3

. . 1 GM = .001 kg
1 mm = .1 cm
= .001 m

= kg

EXAMPLE
Let a parent roll of deckle 3 meter.
GSM
=
50
Thickness
=
0.075 mm
29
SANTOSH SWAR

.
. .

50
= ------ = 666.67 kg/m3
0.075

AD

(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

HP

Where,

T
N

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

torque (inch pounds)

speed (rpm)

45) TENSION HP
Tension HP

fpm x Pli x inches of width

----------------------------------------33,000

46) APPROXIMATION FOR VACUUM COMPONENT IN PLI WHEN

TAKING NIP IMPRESSIONS (Pliv).
30
SANTOSH SWAR

Pliv

Vacuum box width x Vacuum

--------------------------------------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
KWH =

Where

3 V I COS
----------------------------1000

V
=
I
=
COS =

Input voltage (in volt)

Current (in Amp)
Power factor

EXAMPLE
If 10 KW motor taking load 12 Amp
Input voltage V
=
410 V
COS
=
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

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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)

GPM/inch =

( B.D. Ton/24 hr/in) (16.76) (1.5 Tray Consistency)

---- ------------------------------------------------------------1.5 x Net consistency

Where,
Net consistency = Head box consistency - Tray consistency

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

GPM/inch

T.O.
V

=
=

T.O x V
----------- =
19.25

T.O. x V x 0.0052

Throat opening (inches)

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=
C=
D=
d=

Requisite length of the belt

Distance from the center
Diameter of the larger pulley
Diameter of the smaller pulley

Length of Open Belt

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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
Volume
1 US Gallon
% B.D.

=
=
=
=

Weight of dry stock at % consistency

Volume of tank in cubic feet
2.31 Cu.inches
Percent consistency of stock

33
SANTOSH SWAR

53) LOAD FACTOR OF WIRE

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

(.

. F = b.L. )
.

Where,
Ph
F
b
L

=
=
=
=

Production of paper/hr
(in kg/hr)
Working surface of paper m/c wire
Working width of paper web on the wire (in m)
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
Ne
Nc
D1
D2
OR

=
=
=
=
=

Change in total crown of two rolls (inches)

Nip width at the ends (inches)
Nip width at the center (inches)
Top roll diameter (inches)
Bottom roll diameter (inches)

if rolls have equal diameters

C =

Ne2 - Nc2
-------------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
Ne
D

=
=
=

0.7 inches (17.8 mm)

0.9 inches (22.9 mm)
30 inches (762 mm)

(0.9)2 - (0.7)2
C = ------------------30

0.81 - 0.49
-----------------30

0.32
= -----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

H = K x 0.0915 x C

1.89

x Q

0.364

L1
--------- +
D1 2.06

L2
--------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
V
F

=
=
=

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

The vacuum level, in inches (mm) of mercury.
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

bo

Where, bo
P
C2

=
=
=

C3
=
FUN =
V

P x C2 x C3 x 1000
---------------------------FUN x V
Belt width
Kilowatt of motor
Over load factor
(50 % of normal load of motor)
For paper Industry C2 = 1.2 (constant factor)
Ratio between both pulley
Belt type
i.e. 40
(40 means 1 cm of belt take 40 kg load)
Belt speed
d1 x n1
V
=
----------- m/sec
19100
d1
n1

=
=

pulley dia
Motor rpm

(For cone pulley C3 is not required)

58)

% WEAROUT OF WIRE
1) For single layer synthetic wire
Original caliper - Average used caliper
% Wear = --------------------------------------------------- x 100
0.7 x Weft
2) For double layer synthetic wire
Original caliper - Average used caliper
% Wear = --------------------------------------------------- x 100
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SANTOSH SWAR

0.85 x Weft
3)

For Metal wire

Original caliper - Average used caliper
% Wear = --------------------------------------------------- x 100
0.7 x Wrap

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
Average used caliper
Weft

=
=
=

0.565 mm
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,

Grade
Liner board
Bond
Cover
Index
Bristol
Offset
Manuscript
Wrapper
News print

Production
Factor
Speed
Deckle
Basis weight

=
=
=
=
=

lbs/hour
From table
Feet/minute
inches at reel
lbs/ream

Ream size

No.of sheets

17 x 22
20 x 26
25 x 30
22 x 28
25 x 38
18 x 31
24 x 36
24 x 36

500
500
500
500
500
500
480
500

Ft2/Ream
1000
1300
1805
2700
2110
3300
1948
2880
3000

Factor
0.005
0.00385
0.00277
0.00185
0.00225
0.00152
0.00258
0.00174
0.00167

37
SANTOSH SWAR

60) M/C EFFICIENCY CALCULATION

M/C Efficiency =
(%)

Total Actual Prod. (MT)

---------------------------------- 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
Production
(T)
2T
11.3 T
5.4 T
12.7 T

GSM

Speed

Deckle

Total Running Efficiency

Time (in min.)
(%)

54
65
60
50

170
155
160
180

3.04
3.05
3.08
3.04

1.15 = 75
6.10 = 370
3.05 = 185
9.00 = 540

95.55
99.39
98.72
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

2
2
This is D ----- or (D d ) ----4
4
2

1)

Fulcrum
Air for
Loading

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

2)

Air for

Here Area of

Loading

cylinder is D --4
2

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)

X
1000

500

Y ( 1000) = X (500)

40
SANTOSH SWAR

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

= 2

2)

X
14

26

(14 + 26 )
Y (14 + 26 )

X
---Y

X (26)
40
----26

= 1.538

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,

So roll weight is -ve.

Here loading roll is on upper side,

So roll weight is +ve.

EXAMPLE

41
SANTOSH SWAR

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
Piston rod dia (in cms)
d
= 5 cm
Distance from roll center to fulcrum = 26
Distance from loading edge to fulcrum = 40

Now

Area of cylinder is

2
2
(D d ) ----4
3.142
= (252 52) ----------4
= 600 x 0.7855
= 471.3 cm2

Lever edge
Y (14 + 26)
X
--Y

= X (26)
40
---26

= 1.538

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
-----220

23.8 kg/cm

kg/cm

2)

|
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
---Y

1000
-----500

= 2

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
---------320

= 44.26 kg/cm

44
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62) MAXIMUM SPEED OF COUCH

Required Data
1)
2)
3)
4)
5)
6)
7)

Dia of couch (d) (in metres)

Couch gear box teeth details (ratio)
Couch gear box pulley ( Max. (in mm), Min. (in mm)
Line shaft couch cone pulley ( Max. (in mm), Min. (in mm)
Main motor pulley (in mm)
Main motor RPM
Line shaft pulley ( in mm)

EXAMPLE
Main motor pulley =
Main motor RPM
=
Line shaft pulley =

360 mm
1500
840 mm

360 x 1500
. . Line shaft pulley RPM = ---------------840
= 642.8
Couch Gear Box pulley Maximum = 760 mm
Minimum = 710 mm
Shaft Couch Cone Pulley , Max. = 460 mm
Min. = 410 mm
735
. . Ratio = -------- = 1.68
435

Mean = 735 mm

Mean = 435 mm

1.7

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
Now Dia of couch = 0.66 metres
. . Speed of couch = d x RPM
45
SANTOSH SWAR

= 3. 142 x 0.66 x 116

= 240 M/min.

63) WATER EVAPORATED AT DRYER

Water evaporated at Dryer =

Final Dryness
-------------------- -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

Shake Number =

Where,

Amplitude x (Frequency)2
-------------------------------Wire speed

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

V (fps) =

Stock flow (gpm)

-------------------- 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
S
W
N

# paper /ft2 dryer surface/hr

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

=
=
=
=

4 ft
5 ft
6ft

C Value
628.3
785.4
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

|
|
|
|
|
|
|
|
|
|

F
|

|
|
|
|
|
|
|
|
|
|

d
WF3 (12 B 7F)
d = --------------------------384 E I

Where,
d
W
F
B
E
I
Do
Di

=
=
=
=
=
=
=
=
=

deflection (inches) overface

Resultant unit load of shell (pounds/inch)
Shell face (inches)
Centerline to centerline bearings (inches)
Modulus of elasticity (lb/in2)
Moment of inertia (inches 4)
0.0491 ( Do4 - Di 4)
Outside diameter (inches)
Inside diameter (inches)

69) APPROXIMATE CRITICAL SPEED OF A ROLL

C.S.

55.37 Do (0.9)
------------------_____
d

48
SANTOSH SWAR

Where,
C.S.
Do
d

70)

=
=
=

Critical speed (fpm)

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

RIMMING SPEED (5 & 6 dryers)

2160
Remming speed (fpm) = ( 5720 - -------- ) L 1/3
D
30000
Rimming speed (M/min) = (260 - -----------) L
D
Where D in mm
L in mm
Where, D
L

=
=

0.33

Inside diameter of roll (feet)

Condensate film thickness (feet)

71) NATURAL FREQUENCY OF SINGLE DEGREE OF FREEDOM

SYSTEM
3.127
F = ---------_____
d
Where

F
d

=
=

Natural frequency (cycles/second)

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