ENGINE INSTALLATION & SERVICE HANDBOOK General Rules of Thumb Caterpillar

Direct injection engines

Hours Per:

Year = 8760 (365 Days)

Week = 168 (7 Days)

Month = 720 (30 Days)

Oilfield Drilling:

Hoisting

Mud Pumps

Rotary Table

On Site Power Requirements:

Based on 100,000 sq. ft. of office bldg., etc., and 40°N. latitudes

Electric Requirements:

Air Conditioning Compressor

Pumps:

Pipe Line BHP = Barrels per hour × psi × 0.00053

Refrigeration

One ton refrigeration = 200 BTU/Min. = 12,000 BTU/Hr.

One boiler HP = 33,475 BTU/Hr.

One ton compressor rating = One Engine HP

Auxiliary air conditioning equipment requires 1/4 HP per ton of compressor rating

Ice Plant:

Complete power requires 4-5 HP per daily ton capacity

Sawmill:

11/2 BHP per inch of saw diameter at 500 RPM

Increase or decrease in proportion to RPM

Swing Cut-Off Saw

Table Trimmer 71/2 to 10 BHP

Blower Fan 12-foot sawdust 3 to 5 BHP

Planer Mill 2 to 4 BHP per 100 board feet per hour 24 to 30-inch planers 15 to 25 BHP

Edgers

Approximate fuel consumption:

Softwood 1 gal. per 1000 board feet

Hardwood 1 gal. per 750 board feet

Propellor Shaft Size Selection:

For intermediate shaft and tailshaft in marine installations

Where: D = Diameter in inches

HP = Horsepower

S = Torsional stress in PSI (usually 5000)

Shovels and Draglines:

Use manufacturer's recommendations.

Torque: (4 cycle only)

Torque Converters:

Peak output shaft horsepower:

Normally 80% of input horsepower for either single or three-stage converter

Output shaft speed at peak output horsepower:

Single-stage - 0.7 to 0.85 engine full load speed

Three-stage - 0.5 to 0.6 engine full load speed

Torque multiplication at or near stall:

Single-stage - 2.2 to 3.4 times engine torque

Three-stage - 3.6 to 5.4 times engine torque

Ventilation:

Natural 1/2 net square inch for each BHP

Blown 1/3 net square inch for each BHP

Metric Units

Air Compressors:

110 kW = 1 m³/min @ 850 kPa

100 kW = 1 m³/min @ 675 kPa

90 kW = 1 m³/min @ 550 kPa

AMA Power for U.S.A. Tax Purposes:

Where: N = No. of Cylinders

D = Piston Diameter in millimeters

Brake Mean Effective Pressure:

Conveyors: 15 to 20° incline.

Cooling:

Heat Exchanger Flow Rate

Raw water to jacket water 1:1 to 2:1

Submerged Pipe Cooling

1 m² surface area per 16 kW with 30°C flowing raw water

Electricity:

Generator Capacity Required:

Motors:

11/3 kW per nameplate kW (motor running cool or warm to touch)

12/3 kW per nameplate kW (motor running hot to touch)

Engine Power Requirements:

Electric Sets:

Motor Starting Requirements:

Inrush kVa (Code F motor) = 41/8 × nameplate kW

Inrush Current (Code F motor) = 6.2 × full load rated current

11/3 kVa per kW at full load

Generator full load rated current capacity:

Generator Cooling Requirements:

Air Flow = 41/4 m³ per kW loss × efficiency

Circuit Breaker Trip Selection:

1.15 to 1.25 × full load generator amp rating

Single Phase Rating of 3-Phase Generator:

60% of 3-Phase rating

Generator Temperature Rise:

Increase 1°C for each 100 meters above 1000 meters

Fuel Consumption

³

Gas Compressor:

kW = 777 Rc VS

Where : Rc = Stage Compression Ratio

V = Millions cubic meters per day

S = Number of Stages

Heat Rejection:

Hours Per:

Year = 8760 (365 Days)

Week = 168 (7 Days)

Month = 720 (30 Days)

Oilfield Drilling:

Mud Pumps

Rotary Table

On Site Power Requirements:

Based on 10 000 m² of office bldg., etc. and 40°N latitude.

Electric Requirements:

Air Conditioning Compressor:

Pumps:

Deep Well kW = (meters of lift × L/min × 4640)

Pipe Line kW = L/H × kPa × 2 775 000

Refrigeration:

One ton refrigeration = 3.5 kW

One boiler hp = 9.8 kW

One ton compressor rating = 0.75 kW

Auxiliary air conditioning equipment requires 1/5 kW per ton of compressor rating

Ice Plant:

Complete power requires 3.25-4.25 kW per daily ton capacity

Sawmill:

1 kW per 20 to 25 mm saw diameter at 500 RPM

Increase or decrease in proportion to RPM

Swing Cut-Off Saw

Table Trimmer 51/2 to 71/2 kW

Blower Fan 4 meter sawdust 21/4 to 33/4 kW

Planer Mill 5-10 kW m³ per hour 600-750 mm planers 11 to 19 kW

Edgers

2 saws 9 to 11 kW

3 saws 11 to 19 kW

Slab saw 7.5 kW

Jack Ladder 7.5 kW

Approximate fuel consumption:

Shaft Size Selection:

For intermediate shaft and tailshaft in marine installations

Where: D = Diameter in millimeters

kW = Power in kilowatts

S = Torsional stress in MPa (usually 35)

Shovels and Draglines:

Use manufacturer's recommendations.

Torque: (4-cycle only)

Torque Converters:

Peak output shaft kilowatts:

Normally 80% of input power for either single or three stage converter

Output shaft speed at peak output kilowatts:

Single-stage - 0.7 to 0.85 engine full load speed

Three-stage - 0.5 to 0.6 engine full load speed

Torque multiplication at or near stall:

Single-stage - 2.2 to 3.4 times engine torque

Three-stage - 3.6 to 5.4 times engine torque

Ventilation:

Natural 41/2 cm²/kW

Blown 3 cm²/kW

English to Metric Conversion Factor

Energy

Power

Length

Volume and Capacity

Weight

Angle

Pressure and Head

Flow

Area

Temperature Conversion