useful information for foundrymen

WHITINGMETALLURGICAL EQUIPMENT SYSTEMS

A complete line of Ferrous Melting Equipment With Material and Hot Metal Handling Equipment Engineered for the job.

Copyright 2004, by Whiting Equipment Canada Inc., Welland, Ontario, L3B 5P4

To Our Friends in the Metal Casting Industry:The information herein is revised periodically to include the most current practical data useful to the people in the Metallurgical Industry. Data is included on Induction Furnaces to complete the line of melting and metal handling equipment covered herein. We hope you find this useful. For more information or additional copies of this booklet, please contact us.

Metallurgical Equipment Division WHITING EQUIPMENT CANADA INC.Welland, Ontario, Canada +1 905-732-7585

POINTS TO CONSIDER IN PLANNING NEW CUPOLA INSTALLATION

Tonnage Requirements Mechanical charging Air weight control and recording Hot blast system Moisture control Water cooling for heats of 16 hours and over Slag Handling and Disposal Front slag spout for continuous tapping, lower carbons and higher temperatures Insulated mixing and desulphurizing ladle, forehearth, or duplexing furnace Cupola service platform at charging door Height of charging opening Tappers platform Cast iron block lining at charging zone Blower capacity Facilities for removing bottom drop Bottom door hoist Weighing and recording of charge materials Emission Control Equipment Roof hood Ample height of cupola legs to allow for mixing ladle, forehearth or duplexing furnace Automatic gas vents in wind box Safety Overflow Spout

Page 2

POINTERS ON CONVENTIONAL CUPOLA OPERATION1. AIR SUPPLYMake sure that the blower or fan is in good operating condition, particularly the bearings. Check the air line from blower to windbox for possible leaks. Check air losses with the air circuit under pressure. Check function and calibration of air weight controller.

2.

LINING

Check for proper repair after each heat. See that all slag adhering after the heat is removed and worn spots patched up. Lining should be repaired to a true circle at all times.

3. 4.zero.

BOTTOM PLATE AND DOORSInspect frequently for distortion or cracks.

BLAST PRESSURESee that the pressure gauge is working correctly and that it registers zero when the pressure is actually

5. 6. 7.

SAFETY SPOUTMake sure that the lead disc is in place and clear from sand and clay.

TAP HOLE AND SLAG HOLEThese should be maintained at the desired size and positions.

TUYERES

Tuyeres should fit tight against the shell to minimize air leakage. These joints should be regularly inspected and kept sealed with suitable refractory.

8.

SCALES

Scales for weighing up charges should be checked frequently. We recommend separate scales for metallic charges and for coke and stone.

9.

CHARGES

Keep close tab on the charge makeup. See that proper amounts of pig, scrap, coke, and flux are delivered to the cupola as called for by the metallurgist. Check the tares for buckets and harrows used in making up charges.

10.

SIZE OF MATERIALS

Pig iron as well as scrap should not be larger than 1/3, and the coke from 1/10 to 1/12 of the inside diameter of the cupola.

11.

TEMPERATURE

Check metal temperatures with pyrometer. Know what you are getting. Have pyrometer checked for accuracy.

12.

ANALYSIS

Analyze all materials going into the cupola, also the test bars from every heat. Make chill tests frequently.

13.

LOGInsist on an accurate record of every heat.

NOTE: Heavy exhaust systems in the foundry may create a partial vacuum condition, causing a down draftthrough the cupola stack. The cupola building should be properly vented.

Page 3

APPOXIMATE MELTING RATES IN TONS PER HOUR FOR WHITING LINED CUPOLAS (Uninterrupted Operation)Area Inside Lining Sq. In. 254 415 573 573 804 1075 1385 1590 1810 2290 2827 3421 4072 4778 4778 5542 Theoretical Air Flow thru Tuyeres SCFM 573 937 1293 1293 1815 2426 3126 3589 4085 5170 6380 7720 9190 10790 10790 12510 Recommended Blower Cap'y. Volume ICFM 640 1040 1430 1430 2000 2700 3450 4000 4500 5750 7100 8600 10200 11900 11900 13900 Pressure 2* oz./in. 8 16 20 20 24 24 24 28 32 32 32 36 36 36 36 36 METAL TO COKE RATIO (Carbon Content of Coke 90%) 6:1333#/ton 99ft3/#c

Cupola Size

Shell Diam.

Lower Lining Thickness** 4" 4" 4" 7" 7" 7" 7" 9" 9" 9" 9" 9" 9" 9" 12" 12"

Diam. Inside Lining

7:1286#/ton 107ft3/#c

8:1250#/ton 112ft3/#c

9:1222#/ton 118ft3/#c

10:1200#/ton 123ft3/#c

11:1182#/ton 128ft3/#c

12:1167#/ton 132ft3/#c

0 1 2 2 3 3 4 5 6 7 8 9 9 10 11 12

27" 32" 36" 41" 46" 51" 56" 63" 66" 72" 78" 84" 90" 96" 102" 108"

18" 23" 27" 27" 32" 37" 42" 45" 48" 54" 60" 66" 72" 78" 78" 84"

1.1 1.9 2.6 2.6 3.7 4.9 6.3 7.3 8.3 10.4 12.9 15.6 18.6 21.8 21.8 25.3

1.3 2.0 2.8 2.8 4.0 5.3 6.8 7.8 8.9 11.3 13.9 16.8 20.0 23.5 23.5 27.3

1.4 2.2 3.1 3.1 4.3 5.8 7.4 8.5 9.7 12.3 15.2 18.4 21.9 25.7 25.7 29.8

----2.4 3.3 3.3 4.6 6.2 7.9 9.1 10.4 13.1 16.2 19.6 23.4 27.4 27.4 31.8

----------------4.9 6.6 8.5 9.7 11.1 14.0 17.3 20.9 24.9 29.2 29.2 33.9

------------------------9.0 10.3 11.7 14.8 18.3 22.1 26.3 30.9 30.9 35.8

--------------------------------12.4 15.7 19.3 23.4 27.8 32.7 32.7 37.9

* Additional pressure capacity may be required when auxiliary equipment is added to the blast system or when ductwork is long or complicated. ** For long heats use heavier lining or use water cooling.

Page 4

APPOXIMATE MELTING RATES IN TONS PER HOUR FOR WHITING LININGLESS HOT BLAST CUPOLAS (Uninterrupted Operation)Cupola Cupola I.D. of Area Melt Sq. Zone In. 54" 60" 66" 72" 78" 84" 90" 96" 102" 108" 114" 2290 2827 3421 4072 4778 5542 6362 7238 8171 9161 10207 Theoretical Recommended Air Flow Blower Cap'y. thru Volume Pressure Tuyeres ICFM oz./in2* SCFM 5170 6000 48 6380 7100 48 7720 8600 48 9190 10500 56 10790 12000 56 12510 13900 56 14360 16000 64 16340 18000 64 18440 20300 72 20680 22800 72 23040 25500 80 METAL TO COKE RATIO (Carbon Content of Coke 90%) 5:1 6:1 7:1 8:1 9:1 10:1400#Coke/Ton 86ft3/#c 333#Coke/Ton 99ft3/#c 286#Coke/Ton 107ft3/#c 250#Coke/Ton 112ft3/#c 222#Coke/Ton 118ft3/#c 200#Coke/Ton 123ft3/#c

10.0 12.4 15.0 17.8 20.9 24.2 27.8 31.7 35.7 40.1 44.7

10.4 12.9 15.6 18.6 21.8 25.3 29.0 29.0 37.3 41.8 46.5

11.3 13.9 16.8 20.0 23.5 27.3 31.3 35.6 40.2 45.1 50.2

12.3 15.2 18.4 21.9 25.7 29.8 34.2 38.9 43.9 49.2 54.9

--------19.6 23.4 27.4 31.8 36.5 41.5 46.9 52.6 58.6

----------------29.2 33.9 38.9 44.3 50.0 56.0 62.4

NOTES: For larger Cupola sizes consult Whiting Metallurgical Equipment Division * Recommended minimum pressure for use with 1000 F. Whiting-Thermo hot Blast Heater For detailed specifications consult Whiting Metallurgical Equipment Division

Page 5

CUPOLA LINING DATAB A B B B A B

A B A B A B A B A B A B.9D Approx.

D

D

Key A. 9 4 x 2 Straight B. 9 x 4 x 9 Calliau Block

AC

B B B A B B A B B A B B

Key A. 9 4 x 2 Straights and arches B. 9 x 6 x 4 Cupola Block C. 9 x 4 x 1 Split

.9D Approx.

C. 9x 4 x 2 Straight

A B A BC

D

B A B B A B B

A

D

7 LINING

9 LINING

A

A A A A A A A A A

B B B B B B B B B B B B

D

Key A. 9 4 x 2 Straights and arches.9D Approx.

B. 9 x 6 x 4 Cupola Block

B B B B B B B B C B B B B A B B B B A B B B B B B A B B

D

Key A. 9x 4 x 2 Straight 9 x 6 x 4 Cupola Block 9x 4 x 1 Split

.9D Approx.

B.

C.

B A B B A B B

D

B B B B B B

B B B B B B

D

10 LINING

12 LINING

Page 6

CUPOLA LININGS NUMBER OF BRICK AND BLOCK REQUIRED FOR WHITING CUPOLASNOTE: For long runs, heavier lining may be required. Consult your supplier for other available shapes. LOWER LINING UPPER LINING Shell Matls Reqd per Foot of Height Matls Reqd per Foot of Height Cupola Lining Lining Cupola Inside Inside Cupola Total No. 1 Total ThickThick- 9 Str. Cupola 9 Str. Fire Fire No. Diam. Diam. Block Weight Arch Weight ness ness Block Brick Clay Brick Clay Inches Approx. Size No. Approx. Brick Approx. Inches Inches Pcs. Pcs. Pcs. Lbs. Lbs. Inches Lbs. Pcs. Lbs. 0 27 4 18 * A 16-25 12 3 15 335 1 32 4 23 * B 21-30 16 3 22 442 2 26 12 210 2 36 4 27 * C 27-36 18 24 494 2 30 14 242 2 41 7 27 * C 27-36 18 34 40 740 2 34 16 267 3 46 7 32 * D 30-39 20 42 44 863 2 39 18 315 3 51 7 27 * D 30-39 6 43 47 924 2 43 20 347 * E 40-49 16 4 56 7 42 * E 40-49 25 51 54 1067 2 48 22 387 5 63 9 45 * * 42-54 27 55 72 1390 4 5 101 44 800 * * 48-60 33 6 66 9 48 * * 48-60 63 56 76 1447 4 11 101 47 852 7 72 9 54 * * 54-66 69 64 83 1681 4 20 101 50 919 8 78 9 60 * * 60-72 78 68 91 1778 4 32 101 55 1000 9 84 9 66 * * 66-78 84 74 98 1920 4 42 101 58 1079 9 90 9 72 * * 72-84 90 80 105 2063 4 52 101 63 1160 10 96 9 78 * * 78-90 96 84 115 2194 4 65 101 65 1238 11 102 12 78 * * 78-90 96 122 3182 4 72 101 69 1318 * * 90-102 108 12 108 12 84 * * 84-96 102 130 3370 4 82 101 75 1400 * * 96-108 114

Page 7

CUPOLA LININGS ALTERNATE ARRANGEMENTS FOR LOWER LINING, Cupola No. 0 Through No. 4Shell Inside Diam. Inches 27 32 36 41 46 51 56 Shell Inside Diam. Inches Using Standard arch and Straight Brick (2 brick) Cupola Materials Required Per Foot of Heigth Lining Inside No. 3 No. 2 No. 1 Total 9 Str. Fire Thickness Diam. Arch Arch Arch Weight Brick Clay Inches (Approx.) Brick Brick Brick (Approx.) Pcs. Lbs. Inches Pcs. Pcs. Pcs. Lbs. 4 18 6 40 18 311 4 23 48 7 22 384 4 27 42 20 25 440 7 27 42 20 34 40 706 7 32 32 38 39 46 820 7 37 24 54 43 50 916 7 42 15 71 48 55 1021

Cupola No. 0 1 2 2 3 3 4

USING STANDARD CIRCLE BRICK (9 x 4 x 2) Cupola No. 1 Through No. 4Materials Required Per Foot of Heigth Cupola Lining Inside 24-33 36-45 45-57 Total Cupola 9 Str. Fire Thickness Diam. Circle Circle Circle Weight No. Brick Clay Inches (Approx.) Brick Brick Brick (Approx.) Pcs. Lbs. Inches Pcs. Pcs. Pcs. Lbs. 1 32 4 23 58 22 382 2 36 4 27 44 20 25 436 2 41 7 27 44 20 34 40 702 3 46 7 32 20 53 39 46 832 3 51 7 37 68 10 43 50 909 4 56 7 42 39 48 48 55 1025 Note: 3 series brick in these shapes are available fewer bricks with fewer joints would be required.

Page 8

STANDARD LINING ARRANGEMENTS4 2

4 2

Upper Lining 9 x 4 x 2 Firebrick

Upper Lining 9 x 4 x 2 Firebrick

9

Lower Lining 9 x 9 x 4 Cupola Block Linings for Std. Cupolas No. 1-2

4 2

9 4 7

Lower Lining 9 x 9 x 4 Cupola Block Linings for Std. Cupolas No. 2-3-3-4 2

4

2 4 4

Upper Lining 9 x 4 x 2 Firebrick

Upper Lining 9 x 4 x 2 Firebrick

4 2

9 6 8

Lower Lining 9 x 4 x 6 Cupola Block Linings for Std. Cupolas No. 5 to 10 Incl.

9 6 6

Lower Lining 9 x 4 x 6 Cupola Block Linings for Std. Cupolas No. 11 & 12

ALTERNATE ARRANGEMENTS FOR UPPER LININGS FOR CUPOLAS NO. 5 THROUGH NO. 12Using Standard Circle Brick (9 x 4 x 2) Upper Lining Thickness Inches 4 4 4 4 4 4 4 4 4 Diam. Inside Upper Lining (Approx.) Inches 54 57 63 69 75 81 87 93 99 MATERIALS REQUIRED PER FOR OF HEIGHT 48-57 Circle Brick Pcs. 48 20 60-69 Circle Brick Pcs. 58 92 82 29 72-81 Circle Brick Pcs. 84-93 Circle Brick Pcs. 96-105 Circle Brick Pcs. 108-117 Circle Brick Pcs. Fire Clay Lbs. 44 47 50 55 58 63 65 69 75 Total Weight (Approx.) Lbs 800 852 919 1000 1079 1160 1238 1318 1400

Cupola No. 5 6 7 8 9 9 10 11 12

Shell Inside Diam. Inches 63 66 72 78 84 90 96 102 108

44 106 101 34

44 120 111 24

53 149 120

63

NOTE:3 series brick in these shapes are available fewer brick with fewer joints would be required.

Page 9

RECOMMENDED TAP HOLE SIZES FOR CONTINUOUS TAPPING AND BACK SLAGGINGMelting Rate in 5 10 15 20 Tons per hr. Diameter 1/2 5/8 3/4 1 Tap Hole Equivalent 1/4 3/8 1/2 3/4 Pipe Size NOTE: For other than round holes, use equivalent cross-sectional area 25 1-1/8 1

GOOD MONOLITHIC REFRACTORY LINING(Acid) for Cupola Melting Zones, Converters, Ladles, Electric Furnace Bottoms, etc.

50% Minus 3/8 Silica Ganister 30% Minus 1/8 Silica Ganister 14% 140 Mesh or finerSilica Flour 6% Western Bentonite 7% Or More Water by weight (Use as much water as possible without causing puffing while ramming). Mull in good muller eight (8) minutes or more. Ram as hard as possible around steel form. Dry slowly at 600F. as long as practicable; up to 36 hours is desirable. Heat slowly from 600 to 1250F. in 3 to 4 hours. Preheat from 1250 to 2000F. before charging with molten iron. NOTE: To guide those wishing to make screen test on mixture. Particle size distribution of dry mixture should be as follows: On 28 Mesh Thru 28 Mesh on 65 Mesh Thru 65 Mesh 53 to 55% 14 to 14 % 33 to 36 %

Page 10

FRONT SLAGGING

SLAG NOTCH

SKIMMER BRICK

S TAP HOLE H*

METAL DAM

SAND BOTTOM

DRAIN HOLE

* H inches > cupola pressure oz./in.2 : 4 1 to 2

RECOMMENDED TAP HOLE SIZES FOR FRONT SLAGGING Melting rate in tons per hour Minimum Diameter of tap hole 5 1-1/4 10 1-3/4 15 2-1/4 20 2-1/2 25 2-3/4

Equivalent Std. Pipe Sizes 1 1-1/2 2 2-1/2 2-1/2 NOTE: For other than round holes, use equivalent cross-sectional area

Page 11

AIR REQUIREMENTS FOR COMBUSTION*(60 F Temp. and 29.92 Inches of Mercury)

Effluent Gas CO2% CO% N2%0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 34.7 33.0 31.4 29.7 28.1 26.4 24.7 23.1 21.5 19.8 18.2 16.5 14.8 13.2 11.6 9.9 8.3 6.6 5.0 3.3 1.7 0.0 65.3 66.0 66.6 67.3 67.9 68.6 69.3 69.9 70.5 71.2 71.8 72.5 73.2 73.8 74.4 75.1 75.7 76.4 77.0 77.7 78.3 79.0

Fraction of 1 Lb. Carbon Burned to A B CO2 CO0.000 0.029 0.060 0.092 0.125 0.159 0.195 0.232 0.271 0.312 0.354 0.400 0.447 0.496 0.547 0.602 0.658 0.720 0.783 0.852 0.922 1.000 1.000 0.971 0.940 0.908 0.875 0.841 0.805 0.768 0.729 0.688 0.646 0.600 0.553 0.504 0.453 0.398 0.342 0.280 0.217 0.148 0.078 0.000

Air Requirements Lbs. per 1 Lb. Carbon O21.33 1.37 1.41 1.45 1.50 1.54 1.59 1.64 1.69 1.75 1.80 1.87 1.93 1.99 2.07 2.13 2.21 2.29 2.38 2.47 2.57 2.67

Gases Produced Lbs. per Lb. Carbon CO20.00 0.11 0.22 0.34 0.46 0.58 0.71 0.85 0.99 1.15 1.30 1.47 1.64 1.82 2.01 2.21 2.42 2.64 2.87 3.13 3.39 3.67

Heat Developed BTU. per Lb. Carbon CO2000 422 873 1338 1819 2314 2837 3376 3943 4540 5151 5820 6504 7217 7959 8759 9576 10476 11393 12397 13410 14550

N24.44 4.57 4.70 4.85 4.99 5.14 5.30 5.47 5.64 5.82 6.01 6.21 6.42 6.64 6.86 7.11 7.35 7.63 7.91 8.21 8.52 8.87

Air5.77 5.94 6.11 6.30 6.49 6.68 6.89 7.11 7.33 7.57 7.81 8.08 8.35 8.63 8.93 9.24 9.57 9.92 10.29 10.68 11.09 11.54

CO2.33 2.26 2.19 2.11 2.04 1.96 1.88 1.79 1.70 1.60 1.51 1.40 1.29 1.17 1.06 0.92 0.80 0.65 0.51 0.34 0.18 0.00

N24.44 4.57 4.70 4.85 4.99 5.14 5.30 5.47 5.64 5.82 6.01 6.21 6.42 6.64 6.86 7.11 7.35 7.63 7.91 8.21 8.52 8.87

Total6.77 6.94 7.11 7.30 7.49 7.68 7.89 8.11 8.33 8.57 8.82 9.08 9.35 9.63 9.93 10.24 10.57 10.92 11.29 11.68 12.09 12.54

CO4350 4224 4089 3950 3806 3658 3502 3340 3171 2993 2810 2610 2406 2192 1971 1731 1488 1218 944 644 339 000

Total4350 4646 4962 5288 5625 5972 6339 6716 7114 7533 7961 8431 8910 9409 9930 10490 11064 11694 12337 13041 13749 14550

Efficiency Lbs. Air Cu. Ft. of per lb. Air Comper. lb. busC C tion %29.9 31.9 34.1 36.3 38.6 41.1 43.5 46.2 48.8 51.7 54.7 57.9 61.2 64.7 68.3 72.1 76.0 80.4 84.8 89.6 94.5 100.0 5.77 5.94 6.11 6.30 6.49 6.68 6.89 7.11 7.33 7.57 7.81 8.08 8.35 8.63 8.93 9.24 9.57 9.92 10.29 10.68 11.09 11.54 75.5 77.7 79.9 82.4 84.8 87.3 90.0 92.9 95.8 99.0 102.1 105.6 109.1 112.8 116.8 120.8 125.1 129.7 134.5 141.2 145.0 151.0

* See Page 13 for an explanation and example of the data contained in this chart.

Page 12

EXPLANATION.(1) C + O2 = CO2 (2) CO2 + C = 2CO For a gas analysis of 14 percent CO2 the table shows 11.6 percent CO and 74.4 percent N2 and the 11.6 percent CO results from the reduction of CO2 no free oxygen being involved. It is now necessary to resort to the use of the Law of Hess which states that the result of a series of reactions is the same regardless of the intermediate steps, and thus, when (2) is added to (1) the result is or 2C + O2 = 2CO C + O2 = CO

This reaction does not actually take place, but by the Law of Hess, its occurrence can be assumed. The CO content of the effluent gases in the problem under consideration has been shown to be 11.6 per cent and this theoretically results from the incomplete combustion of a certain amount of carbon of the coke. At the same time 14 per cent CO2 is derived from the carbon that is completely consumed initially, When 1 lb. C is burned under these conditions, the fraction burned to CO2 is Cco2 = 14/(14 + 11.6) = 0.547 and the fraction burned to CO is Cco = 11.6/(14 + 11.6) 0.453 Consequently, the air required to form CO is 0.547 x 151* = 82.6 cu. ft. and that required to form CO 0.453 x 75.5** = 34.2 cu. ft. The total volume of air used to burn one pound of carbon under these conditions is 116.8 cu. ft. It has been assumed that one ton of iron is being melted at a ratio of 10 to 1, therefore 200 lbs. of coke containing 90% carbon, or 180 lbs. of carbon are being burned. The total air consumption is 180 x 116.8 = 21,000 cu. ft. (approximately) * 151 Cu. ft. of air required to burn 1 lb. of carbon to CO2. ** 755 Cu. ft. of air required to burn 1 lb. of carbon to CO.

Page 13

RELATIONSHIP BETWEEN METAL TEMPERATURE AND MELTING RATE FOR VARIOUS BLAST RATES AND FUEL RATIOS

10

15 Lbs. Metal per Hour per Sq. Ft. Cupola Area

20I.D. Cupola 24 30 36 42 45 48 54 60 66 72 78 84 Area of Cupola Sq. In. Sq. Ft. 452.3 3.142 706.8 4.909 1017.8 7.069 1385.4 9.621 1590.4 11.04 1809.5 12.57 2290 15.90 2827 19.65 3421 23.76 4072 28.27 4778 33.18 5542 38.48

2800 2780 2760 2740 2720

Cu. Ft. per Min. per Sq. In. Cupola Area 2.43 2.20

2800 2780 2760 2740 2720 2700 2680 2660

2.92 280 260 Lbs. Carbon per Ton (2000 Lbs) Metal 220

1.94

240

1.65 2700 1.46 2680 200 180 160 2640 2620 2600 2580 2560 2540 2520 2500 2480 2460 2440 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 16.7 210 235 Lbs. Metal per Lb. Carbon 14.3 280 9.1 10.0 11.1 12.5 317 350

TEMPERATURE F

2660

2640 140 120 420 2580 Cu. Ft. per Min. per Sq. Ft. Cupola Area 2560 2540 Relationship between metal temperature and melting rate for various blast rates and fuel ratios, from data reported by Massori and Lindsay. G.C. Wright American Foundryman Nov. 47 2520 2500 2480 2460 2440 48 50 52 54 56 2620 2600

Lbs. Metal per Minute per Sq. Ft. Cupola Area

MELT RATE

Page 14

FORMULA FOR ESTIMATING HEIGHT OF BED COKEMultiply the square root of the blast pressure by 10.5 and add a factor F for operational variables. Coke Bed Height (above Tuyeres) in inches = 10.5 Wind Box Press. (ox./in. 2 ) +F

For normal operating conditions and using a cone bottom charging bucket, an F factor of 6 may be used. For other than normal operating conditions or when they are not exactly known (as when starting up a new installation), the proper value for F may vary up to 12 to 18 maximum. If lower carbon iron is desired, the F factor is lower than if high carbon iron is desired. If a quick bottom release charging bucket is used, a higher F value is indicated. Some believe if the coke size is smaller or larger than one-tenth 1/10) to one-twelfth (1/12) of the inside diameter of the cupola lining, F is greater. Other conditions may affect the value too. Example: Given a blast pressure of 16 oz., the square root is 4, and 10.5 x 4 is 42.0. Using F = 6, the bed coke should be 48 above the tuyeres; for F = 12, it would be 54; and for F = 18, it would be 60; all for a 16 oz. blast. This should serve to estimate starting requirements. The exact value of F may be established for a particular installation and operation by adjusting the initial value, as suggested above, according to the results obtained and desired. APPROXIMATE HOLDING CAPACITY OF CUPOLA WELLDia. inside lining (inches) 23 27 32 37 42 45 48 54 60 66 72 78 84 Approx Molten Iron Holding Capacity Cupola Well (lbs.) 570 820 1160 1540 1990 2280 2610 3390 4050 4910 5840 6840 7960

(Figures based on (1) 12-inch average depth of metal, and (2) molten metal occupies 46 percent of available volume of the well.) (Courtesy AFSThe Cupola and Its Operation)

Page 15

AIR0.020

Humidity, pounds water vapor per pound dry air

0.018 0.016 0.014 0.012 0.010 0.008 0.006 0.004 0.002 0.000 20 30 40 50 60 70 80 90

Percentage relative humidity curves

Temperature F

Psychrometric chart: temperature range, 20 to 90F; pressure, 29.921 in. Hg.0.50

Humidity, pounds water vapor per pound dry air

0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

Percentage relative humidity curves

Temperature F

Psychrometric chart: temperature range, 10 to 210F; pressure, 29.921 in. Hg. Page 16 (Both charts by permission of O.T. Zimmerman, author, and publishers of Kent Engineering Handbook.)

COKE CONSUMPTION DUE TO MOISTUREGrains Water per Cu. Ft. of Blast20,000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

18,000

16,000

Cu. Ft. Blast per Minute

14,000% Blast Increase* 1 0.9 2 1.9 3 2.9 4 3.8 5 4.8 6 5.8 7 6.7 8 7.7 9 8.7 10 9.8 11 10.8 12 11.8 13 12.8 14 13.8 15 14.9 16 15.9 17 17.0 18 18.0 19 19.1 20 20.1 *Based on Stand. Cond. Grains

12,000

10,000

8,000 6,000

4,000

2,000

0 400 800 1200 1600 2000 2400 2800 3200 3600 4000

Lbs. of Coke per Hour

NOTE: To obtain grains of water per std. Cu. ft. of air, multiply lbs. of water per lb. of dry air by 534.8 Page 17

STANDARD HYDRO-ARC FURNACE SHELL CAPACITIESA C Furnace capacities are based upon lining burned back to this dimension E E L Slag allowance is based upon 1 cu. ft. per ton of hot metal. May be varied with operational requirement H S Slim line These dimensions may be increased to add more scrap holding capacity This dimension may be increased for hot metal capacity Floor line F For duplexing or hot metal operations this dim. May be increased by as much as 25% to increase hot metal capacity D E

B

G

J

Inside Shell Dia. A 3'-4" 4'-0" 5'-0" 6'-0" 7'-3" 8'-0" 9'-0" 10'-0" 11'-0" 12'-6" 13'-6" 14'-0" 15'-0" 16'-0" 17'-0" 18'-0" 19'-0" 20'-0" 21'-0" 22'-0" 23'-0" 24'-0" 25'-0" 26'-0" 28'-0" 30'-0" 32'-0" Depth B 2'-6" 3'-0" 3'-9" 4'-6" 5'-6" 6'-0" 6'-9" 7'-6" 8'-3" 9'-9" 10'-5" 11'-0" 11'-10" 11'-11" 12'-4" 12'-5" 12'-6" 13'-4" 14'-5" 14'-7" 15'-1" 15'-3" 15'-4" 15'-5" 15'-10" 15'-11" 16'-10"

Molten Metal Capy. To Sill Line Lbs. 900 1800 3540 6220 10770 14100 20700 33000 44500 65200 80600 94000 116200 136300 163100 187500 213700 241900 291800 337100 396400 451600 497400 545500 645200 737000 832900

Molten Capy. Inside Total Metal Per Dia. Lining Brick Metal Bottom Wt. Per Thick- Thick- Depth ThickInch of Scrap Foot of New ness To Sill ness ness Depth Capy. Depth Lining Cu. Ft. Cu. Ft. C D E F G Lbs. 150 7 4.3 2'-4" 6" 6 7 1/2" 9" 250 14 7.1 3'-0" 6" 6 9 1/2" 10" 450 31 12.6 4'-0" 6" 9 11" 12" 700 51 19.6 5'-0" 6" 9 1'-1" 15" 930 97 26 5'-9" 9" 9 1'-4" 17" 1190 135 33.2 6'-6" 9" 9 1'-5" 18" 1580 210 44.2 7'-6" 9" 13 1'-7" 18" 2030 310 56.7 8'-6" 9" 13 1'-11" 18" 2540 435 70.9 9'-6" 9" 13 2'-1" 18" 3100 640 86.6 10'-6" 12" 13 2'-5" 20" 3560 800 99.4 11'-3" 13 13 2'-7" 20" 3890 925 108 11'-9" 13 13 2'-9" 21" 4580 1190 128 12'-9" 13 13 2'-11" 21" 5320 1380 149 13'-9" 13 13 3'-0" 21" 6120 1600 171 14'-9" 13 13 3'-2" 24" 6980 1830 195 15'-9" 13 13 3'-3" 24" 7900 2080 220 16'-9" 13 13 3'-4" 24" 8870 2520 247 17'-9" 13 13 3'-5" 24" 9890 3100 276 18'-9" 13 13 3'-8" 24" 10980 3470 306 19'-9" 13 13 3'-10" 24" 12120 3880 338 20'-9" 13 13 4'-1" 27" 13310 4300 372 21'-9" 13 13 4'-3" 27" 14570 4710 407 22'-9" 13 13 4'-4" 27" 15880 5150 443 23'-9" 13 13 4'-5" 27" 18660 6060 521 25'-9" 13 ----4'-7" 30" 21670 7010 605 27'-9" 13 ----4'-8" 30" 24910 8020 695 29'-9" 13 ----4'-9" 30" Ratings Based on Molten Density of 430 lbs/cu .ft.

Shell Above Sill J 13 16 1'-10" 2'-2" 2'-9" 3'-1" 3'-8" 4'-1" 4'-8" 5'-8" 6'-2" 6'-6" 7'-2" 7'-2" 7'-2" 7'-2" 7'-2" 7'-11" 8'-9" 8'-9" 8'-9" 8'-9" 8'-9" 8'-9" 8'-9" 8'-9" 8'-9"

Sill Height Above Floor K 2'-8" 2'-8" 2'-6" 2'-6" 2'-6 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4" 2'-4"

Depth Panels L ----------------1'-3" 1'-7" 2'-2" 2'-7" 3'-2" 4'-2" 4'-8" 5'-0" 5'-8" 5'-8" 5'-8" 5'-8" 5'-8" 6'-5" 7'-3" 7'-3" 7'-3" 7'-3" 7'-3" 7'-3" 7'-3" 7'-3" 7'-3"

Aprox. Slag Allowance S 1 1 1 2 2 2 2 3 3 4 4 4 4 4 4 5 5 6 7 7 8 8 8 9 -------------

Cu. Ft. Per Foot Per Inch* ----------------1.6 1.8 2.1 2.3 2.6 3.0 3.2 3.3 3.5 3.8 4.1 4.3 4.6 4.8 5.1 5.3 5.6 5.9 6.1 6.4 6.9 7.4 8.0

Page 18

GRAPHITE ELECTRODES (Courtesy Union Carbide Corp.)(TYPICAL CURRENT CARRYING RANGES OPEN ARC APPLICATIONS)

The chart below is based on the heating effect in a graphite electrode column from applying an assumed average phase current. Among other important operating factors, however, which must be considered before selecting the electrode grade and size for your particular application are these: Type of scrap Method of charging Proximity of side walls to electrode circle Meltdown time/total heat time ratio, tap-top-tap

Electrode column length below holder Type of fume system120

100 Phase Current (Kilo-Amperes)

80 60

TYPICAL CURRENT CARRYING RANGE

40

20 0 inches 8 mm 200

12 300

16 20 400 500 Electrode Diameter

24 600

28 700

ELECTRIC ARC FURNACE TRANSFORMERS(Approximate equivalent capacities)

Multiply: KVA rating @ 35 C. KVA rating @ 40 C. KVA rating @ 45 C. KVA rating @ 50 C. KVA rating @ 60 C. KVA rating @ 65 C.

By: 1.44 1.30 1.18 1.08 0.93 0.90

To Get: KVA rating @ 55 C. KVA rating @ 55 C. KVA rating @ 55 C. KVA rating @ 55 C. KVA rating @ 55 C. KVA rating @ 55 C.

Page 19

HYDRO-ARC FURNACE DATA POWER COMSUMED IN MELTING IRON AND STEEL WITH AN ELECTRIC ARC FURNACEKEY Curve A Theoretical Curve B Actual for Large Furnaces Curve C Actual for Small Furnaces Curve A taken from pg20 of Metals Handbook 1936. This curve based on investigations by Wust, Meuthen and Duerrer.

% Carbon by Wt.

6504 3 2 1 0

C

1100 1000B

600 550 500 450 400 350 300B 2066F Melting Point for 43% Carbon Iron A C 2785F Melting Point for Pure Iron

900 800 700 600 500 400 300 200 100 0 BTU PER POUND

KHW PER TON

250 200 150 100 50 0 400 800 1200 1600 2000 2400 2800A

3200

TEMPERATURE, F

Page 20

WHITINGVERTICAL TYPE LINE FREQUENCY CHANNEL INDUCTION FURNACEF D 1 B A C C 2Clearance @ Full Tilt I.D.

E

1. POUR SPOUT 2. HOT METAL INLET 3. SLAG BUCKET NOTE: 15 BACK TILT 4. FOUNDATION & TILT STAND 5. HYDRAULIC TILT CYLINDER 6. SLAG DOOR 7. FURNACE ROOF 8. FURNACE SHELL 9. INDUCTOR COOLING FRAME 10. INDUCTOR UNIT NOTE: a) POUR SPOUT AND HOT METAL INLET MAY ALSO BE SUPPLIED OPPOSITE HAND. b) ALSO AVAILABLE WITH ROOF LIFT & SWING MECHANISM FOR COLD CHARGING. c) ALSO AVAILABLE FOR TWO INDUCTOR ACCOMMODATION.

6 J G H K 4-2 3 4 5 910

7

8

IRON CAPACITY (TONS)USABLE HEEL VCF TYPE

A10-10 12-6 13-2 14-10 14-10

B5-5 6-3 6-7 7-5 7-5

C2-11 3-6 3-8 4-0 4-0

D3-11 4-8 4-10 5-3 5-3

E3-10 4-8 4-8 4-8 4-8

F5-6 6-5 6-8 7-6 7-6

G2-2 2-2 2-4 2-7 2-7

H5-3 6-3 6-9 6-9 8-5

J14-2 16-6 17-3 18-10 18-10

I.D.7-1 8-3 8-8 9-9 9-9

K12 12 12 12 12 22

8 15 20 30 40

8 15 20 30 40 50

3 5 6 7 10 12

11 20 26 37 50 62

50 17-6 8-9 4-9 6-3 4-7 8-2 2-8 8-3 20-6 11-0 NOTE: Dimensions are approximate and may vary with operational requirement.

Page 21

TOTAL

WHITINGHORIZONTAL TYPE LINE FREQUENCY CHANNEL INDUCTION FURNACEB A 6 5 1 ER3 R4 R1 R2

C 2 7 8

F 5 4 J

D 9 FIG.-1 B C A 3

K K

1. POUR SPOUT 2. HOT METAL INLET 3. TILT ROLLER ASSEMBLY 4. TILT DRIVE 5. TILT CHAIN 6. SLAG DOOR (OPEN POSITION) 7. FURNACE SHELL 8. INDUCTOR COOLING FRAME 9. INDUCTOR UNIT NOTE: a) POUR SPOUT AND HOT METAL INLET MAY ALSO BE SUPPLIED OPPOSITE HAND. b) POUR SPOUT CAN BE OF END POUT TYPE AS SHOWN OR OF FRONT POUR TYPE.

FIG.-2

IRON CAPACITY (TONS)USABLE HEEL HCF TYPE

35 50 65 85 110 150 200

1 1 1 1 1 2 2

FIG

A13-6 18-4 17-6 22-2 26-9 28-6

B20-6 25-4 24-6 29-2 33-9 35-6

C4-0 4-0 4-0 4-0 4-0 4-0

D

E

F

G

H

J

K

R1

R2

R3

R4

7-10 2-2 8-7 1-6 2-6 4-0 8-0 8-0 9-0 2-5 8-9 1-6 2-6 4-0 2-5 8-9 1-6 2-6 4-0 3-0 9-3 2-0 3-0 5-0

35 4-7 5-7 8-10 5-2 35 4-9 5-9 9-0 35 4-9 5-9 9-0 35 5-3 6-3 9-6 35 5-3 6-3 9-6 35 5-3 6-3 9-6 5-4 5-4 6-3

35 10 50 14 65 15

45 64 80

15-10 22-10 4-0

85 15 100

10-0 3-0 9-3 2-0 3-0 5-0 10-0 3-0 9-3 2-6 5-0 6-0 10-6 3-3 9-9 2-6 5-0 6-0

6-3 110 20 130 6-3 150 27 177

35 5-9 6-9 10-0 6-7 200 35 235

NOTE: Dimensions are approximate and may vary with operational requirement.

Page 22

TOTAL

USEFUL DATA ON COMBUSTIONAIR Consists of 23% (by weight) of oxygen and 77% (by weight) of nitrogen; or by volume 20.7% oxygen and 79.3% nitrogen. One pound at 62 F. (barometer at 30 inches) occupies 13.1 cu. ft., and 56 cu. ft. at this temperature contain 1 lb. of oxygen. OXYGENO One pound at 62 F. occupies 12 cu. ft. According to Welters theory, any material burned with one pound of oxygen evolves 7,560 B.T.U. CARBONC One pound requires for its complete combustion 2-2/3 lbs. of oxygen, or, 11.54 lbs. air151 cu. ft. of air, developing 20,160 B,T.U., of which 5,760 are latent, being expended in vaporizing the carbon; leaving 14,400 sensible. If perfect combustion takes place, 12,610 effective B.T.U. may he realized with the escaping flue gases at 600 F: CARBON MONOXIDECO One pound occupies 13 cu. ft. at 62 F. requires 4-7 lb. of oxygen or 32 cu. ft. of air for its combustion and evolves 4,320 B.T.U. With perfect combustion and escaping flue gases at 600 F., 3,820 effective B.T.U. may be realized. One cu. ft. requires 2.4 cu. ft. of air for combustion and evolves 320 B.T.U. HYDROGENH One pound at 62 F. occupies 190 Cu. ft., requires 8 lbs. of oxygen or 450 Cu. ft. of air for its combustion and evolves 60,480 B.T.U. when burned to liquid water. 42,000 B.T.U. may be realized with flue gas at 600 F. One cu. ft. of hydrogen gas requires 2-1/3 cu. ft. of air for its combustion and evolves 324 B.T.U. SULPHURS One pound requires one pound of oxygen or 56 cu. ft. of air for combustion and evolves 4,000 BT.U., exclusive of the heat required for volatilization of the sulphur. With perfect combustion and flue gases at 600 F., 3,260 B.T.U. may be realized. NATURAL GAS One pound occupies 22 cu. ft. at 62 F., or 1,000 cu. ft. weigh 45 lbs. One cu. ft. requires 10 cu. ft. of air for its combustion and evolves about 1,000 B.T.U. OIL (BEAUMONT) Specific gravity .92 weighs 7-2/3 lbs. per gallon. One barrel of 42 gals. weighs 322 lbs. Requires for complete combustion 15 lbs. of air per lb. of oil or 1,500 cu ft. of air per gallon of oil. One pound gives about 20,000 B.T.U. HEAT Evolved by the combustion of any organic fuel, such as coal, is approximately that of its carbon plus that of as much of its hydrogen as exceeds the amount required to combine with its oxygen to form water. Pulverized coal weighs approximately 35 lbs. per cu. ft. EXAMPLE If a fuel consists of 87% C, 5% H and 8% O, the 8% of oxygen will be sufficient to combine with 1% of hydrogen, leaving 4% of that element available for combustion. The B.T.U. to be derived from 1 lb. of this fuel will then be that corresponding to .87 lbs. of carbon plus .04 lbs. of hydrogen. The above statements are approximately correct for the theoretical amount of air required at 62 F. with the barometer at 30 in. In practice, 10% to 20% more air should be provided because of the imperfect mixture with the fuel. Further corrections should be made for temperature in hot climates, also for pressure in high altitudes.

Page 23

SELECTION OF U-TYPE HOLDING LADLE FOR DESULPHURIZING WITH SODA ASHThe treatment of molten iron with soda-ash in a ladle or a forehearth has proved a very practical and economical means of refining and mixing cupola metal, and has been adopted by many foundries. For this purpose the U-shaped ladle has been found, by comparative tests, to do the job better and with a smaller amount of refining agent than any of the other types of reservoirs. At the same time that the metal is being purified, there is a distinct mixing action which tends to level off variations in composition. The U-ladle extends the advantages of a mixer ladle and desulphurizer to foundries making the lightest grades of castings and with melting rates as low as 2 or 3 tons per hour. The capacity of the mixer ladle may vary widely for the same diameter cupola, depending upon the class of work, the capacity of the transfer ladle and the extent of desulphurizing that is desired. For refining light castings, where the iron is taken away in 50 or 100 lb. ladles the mixer should have a working capacity of 1/10 to 1/6 the hourly melting rate. For instance, 600 to 1000 lbs. capacity for a melting rate of 3 tons per hour, or 2400 lbs. to 4000 lbs. for a melting rate of 12 tons per hour where the metal is taken away in 250 to 1000 lb. transfer ladles; in either case, holding the iron in the ladle in contact with the desulphurizing slag from 6 to 10 minutes. For heavy castings the capacity may well vary from 1/5 to 1/3 the hourly melting rate, thus providing an elapsed time of 12 to 20 minutes in the refining ladle.

Extent of DesulphurizingOrdinarily one pound of soda ash per ton of iron is required to neutralize silicates and cupola slag entrained in the iron. Thereafter further additions reduce sulphur content about as shown below: Metal at Spout .08% With 2 lb. soda-ash per ton _ _ _ _ _ _ _ _ _ _ _ _ _ _ .070 With 4 lb. soda-ash per ton _ _ _ _ _ _ _ _ _ _ _ _ _ _ .060 With 6 lb. soda-ash per ton _ _ _ _ _ _ _ _ _ _ _ _ _ _ .050 Sulphur .10% .13% .085 .110 .070 .090 .060 .075

.17% .145 .115 .095

The above values are usual for acid cupola operation. Lower sulphurs can be obtained from cupolas operating with basic slag. Choice of insulation between the refractory lining and the shell ranges from a sheet or two of ordinary building asbestos paper to 1 thick insulating brick.

Page 24

WHITING U-LADLES IRON CAPACITY IN POUNDS(Figures in bold and underlined indicate lining customarily used)Lining Thickness 4 5 6 7 8 9 10 11 12 15 18 13 x 46 2314 1856 1460 1123 840 14 x 50 3560 2939 2392 1913 1500 1146 16 x 54 18 x 64 19 x 67 20 x 74 20 x 80 20 x 90 22 x 90 25 x 96 27 x 90 34 x 101 34 x 110

4692 3934 3258 2659 2133 1675

6258 5332 4496 3746 3079 2488

7742 6630 5714 4841 4056 3355 2732

9302 8248 6982 5975 5062 4238 4198

10202 8998 7702 6611 5620 4724 3918

11702 10246 8906 7678 6557 5538 4618

14703 13028 11477 10044 8727 7519 4510

19700 17677 15791 14035 12405 10897 7062

25039 22667 20442 18358 16412 14599 9913

39360 36218 33243 30431 27724 20723 14931

43528 40145 36937 33895 31024 23349 16999

Capacities based on 411 lbs. per cu. ft. or .238 lbs. per cu. in.

Larger sizes engineered to order.H J

F E G9 MIN. GAUGE WHEELBASE

A

B

C

D

STANDARD SPOUT ARRANGEMENTSSize 13 x 46 14 x 50 16 x 54 18 x 64 19 x 67 20 x 80 22 x 90 25 x 96 27 x 90 34 x 101 34 x 110 E 27 27 35 35 35 35 35 35 42 511/8 511/8 F 51 54 65 67 69 69 72 74 86 90 90 G 18 20 27 26 26 24 21 15 14 13 13 H 58 62 681/8 781/8 815/8 955/8 1055/8 1115/8 1055/8 1185/8 1275/8 J 13 13 183/8 183/8 183/8 183/8 183/8 183/8 183/8 20 20 Ga. 24 24 36 36 36 36 36 36 36 36 36 Wheelbase 79 83 891/8 991/8 1025/8 1151/8 1265/8 1325/8 1055/8 118 127

Page 25

IRON CAPACITYTaper Side LadlesTop Allowance Top Dia. Bottom Dia. 1 2 2 3 & Depth 717 556 420 20 18 2 839 863 681 525 21 19 2 1001 23 20 2 1247 1087 873 687 1279 1039 830 24 21 2 1457 1415 1156 26 22 2 1921 1707 1705 1412 27 24 2 2273 2033 2100 1763 29 25 2 2748 2475 2571 32 28 2 3815 3474 3001 3370 34 30 3 4838 4439 3881 3945 36 31 3 5128 4512 4164 36 32 3 5388 4751 40 35 3 7342 6555 5825 40 35 3 7671 6861 6107 43 38 3 8768 7878 44 38 3 9138 8222 46 40 4 10455 9456 48 42 4 12030 10931 48 42 4 12486 11359 51 44 4 13502 52 45 4 14499 55 48 5 17212 56 49 5 18381 58 51 5 20876 61 53 5 62 54 5 66 58 5 72 63 6 77* 70 6 86* 77 7 *NOTE: 79" and 86" ladles are 72" deep. All others have the same depth as top diameter. Based on density of molten iron at 411 lbs. per cu. ft. or 0.238 lbs. per cu. in. Bowl Size CAPACITIES IN POUNDS (Bold Face and Highlighted figures show lining ordinarily used) Lining Thickness 4 4 5 6 7 8 9

1002 1236 1558 2307 3054 3594 3799 3799 5635 7317 7646 8826 10236 10646 12700 13657 16270 17397 19804 23576 24767 31069

1944 2616 3105 3292 3292 4972 6525 6830 7931 9246 9629 11554 12454 14920 15985 18263 21842 22974 28980 38847 48372 58383

2804 2978 2978 4558 6029 6318 7368 8621 8987 10828 11691 14061 15085 17280 20733 21825 27639 37219 46513 56301

5330 5597 6571 7735 8076 9795 10603 12832 13797 15868 19137 20172 25702 34858 43810 53270

8214 8935 10939 11809 13682 16653 17597 22669 31139 39534 48458

15267 16157 20963 29034 37102 45711

25730 33266 41361

Page 26

STEEL CAPACITYTaper Side LadlesTop Allowance Top Dia. Bottom Dia. 1 2 2 3 & Depth 383 20 18 4 777 662 510 482 21 19 4 935 803 630 689 23 20 4 1176 1022 816 778 24 21 4 1381 1209 978 26 22 4 1630 1096 1346 27 24 4 1950 1630 1346 29 25 4 2388 2020 1690 32 28 4 2917 2492 34 30 5 3793 3287 36 31 5 4426 3863 36 32 5 4666 4082 40 35 5 5753 40 35 5 6038 43 38 5 7827 44 38 5 8176 46 40 6 9417 48 42 6 48 42 6 51 44 6 52 45 6 55 48 6 56 49 6 58 51 6 61 53 7 62 54 7 66 58 7 72 63 8 77* 70 8 86* 77 9 *NOTE: 79" and 86" ladles are 72" deep. All others have the same depth as top diameter. Based on 430 lbs. per cu. ft. or 0.25 lbs. per cu. in. Bowl Size CAPACITIES IN POUNDS (Bold Face and Highlighted figures show lining ordinarily used) Lining Thickness 4310 398 536 660 948 1175 1491 2233 2974 3515 3720 5297 5566 7265 7597 8783 10214 10630 12720 13694 16719 17885 20378

4219 289 403 506 749 946 1221 1877 2542 3031 3217 4656 4904 6471 6779 7883 9217 9606 11562 12477 15326 16428 18787 22048 23208 29359 39474

5

6

7

8

9

810 1060 1661 2278 2733 2907 4258 4491 5974 6266 7318 8588 8959 10829 11706 14440 15499 17771 20920 22040 27991 37808 47249 57161

1367 1915 2322 2478 3702 3915 5274 5543 6519 7697 8042 9786 10607 13173 14170 16314 19297 20358 26016 35395 44485 54059

2882 3063 4228 4460 5315 6347 6651 8194 8925 11222 12120 14058 16775 17741 22926 31596 40114 49138

5614 5895 7323 8002 10145 10586 12805 15368 16279 21189 29446 37629 46331

13193 14015 18484 26075 33712 41888

Page 27

TEMPERATURE IN DEGREES FAHRENHEIT

Courtesy of

Central Foundry Division (G.M. Co.)

2700

2500

5

25

27.5

30 TIME IN MINUTES

35

LAST IRON FROM BULL LADLE INTO POURING LADLE

FORHEARTH

ELECTRIC FURNACE TAPPED

2600

& IRON INTO FURNACES

FLUIDITY DANGER LEVEL

40

45

Page 28

LAST IRON FROM POURING LADLE

Carl F. Joseph

TIME SCAL CHANGES

Time temperature curve showing temperature of iron from the time it is tapped to the last iron from pouring ladle, including period of superheating in the electric furnace.

2900

(OPEN TOP)

(COVERED) 2800

TAPPED

PRACTICAL METHOD FOR CALCULATING LADLE CAPACITIES

G

A D

A Top Dia. Bowl G H B Bottom Dia. Bowl C Height Bowl D Top Dia. Inside of Lining E Bot. Dia. Inside of Lining

V

F

C

F Height of Metal G Thickness of Lining H Top Allowance

G G E B G

V Vol. of Metal W Weight of Metal Z Density of Metal

D+E V = Vol. of Metal = .7854 F 2 W = V Z

2

APPROX. DENSITIES OF VARIOUS METALS IN THE MOLTEN STATE Metal Aluminum Brass Copper Cast Iron Blast Furnace Iron Lead Magnesium Silicon Steel Tin Zinc Lbs./Cu. In. .079 .243 .288 .238 .231 .379 .056 .0758 .250 .230 .237 Lbs./Cu. Ft. 137 420 487 411 400 655 97 131 430 400 410

Page 29

SUGGESTED CRANE OPERATING SPEEDS FEET PER MINUTECapacity in Tons 5 7 10 15 20 25 30 35 40 50 60 75 100 125 150 175 200 HOIST Slow 20 20 20 15 15 15 15 10 8 5 5 5 5 5 5 3 3 Medium 35 35 30 30 25 25 25 15 15 10 10 10 8 8 8 4 4 Fast 70 70 60 50 40 30 30 25 25 20 20 18 12 12 12 5 5 Slow 125 125 125 125 125 100 100 100 100 75 75 0 50 40 30 30 30 TROLLEY Medium 150 150 150 150 150 150 125 125 125 125 100 100 100 75 50 50 50 Fast 200 200 200 200 200 175 175 150 150 150 150 125 125 100 100 75 75 Slow 200 200 200 200 200 200 150 150 150 100 100 75 50 50 50 50 50 BRIDGE Medium 300 300 300 300 300 300 250 250 250 200 200 150 100 100 75 75 75 Fast 400 400 400 400 400 400 350 350 350 300 300 200 150 150 100 100 100

NOTE: For Floor Controlled Cranes, it is recommended that trolley and bridge speeds not exceed those given in the slow columns.

Page 30

HOISTING ROPEThe following table shows breaking strengths for wire rope commonly used on cranes, ship hoists & winches. To obtain the safe working load for each diameter of rope, divide the breaking strength by the factor of safety. Minimum factor of safety for general use is 5:1. For hot metal handling equipment and high capacity ship hoists 10:1 is recommended. Wire rope in daily use should be inspected at least once each week and more frequently if rope is subjected to heavy duty service. Special attention should be given to sections of rope which pass over sheaves as well as all rope end connections. A special wire rope lubricant should be applied regularly. When installing new hoist rope, not less than 2 turns should remain on the drum when the load is in its lowest position to relieve stresses on the rope anchor.

Ultimate Strength In Tons Of Improved Plow Steel Wire Rope

Class 6 x 37 Class 6 x l9 Rope 6 Strands, 37 Wires/Strand 6 Strands, 19 Wires/Strand Diam. Wire Rope Wire Rope Fiber Core Fiber Core Core Core 3/8 5.77 6.20 6.10 6.56 1/16 7.82 8.41 8.27 8.89 1/2 10.2 11.0 10.7 11.5 9/16 12.9 13.9 13.5 14.5 5/8 15.8 17.0 16.7 17.9 3/4 22.6 24.3 23.8 25.6 7/8 30.6 32.9 32.2 34.6 1 39.8 42.8 41.8 44.9 1-1/8 50.1 53.9 52.6 56.5 1-1/4 61.5 66.1 64.6 69.4

Page 31

SCRAP HANDLING MAGNETS (DEEP COIL)Diameter, Inches Net Weight, Pounds Head Room Required, Inches Cold Current @ 230 Volts Generator Capacity Required Rectifier Capacity Required Size of Duplex Flexible Cable Recommended Crane Capacity 45 2650 43 40 amps. 7.5 K.W. 10 K.W. #8 B&S 4 Ton 54 4000 44 59 amps. 10 K.W. 13.5 K.W. #6 B&S 5 Ton 63 6100 55 78 amps. 14 K.W. 18 K.W. #6 B&S 8 Ton 69 7700 56 95 amps. 17 K.W. 22 K.W. #4 B&S 10 Ton 75 10100 60 115 amps. 20 K.W. 27 K.W. #4 B&S 13 Ton

AVERAGE (All Day) LIFTING CAPACITY IN POUNDSMachine Cast Pig No. 1 Heavy Melting Scrap No. 2 Melting Scrap No. 1 Machinery Scrap (Cast Iron) No. 2 Busheling Steel Turnings Plate Punchings 1500 1500 1030 815 565 475 1720 2560 2560 1660 1300 870 725 3000 3970 3970 2580 2040 1360 1230 4350 4520 4520 3000 2480 1630 1360 5770 5650 5650 3880 3320 2140 1800 7380

Page 32

Grade Cupola * 32510 (B) * 35018 (A) ** Pearlitic

GRADES OF MALLEABLE IRON Ultimate Yield Lbs./Sq. In. Lbs./Sq. In. 40,000 (Min.) 30,000 (Min.) 50,000 (Min.) 32,500 (Min.) 53,000 (Min.) 35,000 (Min.) 60,000 to 90,000 43,000 to 70,000

Elongation % 5 (Min.) 10 (Min.) 18 (Min.) 10 to 2

* Grades 32510 and 35018 refer to A.S.T.M. Specification A-47 and are frequently referred to as grades B and A. ** Specifications on mechanical properties for the many special grades of malleable iron are frequently decided upon by agreement between producer and consumer.

COLOR SCALE FOR TEMPERATURESThe following color scale permits a rough approximation of high temperatures. Degrees Color Centigrade Lowest visible red 475 Lowest visible red to dark red 475 to 650 650 to 750 Dark red to cherry red Cherry red to bright cherry red 750 to 815 Bright cherry red to orange 815 to 900 Orange to yellow 900 to 1090 Yellow to light yellow 1090 to 1315 1315 to 1540 Light yellow to white White to dazzling white 1540 or higher Degrees Fahrenheit 885 885 to 1200 1200 to 1380 1380 to 1500 1500 to 1650 1650 to 2000 2000 to 2400 2400 to 2800 2800 or higher

FUSION POINTS OF ASH AND SLAGSCoal Ash Easily fusible Moderately fusible Refractory Slags Acid open-hearth slag Basic open-hearth slag Blast furnace slag Heating furnace slag Courtesy Harbison-Walker Refractories Co. below 1200 1200 to 1430 above 1430 approx.1250 approx. 1250 approx. 1170 approx. 1165 below 2200 2200 to 2600 above 2600 approx. 2280 approx. 2280 approx. 2140 approx. 2130

MELTING POINTS OF MINERALS AND OXIDES Cent. Fahr. (A12O3) 2050 3722 Corundum Chromium Oxide (Cr2O3) 1990 3614 (SiO2) 1728 3142.4 Cristobalite (2MgOSiO2) 1910 3470 Forsterite Lime (CaO) 2570 4658 (MgO) 2800 5072 Periclase (TiO2) 1825 3317 Rutile Spinel (MgOA12O3) 2135 3875 (ZrO2) 2720 4928 Zirconia Zircon (ZrO2SiO2) 2550 4622 (3Al2O32SiO2) Mullite Mullite melts incongruently at 1830C. (3326F.) to form corundum and a silicious liquid. It is completely melted at approximately 1925C. (3497F.). (A12O32SiO22H2O) Kaolinite Kaolinite has a P.C.E. value of cone 35, corresponding to a temperature of 1785C. (3245F.).

Page 33

INTERNATIONAL ATOMIC WEIGHTSName Symbol Atomic Weight Name Symbol Atomic Weight

Aluminum Antimony Argon Arsenic Barium Beryllium Bismuth Boron Cadmium Calcium Carbon Cerium Cesium Chlorine Chromium Cobalt Copper Fluorine Gallium Germanium Gold Hydrogen Iridium Iron Lead Lithium Magnesium Manganese Mercury

Al Sb A As Ba Be Bi B Cd Ca C Ce Cs Cl Cr Co Cu F Ga Ge Au H Ir Fe Pb Li Mg Mn Hg

26.98 121.75 39.95 74.92 137.34 9.01 208.98 10.81 112.40 40.08 12.010 140.12 132.91 35.45 52.00 58.93 63.54 19.00 69.72 72.59 196.97 1.0080 192.2 55.85 207.19 6.940 24.31 54.94 200.59

Molybdenum Nickel Niobium Nitrogen Osmium Oxygen Palladium Phosphorus Platinum Potassium Radium Selenium Silicon Silver Sodium Strontium Sulfur Tantalum Tellurium Thallium Thorium Tin Titanium Tungsten Uranium Vanadium Yttrium Zinc Zirconium

Mo Ni Nb N Os O Pd P Pt K Ra Se Si Ag Na Sr S Ta Te Ti Tb Sn Ti W U V Yt Zn Zr

95.94 58.71 92.91 14. 008 190.2 16.000 106.4 30.97 195.09 39.10 226 78.96 28.09 107.87 22.99 87.62 32.06 180.95 127.60 204.37 232.04 118.69 47.90 183.85 238.03 50.94 88.90 65.37 91.22

Page 34

PROPERTIES OF VARIOUS METALS AND ALLOYSSpecific Heat (Room Temp) Cal./g/C0.215 0.09 0.09 0.09 0.055 0.11 0.099 0.092 0.031 0.11 0.11 0.031 0.245 0.121 0.127 0.105 0.162 0.056 0.117 0.12 0.11 0.054 0.124 0.028 0.091

Metal

Symbol

Density g/cm3 lbs./in.3

Melting Point C F

Linear Expansion per Unit Length (at Room Temp.) per C23.6x10 20.3 18.4 18.4 29.8 6.2 13.8 16.8 14.2 10.6 11.4 29.3 27.1 23.3 14.0 13.3 19.7 11.0 17.3 11.0 23 8.4 39.7-6

per F13.11x10-6 11.28 10.2 10.2 16.5 3.4 7.7 9.3 7.9 5.9 6.3 16.3 15.0 12.94 7.78 7.39 10.94 6.11 9.61 6.11 12.78 4.67 22.06

Aluminum Brass Yellow Bronze Bronze Cast Cadmium Chromium Cobalt Copper Gold Iron (Cast) Iron (Wrought) Lead Magnesium Manganese Monel Nickel Silicon Silver Steel: Carbon Stainl. 304 Stainl. 410 Tin Titanium Uranium Zinc

Al Cd Cr Co Cu Au Fe Pb Mg Mn Ni Si Ag

2.70 0.098 8.20-8.60 0.296-0.310 8.80-8.78 0.318-0.317 8.78 0.317 8.648 0.312 6.93 0.250 8.71 0.315 8.89 0.321 19.32 0.698 7.03-7.73 0.254-0.279 7.87 0.284 11.36 0.410 1.74 0.063 7.43 0.268 8.84 0.319 8.90 0.322 2.33 0.084 10.49 0.379 7.8 7.9 7.7 7.30 4.51 19.07 7.13 0.282 0.285 0.278 0.264 0.163 0.689 0.258

660 1220 931 1708 1046 1915 1050 1922 321 610 1878 3412 1497 2727 1084 1983 1064 1947 1088-1260 1990-2300 1510 2750 327 621 650 1202 1260 2300 1327 2421 1455 2651 1412 2574 962 1764 1482 > 1399 > 1482 232 1670 1132 419 2700 > 2550 > 2700 450 3038 2070 786

Sn Ti U Zn

Page 35

THERMAL PROPERTIES OF METALSMean Specific Heat 60 to Melting Point BTU per Lb. Per F .254 .054 .634 .032 .120 .105 .106 .126 .095 .100 .107 .107 .060 .156 .105 .034 .168 .168 .164 .141 .190 .180 .153 .032 .281 .182 .078 .127 .136 .037 .076 .062 .165 .165 .165 .059 .173 .036 .153 .101 .066 Total Heat in Liquid at Pouring Temp. F BTU/Lb. 500 136 1981 40.1 284 317 306 368 269 260 303 265 65.1 321 100.3 626

SUBSTANCE

Aluminum Antimony Beryllium Bismuth Brass, Muntz Metal (60 Cu, 40 Zn) Brass, Red (85 Cu, 15 Zn) Brass, Yellow (65 Cu, 35 Zn) Bronze, Aluminum (90 Cu, 10 Al) Bronze, Bearing (80 Cu, 10 Sn, 10 Pb) Bronze, Bell-Metal Bronze, Gun-Metal Bronze, Tobin Cadmium Chromium Copper Gold Iron, Pure 60 to 2802F Iron, Pure 60 to 2554F Iron, Pure 60 to 1670F Iron, Pure 60 to 1414F Iron, Cast, Gray (94 Fe, 3.5 C, 2.5 Si) Iron, Cast, White (97 Fe, 3 C) Iron, Pig (4.22 C, 1.48 Si, 0.73 Mn, 0.12 P, 0.03 S) Lead Magnesium Manganese Molybdenum Monel Metal Nickel Platinum Rhodium Silver Steel (0.00-0.60 C) Steel (0.60-0.80 C) Steel (0.80-1.00 C) Tin Titanium (99.9 Ti) Tungsten Vanadium Zinc Zirconium

Melting Point F 1220 1167 2343 520 1660 1880 1708 1905 1832 1598 1832 1625 610 3412 1983 1947 2802

2246 2102 2012 621 1202 2300 4760 2421 2651 3224 3571 1764 2800 2670 2600 450 3038 6170 3150 786 3200

Heat in Solid at Melting Point BTU/Lb. 288 58.5 1411 14.0 192 191 175 232 168 154 190 167 31.3 525 197 62.9 451 409* 254* 184* 415 368 299 17.4 312 391 372 305 346 116 262 103 445 425 421 21.5 295 220 473 70.9 207

Latent Heat of Fusion BTU/Lb. 170 68.9 470 22.5 69.0 86.5 84.4 98.6 79.9 76.3 84.2 73.5 23.8 136 91.1 29.0 117 3.06 6.53 0.0 41.1 60.3 84.6 11.3 160 115 126 122 133 49 45 118 118 118 26.1 100 79 43.4

Total Heat in Liquid at Melting Temp. BTU/Lb. 458 127 1881 36.5 261 278 259 331 248 230 274 241 55.1 661 288 91.9 568 412** 261** 184** 456 428 384 28.7 472 506 498 427 479 165 148 563 543 539 47.6 395 299 114

Average Pouring Temp. F 1380 1320 2500 620 1850 2250 2150 2200 2050 1900 2100 1850 750 2200 2150 3100

2800 2900 2300 720 1380 2400 2750 2850

583 612 450 31.9 522 529 464 506

1950 3100 2950 2900 650

160 621 644 608 59.5

900

125

* Heat in solid up to transformation point ** Heat in solid after allotropic point

Page 36

PHYSICAL PROPERTIES OF GASES AND VAPORSSpecific Gravity Density Specific Gravity Air = 10.9073 1.0000 0.5963 2.0854 1.5290 0.9671 1.0493 0.9749 0.1380 0.0695 0.5544 0.9672 1.10527 1.6580 1.5620 2.2638

Gas or VaporAcetylene Air Ammonia Butane Carbon Dioxide Carbon Monoxide Ethane Ethylene Helium Hydrogen Methane Nitrogen Oxygen Ozone Propane Sulfur Dioxide

Chemical FormulaC2H2 NH3 C4H10 CO2 CO C2H6 C2H4 He H2 CH4 N2 O2 O3 C3H8 SO2

Density Lbs./Cu. Ft. 68F. 1 Atmosphere06754 .07528 .04420 .15699 .11420 .07269 .07899 .07280 .01039 .00523 .04163 .07274 .0830b .12481 .11759 .16630

Page 37

PROPERTIES OF DRY AIRTemp. Deg. F. 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 110 120 130 140 150 160 170 180 190 200 220 240 260 280 300 350 400 450 500 550 600 700 800 900 1000 1200 1500 1800 2100 Density, lb./cu. ft. .0863 .0854 .0845 .0836 .0827 .0819 .0810 .0802 .0794 .0786 .0778 .0771 .0764 .0756 .0749 .0742 .0735 .0728 .0722 .0715 .0709 .0696 .0684 .0673 .0662 .0651 .0640 .0630 .0620 .0614 .0601 .0584 .0567 .0551 .0536 .0522 .0490 .0461 .0436 .0413 .0393 .0374 .0342 .0315 .0292 .0272 .0239 .0202 .0175 .0155 Wolume of 1 lb. Dry Air, cu. ft. 11.59 11.71 11.83 11.96 12.09 12.21 12.35 12.47 12.59 12.72 12.85 12.97 13.09 13.23 13.35 13.48 13.61 13.74 13.85 13.99 14.10 14.37 14.62 14.86 15.11 15.36 15.63 15.87 16.13 16.29 16.64 17.12 17.64 18.15 18.66 19.16 20.41 21.69 22.94 24.21 25.45 26.74 29.24 31.75 34.25 36.76 41.84 49.50 57.14 64.52 Fraction of Volume* . 868 .877 .886 .896 .905 .915 .924 .934 .943 .953 .962 .971 .981 .990 1.000 1.009 1.019 1.028 1.038 1.047 1.057 1.075 1.094 1.113 1.132 1.151 1.170 1.189 1.208 1.227 1.245 1.283 1.321 1.359 1.396 1.434 1.528 1.623 1.717 1.811 1.906 2.001 2.190 2.378 2.567 2.756 3.133 3.710 4.278 4.834 Enthalpy BTU/lb. 109.90 111.10 112.30 113.50 114.69 115.89 117.08 118.28 119.48 120.68 121.87 123.07 124.27 125.47 126.66 127.86 129.06 130.26 131.46 132.66 133.86 136.26 138.66 141.06 143.47 145.88 148.28 150.68 153.09 155.50 157.92 162.73 167.56 172.39 177.23 182.08 194.25 206.46 218.72 231.06 243.48 255.96 281.14 306.65 332.48 358.63 411.82 493.64 577.51 662.99

* Fraction of volume at 70F or relative volume compared to 70F (must multiply by 100 for % volume.)

Page 38

TEMPERATURE CONVERSION TABLENOTE: The Fahrenheit equivalent is shown in the bold type to the right of the Centigrade temperature C. The Centigrade equivalent is shown in the bold type to the left of the Fahrenheit temperature F.C.-17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -11.7 -11.1 -10.6 -10.0 -9.44 -8.89 -8.33 -7.78 -7.22 -6.67 -6.11 -5.56 -5.00 -4.44 -3.89 -3.33 -2.78 -2.22 -1.67 -1.11 -0.56 0 0.56 1.11 1.67 2.22 2.78 3.33 3.89 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090

F.32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2

C.4.44 5.00 5.56 6.11 6.67 7.22 7.78 8.33 8.89 9.44 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 1200 1210 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 1400 1410 1420 1430 1440 1450 1460 1470 1480 1490

F.104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2

C.26.7 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 38 43 49 54 60 66 71 77 82 88 93 99 104 110 116 121 127 132 138 143 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 1500 1510 1520 1530 1540 1550 1560 1570 1580 1590 1600 1610 1620 1630 1640 1650 1660 1670 1680 1690 1700 1710 1720 1730 1740 1750 1760 1770 1780 1790 1800 1810 1820 1830 1840 1850 1860 1870 1880 1890

F.176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212 230 248 266 284 302 320 338 356 374 392 410 428 446 464 482 500 518 536 554

C.149 154 160 166 171 177 182 188 193 199 204 210 216 221 227 232 238 243 249 254 260 266 271 277 282 288 293 299 304 310 316 321 327 332 338 343 349 354 360 366 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050 2060 2070 2080 2090 2100 2110 2120 2130 2140 2150 2160 2170 2180 2190 2200 2210 2220 2230 2240 2250 2260 2270 2280 2290

F.572 590 608 626 644 662 680 698 716 734 752 770 788 806 824 842 860 878 896 914 932 950 968 986 1004 1022 1040 1058 1076 1094 1112 1130 1148 1166 1184 1202 1220 1238 1256 1274

C.371 377 382 388 393 399 404 410 416 421 427 432 438 443 449 454 460 466 471 477 482 488 493 499 504 510 516 521 527 532 538 543 549 554 560 566 571 577 582 588

F.1292 1310 1328 1346 1364 1382 1400 1418 1436 1454 1472 1490 1508 1526 1544 1562 1580 1598 1616 1634 1652 1670 1688 1706 1724 1742 1760 1778 1796 1814 1832 1850 1868 1886 1904 1922 1940 1958 1976 1994

C.593 599 604 610 616 621 627 632 638 643 649 654 660 666 671 677 682 688 693 699 704 710 716 721 727 732 738 743 749 754 760 766 771 777 782 788 793 799 804 810

F.2012 2030 2048 2066 2084 2102 2120 2138 2156 2174 2192 2210 2228 2246 2264 2282 2300 2318 2336 2354 2372 2390 2408 2426 2444 2462 2480 2498 2516 2534 2552 2570 2588 2606 2624 2642 2660 2678 2696 2714

C.816 821 827 832 838 843 849 854 860 866 871 877 882 888 893 899 904 910 916 921 927 932 938 943 949 954 960 966 971 977 982 988 993 999 1004 1010 1016 1021 1027 1032

F.2732 2750 2768 2786 2804 2822 2840 2858 2876 2894 2912 2930 2948 2966 2984 3002 3020 3038 3056 3074 3092 3110 3128 3146 3164 3182 3200 3218 3236 3254 3272 3290 3308 3326 3344 3362 3380 3398 3416 3434

C.1038 1043 1049 1054 1060 1066 1071 1077 1082 1088 1093 1099 1104 1110 1116 1121 1127 1132 1138 1143 1149 1154 1160 1166 1171 1177 1182 1188 1193 1199 1204 1210 1216 1221 1227 1232 1238 1243 1249 1254

F.3452 3470 3488 3506 3524 3542 3560 3578 3596 3614 3632 3650 3668 3686 3704 3722 3740 3758 3776 3794 3812 3830 3848 3866 3884 3902 3920 3938 3956 3974 3992 4010 4028 4046 4064 4082 4100 4118 4136 4154

Page 39

USEFUL FORMULASHp 5250 Torque RPM Hp = RPM 5250 120 Frequency Rpm = No. of Poles P( pounds ) 2 R(inches) RPM Horsepower = 33,000 12 P R RPM Torque RPM or Horsepower = 63,000 63,000Torque in Lb.-ft. = 1 KW = 1.341 HPRPM 1750 1430 1170 950 870 780 640 580 520 420 LB.-IN 36 44 54 66 72 81 98 109 121 150 RPM 350 280 230 190 155 125 100 84 68 56

MECHANICAL FORMULAS

1 HP = 0.7457 KWTORQUE (LB.-IN.) AT 1 HP LB.-IN RPM 180 45 225 37 274 30 331 25 406 20 504 16.5 630 13.5 750 11 926 9 1125 7.5 LB.-IN 1400 1703 2100 2520 3150 3818 4667 5727 7000 8400 RPM 6 4.7 4.0 3.2 2.7 2.2 1.8 1.5 1.2 1.0 LB.-IN 10500 13404 15750 19687 23370 28636 35000 42000 52500 63000

To compute torque at any horsepower, multiply torque values above by horsepower required. Examples: 10 hp @ 350 rpm, Torque = 10 x 180 or 18000 lb.-in. hp @ 30 rpm, Torque = x 2100 or 1050 lb.-in. For intermediate speeds, approximate the torque from table, or apply standard torque formula above.

ELECTRICAL FORMULAS To Find Amperes when horsepower is known Amperes when kilowatts are known Amperes when kva are known Kilowatts Kva Horsepower (output) Alternating Current Single-phase Three-phase

Hp 746 E Eff pf Kw 1000 E pf Kva 1000 E I E pf 1000 IE 1000 I E Eff pf 1000

Hp 746 1.73 E Eff pf Kw 1000 1.73 E pf Kva 1000 E 1.73 I E pf 1000 1.73 I E 1000 1.73 I E Eff pf 1000

I = Amperes; E = Volts; Eff. = Efficiency; pf= Power factor; Kva = Kilovolt-amperes; Kw = Kilowatts

RULES OF THUMB (Approximation)At 1800 rpm, a motor develops 3 lb.-ft. per hp At 575 volts, a 3-phase motor draws 1 amp per hp At 230 volts, a 3-phase motor draws 2.5 amp per hp At 115 volts, a single-phase motor draws 10 amp per hp At 1200 rpm, a motor develops 4.5 lb.-ft. per hp At 460 volts, a 3-phase motor draws 1.25 amp per hp At 230 volts, a single-phase motor draws 5 amp per hp

Page 40

WEIGHTS OF VARIOUS MATERIALSAverage per cubic foot in pounds 100 Average per cubic foot in pounds 708 711 537 490 495 473 - 516 455 443

Material Brick Common Cements Portland Coal and Coke Anthracite Bituminous Charcoal Coke Concrete Cement, fine Rubble, coarse Earth Loam, dry, loose Loam, packed Loam, soft loose mud Loam, dense mud Gravel Dry, packed Wet, packed Lime Quick, loose lumps Quick, fine Stone, large rocks Stone, irregular lumps Masonry Dry Granite or limestone Mortar, rubble Sandstone, dressed Metals Aluminum Brass, cast Bronze Copper, cast Copper, rolled or wire Iron, gray cast Iron, white cast Iron, wrought

Material Metals (Contd) Lead, cast Lead, rolled Nickel Steel, cast Steel, rolled Steel, stainless Tin, cast Zinc, cast Oils Crude Engine Gasoline Petroleum Refractory Materials Firebrick, insulating Firebrick material (superplastic) Fireclay brick (superduty) Ganister, ground silica Magnesite and magnesitechrome brick Magnesite (loose) Silica brick Sand Dry, loose Dry, packed Water At 39.2F (Max density) Woods, Dry Hemlock Hickory Ironwood Mahogany Maple Oak, live Oak, white Pine, white Pine, yellow northern Pine, yellow southern Spruce

94

60 49 18.5 26.3

137 119

48 55 43 55

76 95 108 125

30 - 60 135 137 - 154 123 170 - 197 155 102 - 115

118 130

53 75 168 96

100 110

138 165 154 144

62.425

166 524 548 537 555 445 475 490

25 53 114 35 - 53 49 59 50 25 34 45 25

Page 41

PRESSURE EQUIVALENTSOunces per Sq. In. 0.25 0.50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Lbs per Sq. In. 0.016 0.031 0.062 0.125 0.187 0.250 0.312 0.375 0.437 0.500 0.562 0.625 0.687 0.750 0.812 0.875 0.937 1.000 1.062 1.125 1.187 1.250 1.312 1.375 1.437 1.500 1.562 1.625 1.687 1.750 1.812 1.875 1.937 2.000 2.062 2.125 2.187 Inches of Water 0.433 0.866 1.732 3.464 5.20 6.92 8.66 10.39 12.12 13.86 15.59 17.32 19.05 20.78 22 52 21 25 25 98 27 71 29.44 31.18 32.91 34.64 36.37 38.10 39.84 41.57 43.30 45.00 46.8 48.5 50.2 52.0 53.7 55.4 57.2 58.9 60.6 Millimeters of Water 11.00 22.00 44.00 88.0 132.0 176.0 220.0 264.0 308.0 350.9 395.0 439.0 483.0 527.0 571 615 659 703 747 791 835 879 923 967 1011 1055 1099 1143 1187 1231 1275 1319 1363 1407 1451 1495 1539 Inches of Mercury 0.0319 0.0638 0.1275 0.2551 0.3826 0.570 0.638 0.765 0.893 1.020 1.148 1.275 1.403 1.531 1.658 1.786 1.913 2.041 2.169 2.296 2.424 2.551 2.679 2.806 2.934 3.061 3.189 3.317 3.444 3.572 3.699 3.827 3.954 4.08 4.21 4.34 4.46 Millimeters of Mercury 0.810 1.621 3.239 6.478 9.72 12.95 16.19 19.43 22.67 25.91 29.15 32.38 35.62 38.86 42.1 45.3 48.6 51.8 55.1 58.3 61.5 64.8 68.0 71.2 74.5 77.7 81.0 84.2 87.4 90.7 93.9 97.2 100.4 103.6 106.9 110.1 113.3

Page 42

METRIC EQUIVALENTS(Based on National Bureau of Standards)

LENGTH cm m m km cm2 m2 m2 km2 hectare = = = = 0.3937 in. 3.2808 ft. 1.0936 yd. 0.6213 mile 0.1549 in.2 10.7638 ft.2 1.1959 yd.2 0.3861 mi. 2 2.471 acres AREA in. ft. yd. mile in.2 ft.2 yd.2 mi.2 acres one hectare = 10,000 m2 VOLUME = = = = 2.5400 cm 0.3048 m 0.9144 m 1.6093 km 6.4516 cm2 0.0929 m2 0.7645 m2 2.5900 km2 0.4047 hectare

= = = = =

= = = = =

cm m3 m3 Liter Liter Liter

3

= = = = = =

0.0610 in. in.3 = 16.3871 cm3 35.3142 ft.3 ft.3 = 0.0283 m3 3 3 1.3079 yd. yd. = 0.7645 m3 0.0353 ft.3 ft.3 = 28.32 liters 0.2641 gal. (U.S.) gal. = 3.7853 liters 61.0250 in.3 in.3 = 0.0163 liters one Liter of pure water @ 4C = 2.2046 lb. = 1 kg WEIGHT

3

g g kg kg m ton m ton2

= 15.4323 grains = 0.0352 oz. = 2.2046 lbs. = 0.0011 ton (short) = 1.1023 ton (short) = 2205 lbs.2

grain oz. lb. ton (short) ton (short) ton (long)

= = = = = =

0.0647 g 28.3496 g 0.4535 kg 907.1848 kg 0.9071 m ton 1016 kg

1 kg per cm = 1 kg per m2 = 1 kg per cm2 =

PRESSURE 14.22 lb. per in. 1 lb. per in.2 = 0.07031 kg per cm2 0.2048 lb. per ft.2 1 lb. per ft.2 = 4.882 kg per m2 0.9678 normal atmosphere 1 normal atmosphere = 1.0332 kg per cm2 1 normal atmosphere = 14.70 lb. per in.2 MISCELLANEOUS 1 lb./ft.3 = 16.0185 kg/m3 1 BTU = 0.252 kg-calorie 1 ft. lb. = 0.13826 kg-m 1 KW = 14.3328 kg-Cal/min.

Density = Energy = Work = Density =

Page 43

CONVERSION FACTORSBTU per min. BTU per min. Ft. Lbs. per min. Horsepower Horsepower Horsepower Horsepower Watts Kilowatts Inches of Water Oz. per Sq. In. In. of Water U.S. Gallons U.S. Gallons In. of Mercury Ft. of Water Cu. Ft. U.S. Gallons BTU per Lb. Cal per g g per cm M.P.H. Diameter Circle Side of Square Side of Cube Joule Miles Long Tons Acres Lbs. x 0.02356 x 0.01757 x 0.0000303 x 42.44 x 33,000 x 10.70 x 745.7 x 0.7373 x 1.3410 x 0.5773 x 1.732 x 0.03613 x 0.8327 x 0.1337 x 0.4912 x 0.4335 x 62.428 x 8.336 x 0.586 x 1.8 x 62.428 x 88 x 0.886 x 1.414 x 1.732 x 0.7373 x 5,280 x 2,240 x 43,560 x 7,000 = Horsepower = Kilowatts = Horsepower = BTU per min = Ft. Lbs. per min = kg cal per min. = Watts = Ft. Lbs. per sec. = Horsepower = Oz. per Sq. In. = In. of Water = P.S.I. = Imperial Gallons = Cubic Ft. = P.S.I. = P.S.I. = Pounds of Water = Pounds of Water = KWH per Ton (Short) = BTU per Pound = Pounds per Ft. = Ft. per Sec. = Side of Equal Square = Diagonal = Space Diagonal = Foot Pounds = Feet = Pounds = Sq. Ft. = Grains

POWER1 KW 1 KW 1 HP 1 Watt 1 Watt = = = = = 56.87 BTU per min. 1.341 HP 550 Ft.-Lb. per sec. 44.25 Ft.-Lb. per min. 14.34 g-cal per min.

TEMPERATURE SCALESDegrees Fahrenheit = Degrees Kelvin = Degrees Rankine = 1.8 (Deg C) + 32 Deg C + 273.16 Deg F + 459.69

ENERGY1 BTU 1 HP-HR 1 KWH 1 KWH 1 KWH 1 KWH = = = = = = 252.161 Calories 2544.48 BTU One KW for one our 2,655,218 Ft.-Lb. 1.34 HP-HR 3412.19 BTU

COST OF OPERATING ELECTRIC MOTORSOne KWH is consumed for each one (1) HP used per hour. Calculate HP used per hour and multiply by prevailing rate per KWH to get cost of operation. (Above is based on a motor efficiency of 85% and average line loss.)

Page 44

INCHES TO MILLIMETERSInches 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 33/64 17/32 35/64 Millimeters 0.3969 0.7938 1.1906 1.5875 1.9844 2.3813 2.7781 3.1750 3.5719 3.9688 4.3656 4.7625 5.1594 5.5563 5.9531 6.3500 6.7469 7.1438 7.5406 7.9375 8.3344 8.7313 9.1281 9.5250 9.9219 10.3188 10.7156 11.1125 11.5094 11.9063 12.3031 12.7000 13.0969 13.4938 13.8906 Inches 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 2 3 4 5 6 7 Millimeters 14.2875 14.6844 15.0813 15.4781 15.8750 16.2719 16.6688 17.0656 17.4625 17.8594 18.2563 18.6531 19.0500 19.4469 19.8438 20.2406 20.6375 21.0344 21.4313 21.8281 22.2250 22.6219 23.0188 23.4156 23.8125 24.2094 24.6063 25.0031 25.4000 50.8000 76.2000 101.600 127.000 152.400 177.800 Inches 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Feet 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 Millimeters 203.200 228.600 254.000 279.400 304.800 330.200 355.600 381.000 406.400 431.800 457.200 482.600 508.000 533.400 558.800 584.200 609.600 Meters 0.9144 1.2192 1.5240 1.8288 2.1336 2.4384 2.7432 3.0480 6.0960 9.1440 12.1920 15.2400 18.2880 21.3360 24.3840 27.4320 30.4800

Page 45

MEASURES AND WEIGHTSDECIMAL OF AN INCH AND A FOOTInch Equivalents to Foot Fractions Inch Equivalents to Foot Fractions Inch Equivalents to Foot Fractions Inch Equivalents to Foot Fractions 9 1/16 9 1/8 9 3/16 9 1/4 9 5/16 9 3/8 9 7/16 9 1/2 9 9/16 9 5/8 9 11/16 9 3/4 9 13/16 9 7/8 9 15/16 10 10 1/16 10 1/8 10 3/16 10 1/4 10 5/16 10 3/8 10 7/16 10 1/2 10 9/16 10 5/8 10 11/16 10 3/4 10 13/16 10 7/8 10 15/16 11 11 1/16 11 1/8 11 3/16 11 1/4 11 5/16 11 3/8 11 7/16 11 1/2 11 9/16 11 5/8 11 11/16 11 3/4 11 13/16 11 7/8 11 15/16 12

Fractions Of Inch of Foot

Fractions Of Inch of Foot

Fractions Of Inch of Foot

Fractions Of Inch of Foot

0.0052 0.0104 1/64 0.015625 0.0208 0.0260 0.03125 0.0365 0.0417 0.046875 0.0521 0.0573 0.06250 0.0677 0.0729 0.078125 0.0833 0.0885 0.09375 0.0990 0.1042 0.109375 0.1146 0.1198 0.12500 0.1302 0.1354 0.140625 0.1458 0.1510 0.15625 0.1615 0.1667 0.171875 0.1771 0.1823 0.18750 0.1927 0.1979 0.203125 0.2083 0.2135 0.21875 0.2240 0.2292 0.234375 0.2396 0.2448 0.25000

1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1 7/16 1 1/2 1 9/16 1 5/8 1 11/16 1 3/4 1 13/16 1 7/8 1 15/16 2 2 1/16 2 1/8 2 3/16 2 1/4 2 5/16 2 3/8 2 7/16 2 1/2 2 9/16 2 5/8 2 11/16 2 3/4 2 13/16 2 7/8 2 15/16 3 17/64

0.2552 0.2604 0.265625 0.2708 0.2760 0.28125 0.2865 0.2917 0.296875 0.3021 0.3073 0.31250 0.3177 0.3229 0.328125 0.3333 0.3385 0.34375 0.3490 0.3542 0.359375 0.3646 0.3698 0.37500 0.3802 0.3854 0.390625 0.3958 0.4010 0.40625 0.4115 0.4167 0.421875 0.4271 0.4323 0.43750 0.4427 0.4479 0.453125 0.4583 0.4635 0.46875 0.4740 0.4792 0.484375 0.4896 0.4948 0.50000

3 1/16 3 1/8 3 3/16 3 1/4 3 5/16 3 3/8 3 7/16 3 1/2 3 9/16 3 5/8 3 11/16 3 3/4 3 13/16 3 7/8 3 15/16 4 4 1/16 4 1/8 4 3/16 4 1/4 4 5/16 4 3/8 4 7/16 4 1/2 4 9/16 4 5/8 4 11/16 4 3/4 4 13/16 4 7/8 4 15/16 5 5 1/16 5 1/8 5 3/16 5 1/4 5 5/16 5 3/8 5 7/16 5 1/2 5 9/16 5 5/8 5 11/16 5 3/4 5 13/16 5 7/8 5 15/16 6 33/64

0.5052 0.5104 0.515625 0.5208 0.5260 0.53125 0.5365 0.5417 0.546875 0.5521 0.5573 0.56250 0.5677 0.5729 0.578125 0.5833 0.5885 0.59375 0.5990 0.6042 0.609375 0.6146 0.6198 0.62500 0.6302 0.6354 0.640625 0.6458 0.6510 0.65625 0.6615 0.6667 0.671875 0.6771 0.6823 0.68750 0.6927 0.6979 0.703125 0.7083 0.7135 0.71875 0.7240 0.7292 0.734375 0.7396 0.7448 0.75000

6 1/16 6 1/8 6 3/16 6 1/4 6 5/16 6 3/8 6 7/16 6 1/2 6 9/16 6 5/8 6 11/16 6 3/4 6 13/16 6 7/8 6 15/16 7 7 1/16 7 1/8 7 3/16 7 1/4 7 5/16 7 3/8 7 7/16 7 1/2 7 9/16 7 5/8 7 11/16 7 3/4 7 13/16 7 7/8 7 15/16 8 8 1/16 8 1/8 8 3/16 8 1/4 8 5/16 8 3/8 8 7/16 8 1/2 8 9/16 8 5/8 8 11/16 8 3/4 8 13/16 8 7/8 8 15/16 9 49/64

0.7552 0.7604 0.765625 0.7708 0.7760 0.78125 0.7865 0.7917 0.796875 0.8021 0.8073 0.81250 0.8177 0.8229 0.828125 0.8333 0.8385 0.84375 0.8490 0.8542 0.859375 0.8646 0.8698 0.87500 0.8802 0.8854 0.890625 0.8958 0.9010 0.90625 0.9115 0.9167 0.921875 0.9271 0.9323 0.93750 0.9427 0.9479 0.953125 0.9583 0.9635 0.96875 0.9740 0.9792 0.984375 0.9896 0.9948 1.00000

1/32

9/32

17/32

25/32

3/64

19/64

35/64

51/64

1/16

5/16

9/16

13/16

5/64

21/64

37/64

53/64

3/32

11/32

19/32

27/32

7/64

23/64

39/64

55/64

1/8

3/8

5/8

7/8

9/64

25/64

41/64

57/64

5/32

13/32

21/32

29/32

11/64

27/64

43/64

59/64

3/16

7/16

11/16

15/16

13/64

29/64

45/64

61/64

7/32

15/32

23/32

31/32

15/64

31/64

47/64

63/64

1/4

1/2

3/4

1

Page 46

AREA AND CIRCUMFERENCE OF CIRCLESDia. In. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Area Sq. In. Sq. Ft. 0.7854 0.0055 3.14 0.0218 7.07 0.0491 12.57 0.0873 19.63 0.1364 28.27 0.1963 38.48 0.2673 50.27 0.3491 63.62 0.4418 78.54 0.5454 95.03 0.6600 113.1 0.7854 132.7 0.9218 153.9 1.069 176.7 1.227 201.1 1.396 227.0 1.576 254.5 1.767 283.5 1.969 314.2 2.182 346.4 2.405 380.1 2.640 415.5 2.885 452.4 3.142 490.9 3.409 530.9 3.687 572.6 3.976 615.8 4.276 660.5 4.587 706.9 4.909 754.8 5.241 804.2 5.585 855.3 5.940 907.9 6.305 962.1 6.681 1017.9 7.069 Circumference In. Ft. 3.1416 0.2618 6.28 0.5236 9.42 0.7854 12.57 1.047 15.71 1.309 18.85 1.571 21.99 1.833 25.13 2.094 28.27 2.356 31.42 2.618 34.56 2.880 37.70 3.142 40.84 3.403 43.98 3.665 47.12 3.927 50.27 4.189 53.41 4.451 56.55 4.712 59.69 4.974 62.83 5.236 65.97 5.498 69.12 5.760 72.26 6.021 75.40 6.283 78.54 6.545 81.68 6.807 84.82 7.069 87.96 7.330 91.11 7.592 94.25 7.854 97.39 8.116 100.5 8.378 103.7 8.639 106.8 8.901 110.0 9.163 113.1 9.425 Dia. In. 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 Area Sq. In. Sq. Ft. 1075.2 7.467 1134.1 7.876 1194.6 8.296 1256.6 8.727 1320.3 9.168 1385.4 9.621 1452.2 10.08 1520.5 10.56 1590.4 11.04 1661.9 11.54 1734.9 12.05 1809.6 12.57 1885.7 13.10 1963.5 13.64 2043 14.19 2124 14.75 2206 15.32 2290 15.90 2376 16.50 2463 17.10 2552 17.72 2642 18.35 2734 18.99 2827 19.63 2922 20.29 3019 20.97 3117 21.65 3217 22.34 3318 23.04 3421 23.76 3526 24.48 3632 25.22 3739 25.97 3848 26.73 3959 27.49 4072 28.27 Circumference In. Ft. 116.2 9.687 119.4 9.948 122.5 10.21 125.7 10.47 128.8 10.73 131.9 11.00 135.1 11.26 138.2 11.52 141.4 11.78 144.5 12.04 147.7 12.30 150.8 12.57 153.9 12.83 157.1 13.09 160.2 13.35 163.4 13.61 166.5 13.88 169.6 14.14 172.8 14.40 175.9 14.66 179.1 14.92 182.2 15.18 185.4 15.45 188.5 15.71 191.6 15.97 194.8 16.23 197.9 16.49 201.1 16.76 204.2 17.02 207.3 17.28 210.5 17.54 213.6 17.80 216.8 18.06 219.9 18.33 223.1 18.59 226.2 18.85 Dia. In. 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 Area Sq. In. Sq. Ft. 4185 29.07 4301 29.87 4418 30.68 4536 31.50 4657 32.34 4778 33.18 4902 34.04 5027 34.91 5153 35.78 5281 36.67 5411 37.57 5542 38.48 5675 39.41 5809 40.34 5945 41.28 6082 42.24 6221 43.20 6362 44.18 6504 45.17 6648 46.16 6793 47.17 6940 48.19 7088 49.22 7238 50.27 7390 51.32 7543 52.38 7698 53.46 7854 54.54 8012 55.64 8171 56.75 8332 57.86 8495 58.99 8659 60.13 8825 61.28 8992 62.44 9161 63.62 Circumference In. Ft. 229.3 19.11 232.5 19.37 235.6 19.63 238.8 19.90 241.9 20.16 245.0 20.42 248.2 20.68 251.3 20.94 254.5 21.21 257.6 21.47 260.8 21.73 263.9 21.99 267.0 22.25 270.2 22.51 273.3 22.78 276.5 23.04 279.6 23.30 282.7 23.56 285.9 23.82 289.0 24.09 292.2 24.35 295.3 24.61 298.5 24.87 301.6 25.13 304.7 25.39 307.9 25.66 311.0 25.92 314.2 26.18 317.3 26.44 320.4 26.70 323.6 26.97 326.7 27.23 329.9 27.49 333.0 27.75 336.2 28.01 339.3 28.27

Page 47

INDEXAir, dry, properties of Air, Humidity percentages Atomic weights Circles, area and circumstances Coke consumption due to moisture Color scale for temperatures Combustion, air required for Combustion, useful data Conversion factors Crane Speeds Crane hoisting rope, size and strength Cupolas, formula for estimating height of bed coke Cupolas, front slagging Cupolas, melting rates for lined Cupolas, melting rates for liningless hot blast Cupolas, planning new installations Cupolas, operation, pointers on Cupolas, recommended tap hole sizes Cupolas well, holding capacities Cupolas lining data Decimal equivalents Electric Arc furnace transformers Electrical motors, cost of operating Electrodes, Graphite Energy Formulas, mechanical, electrical, rules of thumb Fusion, points, ash and slag Gases and vapors, physical properties Hydro-Arc furnace data, power consumption Hydro-Arc furnace, Shell capacities Inches to Millimeters Induction furnace, vertical type Induction furnace, horizontal type Ladles, capacities, iron Ladles, capacities, steel Ladles, selecting size of U-ladles Ladles, capacities of U-Ladles Ladles, method of calculating capacities Ladles, standard spout arrangements Magnets, scrap handling, lifting capacities Malleable iron, grades Metal densities in molten state Melting points, minerals and oxides Metal temperature and melting ratio Metric equivalents Monolithic linings Power Pressure equivalents Properties of metals and alloys Temperature, conversion Temperature, cupola tapping Temperature scales Thermal properties, metals Weights, various materials 38 16 34 47 17 33 12,13 23 44 30 31 15 11 4 5 2 3 10 15 6, 7, 8, 9 46 19 44 19 44 40 33 37 20 18 45 21 22 26 27 24 25 29 25 32 33 29 33 14 43 10 44 42 35 39 28 44 36 41

Page 48

Indexing Vibrating Feeder Type Cupola Charge

133 Cu. Ft. Clamshell Charging Bucket for Loading Vibrating Feeder Cupola Charger

Size 18/19/18 Whiting Hydro-Arc Electric Furnace

Pictured on these pages are a number of reasons why when planning to mechanize or improve your foundry operations you should consult Whiting. No matter what your problem, there is Whiting foundry equipment to solve it better and more economically.

Cupola Being Charged by Vibrating Feeder 50 Cu. Ft. Tilting Weigh Hopper Weighing Cupola Charges and Loading them into Skip Hoist Bucket

Size 11 Whiting Hydro-Arc Electric Furnace

170 Cu. Ft. Charging Bucket and S Type Skip for Cupola Charging

35 Ton A.O.D. Vessel

Trambeam Hot Metal Carrier

2850 Cu. Ft. Clamshell Arc Furnace Charging Bucket on Self-Propelled Radio Controlled Transfer/Scale Car

10 Ton Charge Make-up Crane

80 Ton Channel Induction Holding Furnace

Copyright 2004, by Whiting Equipment Canada Inc., Welland, Ontario, L3B 5P4

WHITING

FY-177R3

available at www.whiting.ca