Engineering Formulas

Nominal Design Parameters

Chillers: 2.4GPM/Ton @ 10° F ∆T Flow Cooling Tower = 15,000 BTU/HR/Ton 
Rate

 3 GPM per Ton

 12,000 BTU/HR/Ton  85° F Leaving Water Temperature
 20° F - 60° F Standard Supply  95° F Entering Water Temperature
Range
 78° F Wet Bulb
 Rating at 50° F Supply
Temperature
 85° F Water Cooled
Condenser
 95° F Air Cooled Condenser

Tower water make-up requirements:  Untreated 2% of flow rate   Treated 1.5% of flow rate
Weighted Water Test
Chiller Ton = GPMx∆T (Delta Temp) Tower Ton =GPMx∆T (Delta Temp)
                 24                          30         

Chiller Sizing
Injection Molding Blow Molding Extrusion
40#/hr Polyolefins= 1
30#/hr H.D. Polyethlene = 1ton 50#/hr H.D. Polyethlene  = 1 ton
ton
35#/hr L.D. Polyethlene = 1ton 40#/hr PET= 1 ton 50#/hr L.D. Polyethlene  = 1 ton
Minimum Flow 04.8
35#/hr Polypropylene   = 1ton 50#/hr Polypropylene = 1 ton         
gpm/ton
45#/hr PVC = 1 ton   75#/hr Polystyrene = 1 ton                 

50#/hr ABS= 1 ton   75#/hr PVC = 1 ton

50#/hr Polystyrene= 1 ton Blown Film Air Ring Cooling

105 CFM (50 ° F @ 78°  F WBT)= 1 ton
40#/hr Nylon= 1 ton

35#/hr Acrylic= 1 ton  

40#/hr Polyurethane = 1 ton

50#/hr Acetal= 1 ton

40#/hr PPO= 1 ton

40#/hr PET= 1 ton

50#/hr Polycarb= 1 ton

Chiller Capacity Loss/Gain

 Decrease nominal tonnage by approximately 2% per degree below a 50 ° F leaving water
temperature.
 Increase nominal tonnage approximately 2% per degree above 50 ° F leaving water
temperature up to 55 ° F

Other Equipment
Air Compressor w/no after cooler=.1 ton/Hp

Air Compressor w/after cooler=.2 Ton/Hp

Vacuum Pump=.1 ton/Hp

 Hydraulic Cooling=.1 ton/Hp

Barrel Cooling=.1 ton/in screw Dia.

Hot Runner Mold= 1 ton/10.5KW

Water Pump in Circuit=.2 Ton/Hr

400Ton Machine or above 1 Ton
Feed Throat
Below 400 Ton - 1/2 Ton

Extrusion Equipment
Gear Box Cooling=1 Ton/100Hp

Feed Throat 3" Screw or Less=1 Ton

Above 3" Screw=2 Tons

Barrel or Screw Cooling=1 Ton/Inch of Screw Diameter

Pipe Sizing Guide 

(Based on 5' - 7' feet/second velocity)

1/8”  = .75 GPM    3/4" = 10 GPM   2" = 70 GPM    6" = 600 GPM

¼” = 1.5 GPM    1" = 15 GPM    2 1/2" = 100 GPM 8" = 1,000 GPM

3/8” =  3 GPM    1 1/4" = 30 GPM  3" = 150 GPM 10" = 3000 GPM

1/2" =  6 GPM     1 1/2" = 40 GPM    4"= 275 GPM 12" = 5000 GPM

Metric Conversion Chart

To Convert     To Convert
Unit Volume Power

US GPM Liters/Min 3.785 FT/Lb/SEC Watts 1.356

US GPM Cum/Hr .2271 KW BTUH 342

CFM Liters/Min 28.317 Boiler HP BTUH 33475

CFM Cum/hr 1.6992 HP BTUH 2545

Unit Weight HP KW .7457

Lb/Ft Kg/m 1.4881

Lbs/Sq
gr/sq cm 70.31 Heat
in
Lbs/Sq
kPA 6.894 BTU Kg-cal .252
in
Lbs/Sq
Kg/Sq Cm.07031 BTU/LB Kg-cal .5556
in
Lbs/Sq gr-cal/sq
gr/cu cm 27.68 BTU/SQ FT .2713
in cm
Kg-cal/
Length BTU/CU FT 8.899
Cum
Inches cm 2.540 Weight

Feet meters .3048 Grains grams .0648

Yards meters .9144 Ounces* grams 28.350

Miles km 1.609 LBS kg .4536

Volume US tons kg 907.2

Cu.
cu cm 16.387 US Tons Tonnes .9072
Inches
Cu.
liters .01639 Long Tons kg 1016
Inches
Cu Feet cu meter .02832 Area

Cu Feet liters 28.317 SQ Inches sq cm 6.452

Cu Years cu meters .7646 SQ Years sq meters.8361

Fl
cu cm 29.57 SQ Miles sq km 2.590
Ounces
US
Gallon
cu meters .003785      
US
Gallon
liters 3.785      
*Auoirdupois pounds and ounces
Temperature
°F °C °F °C °F °C °F °C
0 -17.8 35 1.7   15 -9.4 50 10.0
5 -15 40 4.4   20 -6.7 55 12.8
10 -12.2 45 7.2   30 1.1 60 15.6
°F  to °C = (°F - 32) x .55 =°C   °C  to °F = (°C x 1.8) + 32 =°F
Flow Rate Vs. Temp Differences Per Ton % Ethylene Glycol by Volume vs Freeze Protection
1.2 GPM =   20 °F  T 10%            25°F 
2.4 GPM =   10 °F  T 20%            15°F 
4.8 GPM =     5 °F  T 30%              0°F 
9.6 GPM =  2.5 °F  T 40%           -15°F 
  50%           -40°F 
Abbreviations, Equivalents & Formulas
T = Delta Temperature = Temperature Differential
PSI = Pounds per square inch 1 Cooling Tower Ton= 15,000BTU/HR
GPM = Gallons per Minute 1 Refrigerant Ton = 12,000 BTU/HR
EWT = Entering Water Temperature 1 Gallon = 8.33 lbs (water)
LWT = Leaving Water Temperature 1 Cubic Foot = 7.48 gallons
BTU = British Thermal Unit 1 Mil = .001"
BTU/HR = GMP x 500 x . T (water) 1 Bar = 14.7 PSI
1 HP = 2544 BTU/HR 1 KW = 3413 BTU/HR
Ft. H.D. = PSI x 2.31 1 KW = 1.34 HP

Q=4.5 x CFM x  H = BTUH (Air Cooling) PSI= Ft of head/2.31

Pump HP=  .          GPM x P (Ft.H.D)        . KW = Amps x Volts x 0.85 x 1.73
                  3960 x (0.65 to 0.75) (Pump Eff)                            1,000

Head in Feet to PSI Conversions calculator

Filtration Chart
Mesh Micron Inches Mesh Micron Inches
4 5205 0.2030 80 177 0.0070
8 2487 0.0970 100 149 0.0059
10 1923 0.0750 120 125 0.0049
14 1307 0.0510 140 105 0.0041
18 1000 0.0394   170 88 0.0035
20 840 0.0331 200 74 0.0029
25 710 0.0280 230 62 0.0024
30 590 0.0232 270 53 0.0021
35 500 0.0197 325 44 0.0017
40 420 0.0165 400 37 0.0015
 45 350 0.0138 550 25 0.0009
50 297 0.0117 800 15 0.0006
60 250 0.0098 1250 10 0.0004
70 210 0.0083   5 0.0002