COOLING WATER REQUIREMENT FOR MOLDING MACHINES

INPUTS RECEIVED FROM CLIENT

OLD MACHINES-

HYDRAULIC/HEAT TOTAL COOLING

MACHINE EXCHANGER MOLD WATER WATER
IDENTIFICATION WATER FLOW FLOW RATE (LPM) REQUIREMENT
RATE (LPM) (LPM)
KM 2700 SP 24500
232 60 292
MX02
KM 2300 SP 17200
143 55 198
MX
MITUSHI 1600 130 45 175

NEW MACHINES-
HYDRAULIC/HEAT
MACHINE EXCHANGER SHOT WEIGHT
NO. OF CYCLES
IDENTIFICATION WATER FLOW (KG)
RATE (LPM)
910T 300 3.5 50

650T 220 3 55

550T 220 3 60

ASSUMPTIONS

SP. HEAT OF MATERIAL TO BE MOLDED- 3.6425 KJ/KG C

SP. HEAT OF WATER- 4.20 KJ/KG C

MELTING TEMPRATURE OF MATERIAL TO BE MOLDED IS 227 DEG C

EJECTION TEMPRATURE OF MOLD 49 DEG C

MAX . RISE IN TEMP FOR WATER IS 3 DEG C

60% OF HEAT GENERATED IN MOLDING ONLY WILL BE COOLED BY WATER

AFTER DOING ENERGY BALANCE FOR MOLD, WE HAVE GOT FOLLOWING MOLD WATER FLOW
RATES
MACHINE MOLD WATER
IDENTIFICATION FLOW RATE (LPM)

910T 100

650T 90

550T 90

TOTAL COOLING WATER REQUIREMENTS FOR

TOTAL COOLING
MACHINE WATER
IDENTIFICATION REQUIREMENT
(LPM)
910T 400

650T 310

550T 310

PROPSED MACHINES COMBINATION FOR 6 MACHINES

NO. OF
MACHINE
MACHINES
IDENTIFICATION
PROPOSED
910T 2

650T 2

550T 2

CONSIDERING EXISTING 3 MACHINES AND PRPOSED 6 MACHINES , TOTAL WATER FLOW

REQUIRED WILL BE
2705 LPM OR 162.3 M3/HR

WATER FLOW RATE OF EXISTING COOLING TOWER 195 M3/HR

SO EXISTING COOLING TOWER IS SUFFICIENT FOR PROVIDING COOLING WATER TO EXISTING 3
MACHINES AND NEW 6 MACHINES WITH ABOVE CAPACITIES
 Line sizing
Max. Minimum Actual
SR. Water Requirement Line size Line ID
LINE DESCRIPTION Velocity ID reqd velocity
NO. (m3/hr) considered (mm)
(m/s) (mm) (m/s)

PUMP TO COMMON DISTRIBUTION

8" NB,
1 HEADER FOR NEW AND OLD 195.00 2.000 185.70 202.740 1.678
Sch 40
MACHINES (6 BAR)

FROM COMMON DISTRIBUTION 4" NB,

2 54.00 2.000 97.72 102.260 1.826
HEADER TO MOLD HEADER (6 BAR) Sch 40

FROM COMMON DISTRIBUTION

6" NB,
3 HEADER TO HEAT EXCHANGER 120.00 2.000 145.67 154.051 1.788
Sch 40
HEADER (4.5 BAR)
FROM HEAT EXCHANGER HEADER TO
2" NB,
4 KM 2700 SP 24500 MX02 HEAT 14.00 2.000 49.76 52.501 1.796
Sch 40
EXCHANGER COOLING (4.5 BAR)
FROM HEAT EXCHANGER HEADER TO
1.5" NB,
5 KM 2300 SP 17200 MX HEAT 9.00 2.000 39.89 40.894 1.903
Sch 40
EXCHANGER COOLING (4.5 BAR)
FROM HEAT EXCHANGER HEADER TO
1.5" NB,
6 MITUSHI 1600 HEAT EXCHANGER 8.00 2.000 37.61 40.894 1.692
Sch 40
COOLING (4.5 BAR)
FROM HEAT EXCHANGER HEADER TO
2.5" NB,
7 910T HEAT EXCHANGER COOLING 18.00 2.000 56.42 62.713 1.619
Sch 40
(4.5 BAR)
 Line sizing
Max. Minimum Actual
SR. Water Requirement Line size Line ID
LINE DESCRIPTION Velocity ID reqd velocity
NO. (m3/hr) considered (mm)
(m/s) (mm) (m/s)

FROM HEAT EXCHANGER HEADER TO

2" NB,
8 650T HEAT EXCHANGER COOLING 13.20 2.000 48.31 52.501 1.694
Sch 40
(4.5 BAR)
FROM HEAT EXCHANGER HEADER TO
2" NB,
9 550T HEAT EXCHANGER COOLING 13.20 2.000 48.31 52.501 1.694
Sch 40
(4.5 BAR)
FROM MOLD HEADER TO HEAT
EXCHANGER HEADER TO KM 2700 SP 1.5" NB,
10 3.60 1.500 29.13 40.894 0.761
24500 MX02 MOLD COOLING (6 Sch 40
BAR)
FROM MOLD HEADER TO KM 2300 SP 1.5" NB,
11 3.30 1.500 27.89 40.894 0.698
17200 MX MOLD COOLING (6 BAR) Sch 40

FROM MOLD HEADER TO MITUSHI 1.5" NB,

12 2.70 1.500 25.23 40.894 0.571
1600 MOLD COOLING (6 BAR) Sch 40

FROM MOLD HEADER TO 910T MOLD 1.5" NB,

13 6.00 1.500 37.61 40.894 1.269
COOLING (6 BAR) Sch 40
FROM MOLD HEADER TO 650T MOLD 1.5" NB,
14 5.40 1.500 35.68 40.894 1.142
COOLING (6 BAR) Sch 40
FROM MOLD HEADER TO 550T MOLD 1.5" NB,
15 5.40 1.500 35.68 40.894 1.142
COOLING (6 BAR) Sch 40
Total COOLING Water Demand 195 M3/Hr.
Selected Cooling Water
195 M3/Hr.
Pump
CALCULATION FOR SUCTION PIPE OF COOLING WATER PUMP

3 3
- Water flow of pump 195.00 m /h = 0.05 m /s

- Selected velicity for suction pipe 2 m/s

4Q
- Suction pipe diameter D 186 mm
 [V ]
Selected pipe size DN200

CALCULATION FOR COOLING WATER PUMP HEAD

H (m), calculation head total: Choosing the calculation location is the most disadvantage, furthest & highest :

H = 1.1 x (H1 + H2 + H3 + H4)

H1 Static head between tank surface to highest Point : 10.00 m

H2 Requested pressure in nozzle : 60.00 m

H3 Total head loss from fire tank to farest and highest sprinkler head (H) :

Friction loss in straight pipe calculated with formular :

 Q 1.85  6
H A   L  6.05  1.85 4.87 10
in which C D 
L: Equavalent length, m
Q: Water flow, l/m
D: Pipe size, mm
C: Hazen-William C value, with steel pipe C = 150
H: Friction loss in pipe, m

Friction loss in pipe (H3):

No Pipe D(mm) Equiv. L(m) Q (l/min) HAi(m) Remark

1 H200 Pipe 200 30.000 3,250 0.33 Suction pipe to pump

2 H200 Pipe 200 500.000 3,250 5.57 Discharge pipe from pump

Total H3 5.91 m

H4 Total head loss for fittings by 30%H3 1.77 m

Total head loss (H) 88 m

Select total head of COOLING WATER pump
Selected total head of COOLING WATER pump is : 88 mH

SELECTED DATA OF COOLING WATER PUMP

* 01 set of Working and 01 Set of standby COOLING WATER pump 195m3/h @ 88mH

CAPACITY OF CURRENTCOOLING WATER PUMP IS 144 M3/H @ 44 mH

SO, CURRENT COOLING WATER PUMPS ARE NEEDED TO BE REPLACE .