his “Cement Plant Engineers Pocket Hand Book” has

been compiled from useful information available at various

sources, intended as storage of information so that it will be
useful to the plant personality involved in conservation
activities and can be used by them as a reckoner even at the
site.

This “Cement Plant Engineers Pocket Hand Book”

contains Steel Tables, Quality, Quarry, Production, Civil and
Electrical relevant information quick guide and painless. So it
can be used as an everyday online reference guide for every
Engineer.

Compiled By.
Balasubramanian. M
HOPE-TCP-SPCC

i
 Our Sincere gratitude to the following experts for their
assistance value added support and input and immense
cooperation extended in completing the “Cement Plant
Engineers Pocket Hand Book”.

Mr, Saeed Al Harthi - WM

Mr, Mohmoud H. Awad Mahmoud - TA
Mr, Hanna Saloum - MM
Mr, Mohammed Ziaul-Hassan Fahmi - PM

ii
 LIST OF CONTENTS

Page
General & Mechanical
Material Classification & Category ……………. 1
General Properties of Material …………..……. 2-3
Beams – MB ................................................................. 4
Channels – SMC .......................................................... 5
Angles – SA ................................................................... 6-7
Plate ................................................................................ 8-9
Chequered Plate ......................................................... 9
Flat …………………………………………………..……… 10-11
M.S. & G.I. Pipes ………………………………………... 12-15
Pipe Schedule ………………………………….. 16
Conversion of Pressure Units ……………………. 17
B.S. Pipe Flange ………………………………………… 18-19
Square Bar ……………………………………………….. 20
Round Rod ……………………………………………… 21
Tyre Coupling ………………………………………… 22
STD Pin & Bush Type Coupling ………………… 23
STD Wire/Sheet Gauge ……………………………... 24
Length Conversion …………………………………… 25-26
Weights ……………………………………………………. 26

I
 LIST OF CONTENTS

Page
Square Measures ……………………………………… 27
Cubic Measure ………………………………………….. 28
Force ……………………………………………………….. 28
Torque, Work, Velocity ……………………………... 29
Flow, Temperature Conversion ………………… 30
Plate Cutting & Nozzle Data ………………………. 31
Bolt Tightening Torques …………………………… 32
Trigonometry …………………………………………... 33-35

Conversion Tables
Length Conversion …………………………………… 36
Surface Conversion ………………………………….. 37
Volume Conversion …………………………………... 38
Mass, Energy Conversion ………………………….. 39
Torque Conversion …………………………………… 40
Force, Power Conversion ………………………… 41
Calculation of Areas, Perimeter …………………. 42-43
Calculation of Volumes …………………………… 44-45
Lateral Areas, Total Areas

II
 LIST OF CONTENTS

Page
Quarry
Quarry and Mining ………......................................... 46-47
Machinery used in Making Cement ……………. 48-50

Quality Control
Cement Types & Specification 51-53
Quality Control Formula …………………………… 54-57

Production
Bulk Density …………………………………………….. 58
Atmospheric Pressure and ………………………... 59
Density vs. Altitude
Thermal Energy Consumption Target ………... 60
Types of Preheater & Major Cyclone
60-61
Configurations ……………………………….………...
Types of Kiln & Typical Comparative Data ..... 62
Kiln Burner System …………………………….………. 62-66
Kiln Refractories …………………………….………. 66

III
 LIST OF CONTENTS

Page
Bricks per Ring
ISO key Bricks ………………………………………….. 67
ISO Bricks ………………………………………………… 68
VDZ Bricks ……………………………………………….. 69
VDZ key Bricks …………………………………………. 70-71
Typical Data for Liquid Fuels ……………………. 72
Typical Data for Gaseous Fuels 73
…………………….
Ball Mill-Ball Weigh & Surface Area …………… 74
Ball Mill Charge Volume ……………………………. 75

Formulas
Kiln Related useful Formulas 76-78

Civil
Safe Loads on Studs and Bolts …………………… 79
Materials Required for Plastering ……………… 80
Useful Notes on Cement ……………………………. 81
Quantities of Materials Required ……………… 82
For Mortar and Concrete
Types of Loads …………………………………………. 83-91

IV
 LIST OF CONTENTS

Page
Electrical
Electrical Engineering, Power ………………….. 92
Electrical Technology ……………………………….. 93
Work and Electric Power ………………………….. 94
Characteristic of the …………………………………. 95
Three-Phase Motor
Synchronous Speed of a ……………………………. 95
Three-Phase Electric Motor
Relation between Motor …………………………… 96
Size and Power
Common Mounting Positions ……………………. 97
Comparison between Synchronous …………… 98
Motor and Induction Motor
Cable Rating Table ……………………………………. 99
Useful 3-Phase Formulae ………………………….. 100
Electrical Energy Consumption Target ………. 101
Transformer Loss …………………………………….. 102-103
Fuse Wire Table ……………………………………….. 104-105
Electrical Formulas …………………………………... 106-112
Symbols for Method of Cooling …………………. 113

V
 LIST OF CONTENTS

Page
Characteristic Letter for Coolant ……………… 113-114
Periodic Table of Elements …………………… 115

VI
 GENERAL
&
MECHANICAL
INFORMATION
 MATERIALS CLASSIFICATION AND CATEGORY

Ferrous metals Non-

Steel Iron Ferrous Plastics
metals

Structural Tool Cast Cast Copper, Lead PVC

Malleable iron
Steel Steel Steel iron Zinc, Tin,
Vulcanized
Nickel, Al
fibre
Carbon Carbon Grey White heart
Copper alloys Amino-
Steel Tool Steel cast iron malleable iron
Al alloys plasts
Alloy Alloy Alloy Black heart Zinc Alloys
Phenol-
Steel Tool Steel cast iron malleable iron Solders plasts

1
 GENERAL PROPERTIES OF MATERIAL
Specific Weight, Melting Points, Coefficient of Linear Expansion

Thermal
Sym- Specific Weight Melting Point
Element Expansion
bol gf/cm³ ᵒC
α
Ag Silver 10.5 961 0.000 020
Al Aluminum 2.7 660 0.000 024
Au Gold 19.3 1063 0.000 014
Ba Barium 3.74 704 -
Be Beryllium 1.85 1283 0.000 012
Bi Bismuth 9.75 271 0.000 013
C Carbon - - -
Graphite 2.25 3550 0.000 008
Diamond 3.52 3600 0.000 001
Ca Calcium 1.55 850 -
Cd Cadmium 8.64 321 0.000 029
Ce Cerium 6.9 775 -
Co Cobalt 8.8 1492 0.000 013
Cr Chromium 7.1 1800 0.000 007
Cu Copper 8.9 1083 0.000 017
Fe Iron 7.86 1535 0.000 012
Ir Iridium 22.42 2443 0.000 006
K Potassium 0.86 63 0.000 084
La Lanthanum 6.18 826 -
Li Lithium 0.53 180 0.000 058
Mg Magnesium 1.74 650 0.000 026
mn Manganese 7.3 1244 0.000 023
Mo Molybdenum 10.21 2610 0.000 005
Na Sodium 0.97 98 0.000 071

2
 Thermal
Sym- Specific Weight Melting Point
Element Expansion
bol gf/cm³ ᵒC
α
Nb Niobium 8.55 2415 0.000 007
Ni Nickel 8.9 1453 0.000 013
P Phosphorus 1.82 44 0.000 124
Pb Lead 11.35 327 0.000 029
Pt Platinum 21.45 1769 0.000 009
Ra Radium 5.00 700 -
S Sulphur 2.06 113 0.000 064
Sb Antimony 6.69 630 0.000 011
Se Selenium 4.5 217 0.000 037
Si Silicon 2.4 1410 0.000 008
Sn Tin 7.3 232 0.000 023
Ta Tantalum 16.66 3030 0.000 007
Th Thorium 11.2 1827 0.000 011
Ti Titanium 4.52 1812 0.000 009
U Uranium 18.7 1132 -
V Vanadium 5.96 1730 -
W Tangsten 19.27 3380 0.000 004
Zn Zinc 7.13 420 0.000 026
Zr Zirconium 6.5 1852 0.000 005
Hg Mercury 13.5 -39 -
Cl Chlorine - -101 -
H Hydrogen - -259 -
He Helium - -272 -
N Nitrogen - -210 -
Ne Neon - -249 -
O Oxygen - -219 -

3
 BEAMS – MB

SIZE Kg/m
100 x 75 - 8.9
125 x 75 - 13.3
150 x 80 - 15.0
175 x 90 - 19.6
200 x 100 - 24.2
225 x 110 - 31.1
250 x 125 - 37.3
300 x 140 - 46.0
350 x 140 - 52.4
400 x 140 - 61.5
450 x 150 - 72.4
500 x 180 - 86.9
550 x 190 - 104.0
600 x 210 - 123.0

4
 CHANNELS - SMC

SIZE Kg/m
75 x 40 - 7.14
100 x 50 - 9.56
125 x 65 - 13.1
150 x 75 - 16.8
175 x 75 - 19.6
200 x 75 - 22.3
225 x 80 - 26.1
250 x 80 - 30.6
300 x 90 - 36.3
350 x 100 - 42.7
400 x 100 - 50.1

5
 ANGLES – SA

SIZE Kg/m
25 x 25x 3 - 1.1
25 x 25 x 4 - 1.4
25 x 25 x 5 - 1.8
35 x 35 x 3 - 1.6
35 x 35 x 5 - 2.6
35 x 35 x 6 - 3.0
40 x 40 x 5 - 3.0
40 x 40 x 6 - 3.5
50 x 50 x 5 - 3.8
50 x 50 x 6 - 4.5
65 x 65 x 6 - 5.8
65 x 65 x 8 - 7.7
65 x 65 x 10 - 9.4
75 x 75 x 6 - 6.8
75 x 75 x 8 - 8.9
75 x 75 x 10 - 11.0
6
 ANGLES – SA

SIZE Kg/m
90 x 90 x 6 - 8.2
90 x 90 x 8 - 10.8
90 x 90 x 10 - 13.4
90 x 90 x 12 - 15.8
100 x 100 x 6 - 9.2
100 x 100 x 8 - 12.1
100 x 100 x 10 - 14.9
100 x 100 x 12 - 17.7
130 x 130 x 8 - 15.9
130 x 130 x 10 - 19.7
130 x 130 x 12 - 23.5
130 x 130 x 16 - 30.7
150 x 150 x 10 - 22.9
150 x 150 x 12 - 27.3
150 x 150 x 16 - 35.8

7
 PLATE

THICK mm Kg/Sq.m
1 - 7.85
2 - 15.70
2.5 - 19.62
3.15 - 24.72
4 - 31.40
5 - 39.25
5.5 - 43.20
6 - 47.10
7 - 54.95
8 - 62.80
10 - 78.50
12 - 94.20
14 - 109.90
16 - 125.60
18 - 141.30
20 - 157.00
22 - 172.70
25 - 196.25
8
 PLATE

THICK mm Kg/Sq.m
28 - 219.80
32 - 251.20
36 - 282.60
40 - 314.00
45 - 353.25
50 - 392.50
56 - 439.60
63 - 494.55

CHEQUERED PLATE

THICK
(On Plate) Kg/Sq.m

5 - 43.50
6 - 52.30
7 - 61.10
10 - 83.40
12 - 100.80
9
 FLAT

SIZE Kg/m
20 x 3 - 0.5
25 x 3 - 0.6
25 x 6 - 1.2
40 x 6 - 1.9
50 x 6 - 2.4
50 x 8 - 3.1
50 x 10 - 3.9
50 x 12 - 4.7
50 x 16 - 6.28
65 x 6 - 3.1
65 x 8 - 4.1
65 x 10 - 5.1
65 x 12 - 6.1

10
 FLAT

SIZE Kg/m
75 x 6 - 3.5
75 x 8 - 4.7
75 x 10 - 5.9
75 x 12 - 7.1
90 x 6 - 4.2
90 x 8 - 5.6
90 x 10 - 7.1
90 x 12 - 8.5
100 x 6 - 4.7
100 x 8 - 6.3
100 x 10 - 7.8
100 x 12 - 9.4
100 x 16 - 12.6

11
 M.S. & G.I. PIPES IS
1239 : 1979
Nominal Bore

inch mm O.D
1/8” - 3 - 10.32
1/4” - 6 - 13.49
3/8” - 10 - 17.10
1/2" - 15 - 21.43
3/4" - 20 - 27.20
1” - 25 - 33.80
1 – 1/4” - 32 - 42.90
1 – 1/2" - 40 - 48.40
2” - 50 - 60.30
2 – 1/2" - 65 - 76.20
3” - 80 - 88.90
4” - 100 - 114.30
5” - 125 - 139.70
6” - 150 - 165.10

12
 M.S. & G.I. PIPES
Light

NB (THK.) mm Kg/m
1/8” - 1.80 - 0.361
1/4” - 1.80 - 0.517
3/8” - 1.80 - 0.674
1/2" - 2.00 - 0.952
3/4" - 2.35 - 1.410
1” - 2.65 - 2.010
1 – 1/4” - 2.65 - 2.580
1 – 1/2" - 2.90 - 3.250
2” - 2.90 - 4.110
2 – 1/2" - 3.25 - 5.840
3” - 3.25 - 6.810
4” - 3.65 - 9.890
5” - - - -
6” - - - -

13
 M.S. & G.I. PIPES
Medium

NB (THK.) mm Kg/m
1/8” - 2.00 - 0.407
1/4” - 2.35 - 0.650
3/8” - 2.35 - 0.852
1/2" - 2.65 - 1.220
3/4" - 2.65 - 1.580
1” - 3.25 - 2.440
1 – 1/4” - 3.25 - 3.140
1 – 1/2" - 3.25 - 3.610
2” - 3.65 - 5.100
2 – 1/2" - 3.65 - 6.610
3” - 4.05 - 8.470
4” - 4.50 - 12.100
5” - 4.85 - 16.200
6” - 4.85 - 19.200

14
 M.S. & G.I. PIPES
Heavy

NB (THK.) mm Kg/m
1/8” - 2.65 - 0.493
1/4” - 2.90 - 0.769
3/8” - 2.90 - 1.02
1/2" - 3.25 - 1.45
3/4" - 3.25 - 1.90
1” - 4.05 - 2.97
1 – 1/4” - 4.05 - 3.84
1 – 1/2" - 4.05 - 4.43
2” - 4.50 - 6.17
2 – 1/2" - 4.50 - 7.90
3” - 4.85 - 10.1
4” - 5.40 - 14.4
5” - 5.40 - 17.8
6” - 5.40 - 21.2

15
 PIPE SCHEDULE
N.B O.D SCH.40 SCH.80
inch mm Wall thk. mm
1/4” - 13.7 - 2.24 - 3.02
3/8” - 17.1 - 2.31 - 3.20
1/2" - 21.3 - 2.77 - 3.73
3/4" - 26.7 - 2.87 - 3.91
1” - 33.4 - 3.38 - 4.55
1 – 1/4” - 42.2 - 3.56 - 4.85
1 – 1/2" - 48.3 - 3.68 - 5.08
2” - 60.3 - 3.91 - 5.54
2 – 1/2" - 73.0 - 5.16 - 7.01
3” - 88.9 - 5.49 - 7.62
3 – 1/2" - 101.6 - 5.74 - 8.08
4” - 114.3 - 6.02 - 8.56
5” - 141.3 - 6.55 - 9.53
6” - 168.3 - 7.11 - 10.97
8” - 219.1 - 8.18 - 12.7
10” - 273 - 9.27 - 12.7
12” - 323.9 - 10.31 - 12.7

16
 CONVERSION OF PRESSURE UNITS

PSI Kg/Sq.Cm. Atmp. Bar mmWC Pascal

PSI 1 0.07031 0.08804 0.069 703.1 6896

Kg/Sq.Cm 14.223 1 0.0678 0.981 10000 98087

Atmp. 14.69 1.033 1 1.0133 10330 101325

Bar 4.5 1.019 0.98 1 10200 100000

mmWC 14.223x10-4 1.0x10-4 9.67x10-5 9.81x10-5 1 9.808

Pascal 145x10-6 10.19x10-6 9.869x10-5 10-5 0.1019 1

17
 B.S. PIPE FLANGE UP TO 100 PSI ( inch )
PIPE FL.O.D P.C.D BOLT No. THK.
1/2 - 3-3/4 - 2-5/8 - 1/2 - 4 - 3/16
3/4 - 4 - 2-7/8 - 1/2 - 4 - 3/16
1 - 4-1/2 - 3-1/4 - 1/2 - 4 - 3/16
1 – 1/4 - 4-3/4 - 3-7/16 - 1/2 - 4 - 1/4
1 – 1/2 - 5-1/4 - 3-7/8 - 1/2 - 4 - 1/4
2 - 6 - 4-1/2 - 5/8 - 4 - 5/16
2 – 1/2 - 6-1/2 - 5 - 5/8 - 4 - 5/16
3 - 7-1/4 - 5-3/4 - 5/8 - 4 - 3/8
3 – 1/2 - 8 - 6-1/2 - 5/8 - 4 - 3/8
4 - 8-1/2 - 7 - 5/8 - 4 - 3/8

18
 B.S. PIPE FLANGE UP TO 100 PSI ( inch )
PIPE FL.O.D P.C.D BOLT No. THK.
5 - 10 - 8-1/4 - 5/8 - 8 - 1/2
6 - 11 - 9-1/4 - 5/8 - 8 - 1/2
7 - 12 - 10-1/4 - 5/8 - 8 - 1/2
8 - 13-1/4 - 11-1/2 - 5/8 - 8 - 1/2
9 - 14-1/2 - 12-3/4 - 5/8 - 8 - 5/8
10 - 16 - 14 - 3/4 - 8 - 5/8
12 - 18 - 16 - 3/4 - 12 - 5/8
14 - 20-3/4 - 18-1/2 - 7/8 - 12 - 5/8
15 - 21-3/4 - 19-1/2 - 7/8 - 12 - 5/8

19
 SQUARE BAR

SIZE Kg/m
5 - 0.2
6 - 0.3
8 - 0.5
10 - 0.8
12 - 1.1
16 - 2.0
20 - 3.1
25 - 4.9
32 - 8.0
40 - 12.6
50 - 19.6
63 - 31.2
80 - 50.2
100 - 78.5

20
 ROUND ROD

SIZE Kg/m SIZE Kg/m

5 - 0.15 40 - 9.86
6 - 0.22 45 - 12.49
8 - 0.39 50 - 15.41
10 - 0.62 56 - 19.34
12 - 0.89 63 - 24.47
14 - 1.21 71 - 31.08
16 - 1.58 80 - 39.46
18 - 2.00 90 - 49.94
20 - 2.47 100 - 61.66
22 - 2.98 125 - 96.34
25 - 3.85 140 - 120.84
28 - 4.83 160 - 157.84
32 - 6.31 180 - 199.76
36 - 7.99 200 - 246.62

21
 TYRE COUPLING

O.D GAP
SIZE
mm mm
F - 40 - 104 - 22
F – 45 - 120 - 24
F - 50 - 133.5 - 25
F – 60 - 165 - 33
F - 70 - 197 - 40
F - 80 - 211 - 43
F - 85 - 222 - 44
F – 90 - 235 - 46
F – 100 - 254 - 48
F – 110 - 279 - 44
F – 120 - 314 - 49
F – 140 - 359 - 24
F – 160 - 402 - 30
F - 180 - 470 - 46

22
STD PIN & BUSH TYPE COUPLING

SIZE O.D GAP

inch mm mm
1 - 127 - 3
1-1/2 - 152 - 3
2 - 194 - 3
2-3/4 - 254 - 3
3-3/4 - 330 - 6
4-1/2 - 406 - 6
5-1/2 - 457 - 6
7-1/8 - 597 - 6

23
 STD WIRE / SHEET GAUGE

SWG mm SWG mm
0 - 8.23 15 - 1.83
1 - 7.62 16 - 1.63
2 - 7.01 17 - 1.42
3 - 6.40 18 - 1.22
4 - 5.89 19 - 1.02
5 - 5.39 20 - 0.91
6 - 4.88 21 - 0.81
7 - 4.47 22 - 0.71
8 - 4.06 24 - 0.56
9 - 3.66 26 - 0.46
10 - 3.25 27 - 0.32
11 - 2.95
12 - 2.64
13 - 2.34
14 - 2.03

24
LENGTH CONVERSION

inch mm
1/64 - 0.3969
1/32 - 0.7938
1/16 - 1.5875
1/8 - 3.1750
3/16 - 4.7625
1/4 - 6.35
5/16 - 7.9375
3/8 - 9.5250
7/16 - 11.1125
1/2 - 12.7
9/16 - 14.2875
5/8 - 15.8750
11/16 - 17.4625
3/4 - 19.05
13/16 - 20.6375
7/8 - 22.2250
15/16 - 23.8125
1 - 25.4

25
 LENGTH CONVERSION

1 mm - 0.03937 in.
1 in. - 25.4 mm
1m - 39.3701 in.
1m - 3.28084 Ft.
1m - 1.09361 Yd.
1 Ft. - 0.3048 m
1 Yd. - 0.9144 m
1 Chain - 66 Ft.
100 Links - 1 Chain

WEIGHTS

1 Kg. - 2.20462 Lbs.

1 Lb. - 0.453592 Kg.
1 gm. - 0.035274 oz.
1 oz. - 28.3495 gm.
1 Lb. - 16 oz.

26
 SQUARE MEASURES
1 Sq. mm - 0.00155 Sq. in.
1 Sq. cm. - 0.155 Sq. in.
1 Sq. in. - 645.16 Sq. mm
1 Sq. in. - 6.4516 Sq. cm
1 Sq. m - 1550 Sq. in.
1 Sq. m - 10.7639 Sq. ft.
1 Sq. m - 1.19599 Sq. Yd.
1 Sq. ft. - 0.092903 Sq. m
1 Sq. Yd. - 0.83613 Sq. m
1 Acre - 4046.86 Sq. m
1 Acre - 4840 Sq. Yd.
1 Acre - 10 Sq. Chain
1 Acre - 100 Cents
1 Hectare - 2.471 Acre
1 Cent - 435.6 Sq. ft.

27
 CUBIC MEASURES

1 Cu. M - 35.3147 Cu. Ft.

1 Cu. Ft. - 0.028317 Cu. m
1 Cu. Ft. - 28.3161 Litre
1 Gallon - 4.54596 Litre
1 Litre - 0.219975 Gallon
1 Ounce - 28.413 Cu. Cm.

FORCE

1N - 0.102 Kgf.
1N - 0.225 Lbf.
1 Kgf. - 9.81 N
1 Lbf. - 4.45 N
1 KN. - 1000 N
1 KN. - 102 Kgf.
1 Kgf. - 2.205 Lbf.

28
 TORQUE

1 Nm. - 0.102 Kpm

1 Kgf.m - 9.81 Nm

WORK

1 Kg. m - 7.233 ft. Lbs.

1 ft. Lbs. - 0.138255 Kg. m

VELOCITY

1 m/sec. - 3.28 ft./sec.

100 ft./sec. - 0.3048 m/sec.

29
 FLOW

1 Cu.m/min. - 35.3147 Cu.ft./min.

1 Cu.ft./min. - 0.028317 Cu.m/min.

TEMP. CONVERSION

ᵒC - 5/9 ( ᵒF – 32 )
ᵒF - 9/5 ᵒC + 32
ᵒK - ᵒC + 273.15
ᵒK - 5/9 ( ᵒF + 459.67 )

30
 Plate Cutting & Nozzle Data
Type A Cutogen Nozzles are for use only
with acetylene (Generated or dissolved) as the
fuel gas and the cutting data below refers to the
cutting of mild steel.

Material Cutting Oxygen

Thickness Pressure
Size of Nozzle Kg./
mm inch Lb./sq.in
Sq.cm.
6 1/4 1/32 – A - 8 1.4 20
12 1/2 3/64 – A – 12 2.0 30
25 1 1/16 – A – 16 2.5 35
50 2 1/16 – A – 16 3.2 45
75 3 1/16 – A – 16 3.5 50
100 4 1/16 – A – 16 4.2 60
150 6 5/64 – A – 20 4.5 65
200 8 3/32 – A – 24 4.9 70
250 10 7/64 – A – 28 5.3 75
300 12 1/8 – A - 32 5.3 75

Acetylene pressure should be set in all cases

at 1.5 kg./sq.cm. (2 lb./sq.in.)

31
 For bolt make-ups with defined torques

Bolt Tightening Torques in Nm

Grade of
Bolt size 6.9 8.8 10.9 12.9
material
Size
Thread T / Nm T / Nm T / Nm T / Nm
across
size
flats
M14 22 116 138 194 235
M16 24 178 210 299 357
M18 27 245 289 411 490
M20 30 384 411 578 696
M22 32 470 559 784 941
M24 36 598 711 1000 1196
M27 41 887 1049 1481 1775
M30 46 1206 1422 2010 2403
M33 50 1628 1932 2716 3266
M36 55 2099 2481 3491 4197
M39 60 2716 3226 4531 5443
M42 65 3364 3991 5609 6727
M45 70 4207 4992 7012 8414
M48 75 5080 6021 8473 10150
M52 80 6541 7747 10885 13092
M56 85 8149 9650 13582 16279
M60 90 10101 11964 16867 20202
M64 95 12160 14416 20300 24320
M68 100 14863 17615 24771 29725
M72 105 17787 21081 29645 35575
M76 110 21071 24973 35118 42141
M80 115 24733 29314 41222 49467
M90 130 35880 42525 59801 71761
M100 145 49950 59200 83250 99900

32
 TRIGONOMETRY

୷ ୟ୪୲୧୲୳ୢୣ
sine of angle ߠ = ୰
i.e., ୦୷୮୭୲ୣ୬୳ୱୣ opp
୑୔ ୷ ୷
it is written as sin ߠ = or i.e., sin ߠ = ୰ hyp
୓୔ ୰

୶ ୠୟୱୣ
Co-sine of angle ߠ = i.e.,
୰ ୦୷୮୭୲ୣ୬୳ୱୣ
୓୑ ୶ ୶
adj
it is written as cos ߠ = ୓୔
or ୰
i.e., cos ߠ = ୰ hyp

୷ ୟ୪୲୧୲୳ୢୣ
tangent of angle ߠ = ୶ i.e., ୠୟୱୣ opp
୑୔ ୷ ୷
it is written as tan ߠ = ୓୑ or ୶ i.e., tan ߠ = ୶ adj

୰ ୦୷୮୭୲ୣ୬୳ୱୣ
Co-secant of angle ߠ = ୷ i.e.,
ୟ୪୲୧୲୳ୢୣ
୓୔ ୰ ୰
it is written as cosec ߠ = ୑୔ or ୷ i.e., cosec ߠ = ୷

୰ ୦୷୮୭୲ୣ୬୳ୱୣ
secant of angle ߠ = ୶ i.e.,
ୠୟୱୣ
୓୔ ୰ ୰
it is written as cosec ߠ = ୓୑ or ୶ i.e., sec ߠ = ୶

୶ ୠୟୱୣ
Co-tangent of angle ߠ = ୷ i.e.,
ୟ୪୲୧୲୳ୢୣ
୓୑ ୶ ୶
it is written as cot ߠ = or ୷ i.e., cot ߠ = ୷
୑୔

33
 TRIGONOMETRY

QUADRANT ANGLE POSITIVE RATIOS

I 0ᵒ < Ɵ < 90ᵒ ALL
II 90ᵒ < Ɵ < 180ᵒ sin Ɵ, cosec Ɵ
III 180ᵒ < Ɵ < 270ᵒ tan Ɵ & cot Ɵ
IV 270ᵒ < Ɵ < 360ᵒ cos Ɵ & sec Ɵ

34
TRIGONOMETRY

35
36
37
38
39
40
41
42
43
44
45
QUARRY
 QUARRY AND MINING
1.1 Time Utilization
Effective working days per year 300 days
Effective working hours per shift 5-7 hrs.

1.2 Output per Man Shift (OMS), t

Mine Capacity, tpd OMS, t Remarks

C ≤4000 20 - 40 For new and highly

Mechanized mining
C>4000 60 - 80
operations

1.3 Drilling

Type Compressive Drilling Rate, m/hr.*

of Strength, Hole Dia. Hole Dia.
Rock Kg/cm2 115mm 165mm
Hard Rock >800 6-7 8-9
Medium Hard Rock 500 - 800 8 - 10 12 - 14
Soft Rock <500 16 – 18 ---
2
*with respect to 7kg/cm pressure

1.4 Blast Design Parameters

Hole Dia Bench Height Burden Spacing
mm mm m m
115 or less 4–6 2–3 2.5 – 3.5
115 7–9 3–4 4–5
165 9 – 10 4–5 5–6
165 10 - 12 5-6 5.5 – 6.5

46
1.5 Output / meter of Drilling
Hole Dia. Output / meter
mm m
115 25 - 40
165 50 - 70

1.6 Oversize Boulders

Deposit Type Boulder, % (Optimum)

Simplex 1–4
Complex 4-7
Intricate 6-9

1.7 Drill Bit Life

Rock Type Bit Life, m

Soft Rock 5000 - 6000
Medium Hard Rock 2500 - 3000
Hard Rock 1500 - 2000

47
 MACHINERY USED IN MAKING CEMENT

Annexure 1
Shovels, their Sizes and Capacities,
Excavator Shovels
Width Max. Size
Nominal Bucket Hourly Operative
Sr. No of of stone
Size Capacity Capacity Weight
Bucket delivered
m3 tph tons mm mm
1 100 0.5 154 12 1120 740
2 220 1 239 21 1250 825
3 300 1.8 387 31 1660 1095
4 650 3.7 663 65 2070 1366
5 1000 5.5 910 95 1940 1280
6 1600 11 1578 160 2710 1788

Excavator Shovels
Width Max. Size
Nominal Bucket Hourly Operative
Sr. No of of stone
Size Capacity Capacity Weight
Bucket delivered
m3 tph tons mm mm
1 650 4.5 807 67 2320 1530
2 1000 7 1159 98 2650 1750
3 1600 13 1865 162 3800 2500

48
 Annexure 2
Relation between sizes of Shovels, Bucket and Jaw Crushers
Size of Stone Size of Size of
Size of Shovel
Sr. No Passing bucket Jaw Crusher Gyratory
m3
mm x mm depth x breadth Crusher
mm*mm mm
1 0.57 800 x 875 600 x 900 400
2 0.77 825 x 950 750 x 1050 500
3 1.15 750 x 900 900 x 1200 520
4 1.53 825 x 1125 900 x 1200 520
5 2.29 1000 x 1200 1200 x 1500 1200
6 3.06 1200 x 1425 1400 x 1800 1500
7 3.83 1200 x 1500 1650 x 2150 1800
Source: Based on Handbook of M/S Hammermills, U.S.A.
Annexure 3
Rear end Dumpers Sizes and Capacities
Heaped Max. Min. radius
Payload
Sr. No. Nominal Size Capacity speed Of turning
tons
m3 Kmph m
1 35 32 22.5 47 7.16
2 40 36.5 24 66 10.5
3 50 54 34 57 9.8
4 60 55 36.5 62 9.9
5 70 64 42 65 9.9
6 85 78 52 65 9.9
7 90 85 58 65 9.9
8 100 91.5 61 60 9.9
Maximum and optimum gradient for hauling in quarries and for
crusher ramp is one in sixteen.

49
 Annexure 4
Sizes of Bulldozers
Operating Drawbar
Blade dimensions
Sr. No Nominal size weight pull
meters
tons tons
1 31 2.42 x 0.75 6.2 7
2 50 3.35 x 0.85 11 10.3
3 65 4 x 1.15 16.7 27
4 80 4.3 x 1.1 21.5 19.6
5 155 4.13 x 1.6 36 66
6 230 4.3 x 1.13 23 40
7 355 4.32 x 1.9 44 90
8 475 5.3 x 2.6 95 150

Information in Annexures 1, 3 and 4 is based on data furnished by

Bharat Earth Movers Ltd.

50
QUALITY
CONTROL
 Cement Types & Specification

There are numerous national and international cement

specifications together with American Petroleum Institute specification
for oil well cements (API Specification 10A) which latter has virtually
universal recognition (Bensted; WC; 2/1995, pg 40). As an example, a
summary of the ASTM specification is given below.

ASTM C150 Specification for Portland Cement

Type I - General purpose

Type II - Moderate heat/moderate sulphate resistance
Type III - High early strength
Type IV - Low heat of hydration (rare)
Type V - High sulphate resistance
A - Air-entraining
LA - Low alkali

51
Associated ASTM test methods & Specification

C109 - Compressive strength

C114 - Chemical analysis
C151 - Autoclave expansion
C191 - Vicat setting time
C204 - Fineness by air permeability
C266 - Gilmore setting time
C359 - Early stiffening/false set/flash set (Mortar method)
C451 - Early stiffening/false set/flash set (Paste method)
C465 - Processing additions
C563 - Optimum SO3
C917 - Evaluation of cement strength uniformity

Associated ASTM test methods & Specification

Chemical Limits (%): I II III IV V
SiO2, min 20.0
Al2O3, max 6.0
Fe2O3, max 6.0 6.5
MgO, max 6.0 6.0 6.0 6.0 6.0
SO3, max (C3A<8) 3.0 3.0 3.5 2.3 2.3
(C3A>8) 3.5 4.5
Lol, max 3.0 3.0 3.0 2.5 3.0
Insol res, max 0.75 0.75 0.75 0.75 0.75
C3A, max 8 15 7 5
C4AF + 2CaA 25
(Optional)
C3S + C3A, max (moderate heat) 58
Na2O + 0.668K2O, max (LA 0.60 0.60 0.60 0.60 0.60

52
Physical Limits (%): I II III IV V
Air content, max 12 12 12 12 12
(A), max 22 22 22
min 16 16 16
Fineness, mm, cm2/g 2800 2800 2800 2800 280
Autoclave exp, max, % 0.80 0.80 0.80 0.80 0.80

Strength, min, MPa

-1 day 12.0
-3 day 12.0 10.0 24.0 8.0
-7 day 19.0 17/.0 7.0 15.0
-28 day 17.0 21.0

(Note A cements have lower strength requirements)

Gilmore IST / FST, min – 60/500 minutes all types
Vicat, IST / FST, min – 45/385 minutes

Typical Cement Compound Concentrations for the Five

Cement types are:

Type I II III IV V
C3S 55 51 56 28 48
C2S 19 24 19 49 30
C3A 10 6 10 4 4
C4AF 7 11 7 12 10

53
 Quality Control Formula

Sr. No. Item Symbol Unit Formula Normal Range

1.01 loss of iginition L.O.I % 0.44CaCO3 + 0.524MgCO3
0.786 x CaO + 1.089 x MgO
CaCO3 %
MgCO3 %

1.02 silica ratio ( modulus) SR ratio SR = SiO2/(Al2O3 + Fe2O3) 1.2-2.4

Ave. 2.4-2.6
SiO2 %
Al2O3 %

Fe2O3 %
1.03 alumina ratio A/F ratio A/F = Al2O3/Fe2O3 1-4,
Ave 1.2 - 1.5
Al2O3 %
Fe2O3 %

54
Sr. No. Item Symbol Unit Formula Normal Range
1.04 lime saturation factor LSF ratio

CaCO3 %
MgCO3 %

a A/F > 0.64 LSF = CaO/(2.8 × SiO2 + 1.18 × Al2O3 + 0.65 × Fe2O3)
CaO %
SiO2 %
Al2O3 %
Fe2O3 %
b A/F < 0.64 LSF = CaO/(2.8 × SiO2 +1 .1 × Al2O3 + 0.7 × Fe2O3) 90-95
CaO – F CaO x SO3 / 2.8 x SiO2 + 1.18 x Al2O3 + 0.65 x
for OPC
Fe2O3
CaO %
SiO2 % 95-98 for high
Al2O3 % alumina cement
Fe2O3 %

55
Sr. No. Item Symbol Unit Formula Normal Range
1.05 hydraulic HM ratio HM = CaO / (SiO2 + Al2O3 + Fe2O3) 1.7-2.2 for
modulus
OPC
CaO % 0.5- 0.58 for high
SiO2` % alumina cement
Al2O3 %
Fe2O3 %
1.06 percent liquid L % L = 1.13C3A + 1.35C4AF + MgO + Alkalies
3 x Al2O3 + 2.25 x Fe2O3 + MgO + k20 + No2o + S03
C3A C3A = 2.65 × Al2O3 – 1.692 × Fe2O3
C4AF C4AF = 3.043 × Fe2O3
a A/F=>0.64
C3S = 5.071CaO –
C3S 45-55
(7.602×SiO2+6.718×Al203+2.43×Fe2O3+2.852×S03)

C2S C2S = 2.867 × SiO2 – 0.7544 × C3S 25-35

b A/F = < 0.64
C3S=4.071×CaO–
C3S
(7.602×SiO2+5.479×Al203+5.859×Fe2O3×2.852×S03)
C2S C2S = 2.867 × SiO2 – 0.7544 × C3S
C3A = 0

56
Sr. No. Item Symbol Unit Formula Normal Range

1.07 burnability index BI BI = C3S/(C4AF + C3A) 2.8-3.5

1.08 burnability factor BF BF = LSF + 10 × SR – 3 × (MgO + Alkalies) 100-110

57
PRODUCTION
 BULK DENSITY

Angle of
MTL Kg./m³ Repose
(Degree ᵒ)
Limestone (Cru) 1500 35-40
Iron ore 1600-3200 35
Bauxite 1200-1360 30
Clay (Fine Dry) 1600-1920 35
Coal (Bituminous) 800-865 45
Lignite (Raw) 640-720 38
Clinker 1440-1700 30-40
Fly ash (Dry) 640-720 42
Gypsum 1200 -
Cement 1200-1500 25-30
Lignite 25% moisture 750 -
Raw Meal (Loose) 1100 35

58
 Atmospheric Pressure and Density Vs Altitude at
(0ᵒC)

Altitude at (m) Pressure (mmHg) Density (kg/m3)

0 760 1.293
100 751 1.278
200 742 1.262
300 733 1.247
400 724 1.232
500 716 1.218
600 707 1.203
700 699 1.199
800 691 1.186
900 682 1.16
1000 673 1.145
1100 664 1.13
1200 655 1.124
1400 639 1.092
1600 624 1.062
1800 610 1.038
2000 596 1.014
2200 582 0.988
2400 569 0.968
2600 556 0.946
2800 543 0.924

59
 Thermal Energy Consumption Target

Specific Fuel Consumption

Parameter (kCal / kg Clinker)
Theoretical heat consumption 410
Pre-heater loss 105
Cooler loss
(Clinker & Cooler vent gases) 90

Radiation loss 75
Heat Input -30
Total 650

Types of Preheater & Major Cyclone

Preheater Configurations

NSP (New Suspension preheater) - Precalciner technology which was

developed in japan in early 1970s.

AT (Air Through) - Precalciner or riser firing using combustion air drawn

through the kiln.

AS (Air Separate) - Precalciner using tertiary air

ILC (In-Line Calciner) - As precalciner in which kiln exhaust and tertiary air
are premixed before entering the calciner vessel.

SLC (Separate Line Calciner) - As precalciner vessel in parallel with the kiln
riser and fed only with gas from the tertiary duct.

SF (Suspension Preheater with Flash Furnace) - IHI precalciner design which is

an AS/ILC system.

60
Configurations of Cyclone Preheater Kiln

61
 Types of Kiln and Typical Comparative Data

Maximum rating Specific fuel Length :

(tpd) (kcal/kg) Diameter
Shaft Kiln 200 900-1000
Long wet kiln 2000 1200-1500 32-38
Long dry kiln 2000 900-1200 32-38
Lepol kiln 2000 800-900 14-16
Cyclone preheater kiln 2000 800-900 14-16
Precalciner kiln 11000 700-850 11-16

Kiln Burning Systems

Once raw materials have been selected and blended, and ground and homogenized
into a fine and uniform kiln feed, they must then be subjected to enough heat to
allow the clinkering reactions to proceed. This is the pyroprocessing stage of cement
manufacture, beginning with the kiln feed material extracted from storage and
weighed and transported to the kiln, and finishing with the clinker from the cooler
going to clinker storage. A schematic diagram on different stages of cement
manufacturing is shown in Figure

Pyro-Processing system.
62
The pyro-processing stage is generally regarded as the heart of the cement-making
process. It is the stage in which most of the operating costs of cement manufacture
appear, and is also therefore the stage where most of the opportunities for process
improvement exist.

There are many different kiln system designs and enhancements, but they are all in
essence performing the following material transformation, in order from the feed
end:
1. Evaporating free water, at temperatures up to 100°C
2. Removal of adsorbed water in clay materials 100°C - 300°C
3. Removal of chemically bound water 450°C - 900°C
4. Calcination of carbonate materials 700°C - 850°C
5. Formation of C2S, aluminates and ferrites 800°C - 1250°C
6. Formation of liquid phase melt >1250°C
7. Formation of C3S 1330°C - 1450°C
8. Cooling of clinker to solidify liquid phase 1300°C - 1240°C
9. Final clinker microstructure frozen in clinker <1200°C
10. Clinker cooled in cooler 1250°C - 100°C
Figure shows the transformation reactions taking place at different stages of raw
material pyro-processing.

63
 On the gas flow side, the sequence from the firing end is as follows:
1. Ambient air preheated by hot clinker from kiln 20°C up to 600°C to
1100°C
2. Fuel burns in preheated combustion air in kiln 2000°C to 2400°C
3. Combustion gases and excess air travel along kiln, transferring heat to
kiln charge and kiln refractories 2400°C down to 1000°C
4. Preheating system for further recovery of heat from kiln gases into the
material charge in the kiln system 1000°C down to 350°C to 100°C
5. Further heat recovery from gases for drying of raw materials or coal
All kiln systems aspire to optimize heat exchange between the gas
streams and material streams at various stages to minimize waste heat
and maximize thermal efficiency.
Table. Summary of Critical Data Information on Different Kiln Systems

VITAL KILN OPERATIONAL PARAMETERS

The following parameters are typical for any kiln operation and considered critical in
optimizing the performance of a kiln.

Material Residence Time

The residence time of material in the kiln is governed by the kiln slope, the speed of
rotation, and any internal restrictions either by design (dam rings) or through kiln
ring formation.
The residence time, t, can be calculated from Equation 1:

64
Where
t = residence time, min
L = kiln length, m
p = kiln slope, degrees
D = kiln diameter, m
n = kiln speed, rpm
θ = angle of repose of material, (40 degrees)
F = constriction factor (usually1 if no dams, lifters etc.)

Kiln Degree of Fill

This is the percentage of the kiln cross-sectional area filled by the kiln charge, and is
usually in the range of 5% to 17% for most rotary kilns. It should be noted, though,
that a fill degree of more than 13% could impair heat transfer in that some of the
material in the center of the charge will not be exposed to enough heat. It is
sometimes seen that a kiln ring could coincide with high or erratic free lime in the
clinker, possibly because the fill degree has exceeded limits for ensuring that
all kiln charge material is uniformly heated.

Kiln Slope
Rotary kilns slope from the feed end to the discharge end for material to travel in
that direction utilizing gravitational force. The slope is typically 2% to 4%, or 1 to 2°,
and is decided in conjunction with the kiln rotational speed. A lesser slope with a
higher rotational speed may improve heat transfer because of the greater tumbling
of kiln charge.

Kiln Capacity
When designing a kiln for a certain capacity, or when evaluating an existing kiln for
potential
output, there are a number of key parameters that must be evaluated. These
include:
• Burning zone heat loading
• Secondary air velocity
• Burning zone gas velocity
• Kiln exit gas velocity
• Kiln exit gas temperature
• Preheater tower gas velocities
65
• Preheater tower pressure drops
• Preheater tower exit gas temperature
• Volatile concentrations
• Material residence time
• Cooler grate loading
• Cooler air supply
• Kiln dust cycles

There are design limits for all of the above that may vary between different
processes, but any of the above could be the limitation to a kiln’s output. These
limitations will typically manifest themselves as kiln instability and ring or coating
buildup, excessive dust loss, poor refractory life, poor clinker quality, or high fuel
consumption. Usually, however, the limitation is found to be more a question of a
fan capacity, a burner capacity, or milling of raw materials or coal.

Kiln Refractories

A typical arrangement of brick types and Refratechnik’s reported

“average best service lives” in Japanese cyclone preheater kilns (without
precalciners) is as follows:

Discharge - 1D 70-85% alumina 8 months

1D – 8D Basic, dolomite, or spinel 6-10 months
8D – 10D 70% alumina 21 months
10D – feed end 40% alumina 21-37 months
D = kiln diameter

Kilns with precalcination average significantly longer brick life.

66
 Bricks per Ring

ISO key bricks

Dimensions
Type a b h L
BP16 54 49 160 198
BP+16 64 59 160 198
BP18 54 49 180 198
BP+18 64 59 180 198
BP20 54 49 200 198
BP+20 64 59 200 198
BP22 54 49 220 198
BP+22 64 59 220 198
BP25 54 49 250 198
BP+25 64 59 250 198
A230 103 72 300 198
A330 103 82 300 198
A430 103 87.5 300 198
A630 103 92.5 300 198
A730 103 94 300 198
A830 103 95 300 198
P30 83 72.5 300 198
P+30 93 82.5 300 198

67
ISO bricks

Dimensions
Type a b h L
216 103 86.0 160 198
316 103 92.0 160 198
416 103 94.5 160 198
616 103 97.5 160 198
716 103 98.3 160 198
318 103 84.0 180 198
418 103 93.5 180 198
618 103 97.0 180 198
718 103 97.7 180 198
220 103 82.0 200 198
320 103 89.0 200 198
420 103 92.5 200 198
520 103 94.7 200 198
620 103 96.2 200 198
820 103 97.8 200 198
222 103 80.0 220 198
322 103 88.0 220 198
422 103 91.5 220 198
522 103 94.0 220 198
622 103 95.5 220 198
822 103 97.3 220 198
225 103 77.0 220 198
325 103 85.5 250 198
425 103 90.0 250 198
625 103 94.5 250 198
825 103 96.5 250 198
68
VDZ bricks

Dimensions
Type a b h L
B216 78 65 160 198
B416 75 68 160 198
B218 78 65 180 198
B318 76.5 66.5 180 198
B418 75 68 180 198
B618 74 69 180 198
B220 78 65 200 198
B320 76.5 66.5 200 198
B420 75 68 200 198
B620 74 69 200 198
B222 78 65 220 198
B322 76.5 66.5 220 198
B422 75 68 220 198
B622 74 69 220 198
B822 73 69 220 198
B425 76 67 250 198
B616 74 69 160 198
B718 78 74 180 198
B720 73.5 69.5 200 198
B722 73.5 69.5 220 198
B725 74 69 250 198
B820 78 74 200 198

69
VDZ key bricks

Dimensions
Type a b h L
P11 83 79 114 198
P+11 93 89 114 198
P13 83 78.5 130 198
P+13 93 88.5 130 198
P15 83 78 150 198
P+15 93 88 150 198
P16 83 77.5 160 198
P+16 93 87.5 160 198
P18 83 77 180 198
P+18 93 87 180 198
P20 83 76.2 200 198
P+20 93 86.2 200 198
P22 83 75.5 220 198
P+22 93 85.5 220 198
P25 83 74.5 250 198
P+25 93 84.5 250 198
P140 65 56 200 198
P240 79 70 200 198
P340 91 88 200 198
P146 70 60 230 198
P246 90 80 230 198

70
Example:
No of bricks per ring for VDZ shape
Kiln diameter (id shell) : 3800
mm Lining thickness : 200
mm Kiln diameter (id brick) : 3400
mm

Shapes considered : B320, B620

No. of bricks
Shape a in mm b in mm
per ring
B320 76.5 66.5 X
B620 74 69 Y

76.5 X + 74 Y = 3800 *

66.5 X + 69 Y = 3400 *

Solving this equation

We get

X = 93
Y = 65 numbers per ring.

71
 Typical Data for Liquid Fuels

Kerosene Gas Oil Heave Fuel Vacuum Residue Orimulsion Blended Waste
C, % 85.8 86.1 85.4 86.8 61.4 70.1-83.3
H, % 14.1 13.2 11.4 9.9 6.5 7.1-8.4
S, % 0.1 0.7 2.8 1.0-5.5 2.9 2.8-3.3
O, % 0.5 0.0-15.0
N, % 0.40 0.46 0.40
CL, % 4.0-6.7
Ash. % 0.04 0.20 0.22
H2O, % 0.30 29.8
V, Ni, etc, ppm 5-70 70-500 460
SG (water=1) 0.78 0.83 0.96 1.00-1.05 1.01 0.80-1.00
Viscosity, cSt 1.48 3.3 862 1000-3200 600 15-50
@38oC @38oC @38oC @100oC @50oC @38oC
GCV, kcal/kg 11,100 10,250 10,250 10,200 7,260
NVC, kcal/kg 10,390 9,670 9,670 9,610 6,740 5-10,000
Solids
100%-200µ
Air required 14.7 13.8 13.8 13.5 9.3 9.3-12.6
API Gravity = (141.5/SG) -131.5
1 BBL oil = 42 gals (US)
72
 Typical Data for Gaseous Fuels

North Sea W Aust LPG Blast Coke Digester Landfill

NG NG Furn Gas Oven Gas Bio-gas Gas
O2 0.5
CO2 0.2 17.5 4.0 38.0 14-17
CO 24.0 4.0
H2 2.5 30.0
N2 1.5 1.1 56.0 4.0 0-47
CH4 94,4 98.6 52.0 57.0 25-60
CnHm 3.9 0.3 100 55.5
H2S 5.0
GCV kcal/M3 9050 8930 22,430 760 8070 5730 2400-5730
NCV kcal/M3 8270 8050 20,640 740 7260 5180 2150-5160
SG (air=1) 0.6 0.6 1.5 1.0 0.6 1.0 0.9-1.0
Air required* 9.8 9.4 23.8 0.6 8.2 5.8 1.9-5.7
Flame speed 34.0 33.7 39.7 10.5 S9.8 23.9 22.3-24.6
*Air required is theoretical Volume ratio
Flame speed, M/sec

73
 Ball Mill-Ball Weight & Surface Area

Diameter (mm) kg/ball No of balls/MT Surface area M2/MT

20 0.033 30,600 38.46
25 0.064 15,700 30.77
30 0.11 9,100 25.64
40 0.261 3,830 19.23
50 0.511 1,960 15.38
60 0.882 1,130 12.82
70 1.4 710 10.99
80 2.09 480 9.60
90 2.977 336 8.55
100 4.084 245 7.69

Steel density is assumed 7.8g/cm2.

Bulk density of a mixed ball charge may be taken as 4550kg/m3.

74
 Ball Mill Charge Volume

H/D VL %
0.211 24%
0.202 25%
0.194 26%
0.185 27%
0.177 28%
0.168 29%
0.16 30%
0.151 31%
0.143 32%
0.135 33%
0.127 34%
0.119 35%
0.11 36%
0.102 37%
0.094 38%
0.086 39%

H = Free height, m
D = Diameter of the
mill, m VL = Charge
loading, %

75
Kiln Related Useful Formulas

76
77
78
CIVIL
 SAFE LOADS ON STUDS AND BOLTS

G… General Engineering : H… Hydrolic Engineering :

Dia. Of Safe Load that one stud or bolt Stud or will carry (mild steel) Dia. Of Safe Load that one stud or bolt Stud or will carry (mild steel)

Bolt inch G H Bolt inch G H

1/2 250 450 lb. 1 3/4 11000 15600 lb.
5/8 500 900 2 16000 20800
3/4 900 1790 2 1/2 26100 -
7/8 1500 2880 3 38100 -
1 2150 4240 3 1/2 53000 -
1 1/8 3000 5740 4 70100 -
1 1/4 4250 7650 4 1/2 90000 -
1 3/8 5500 9370 5 113000 -
1 1/2 7000 1600 5 1/2 138000 -

Safe Load on Foundations: Safe Load on Foundations:

Per Sq. foot: per sq. foot ton
Made Ground 1/2 ton Granite 30 "
Soft Clay 1 ton Limestone 15 "
Hard Clay or Loam 2 to 4 ton Sandstone 20 "
Dry Compact Sand 2 to 4 ton Cement Concerete 5-1 15 "
Dry Coaree Gravel 3 to 7 ton Cement Concerete 10-1 7.5 "
Ordinary Rock 3 ton Lime Concrete 2 to 4 "
Continuation: Brick in Motor 3.5 "
Brick in
Hard Rock 9 tons 8 to 12 "
Cement
Loose beds with piling 1.82 tons Rubble 3.5 "
Loose beds with Concrete 2.75 tons

79
 Materials Required for Plastering 100 sq. ft. of Surface
With Varying Thickness of Mortar
C = Cement in Bags (Based loose cement weighing 92 lbs. per cu. Ft.)
F.A = Fine Aggregate (Sand) in cu. Ft. in dry state

Mix 1:1 1:1½ 1:2 1:2½ 1:3 1:4 1:6 1:8

Thickness C. F.A C. F.A C. F.A C. F.A C. F.A C. F.A C. F.A C. F.A
3/8” 1.8 2.2 1.5 2.6 1.2 2.9 1.0 3.1 0.9 3.3 0.7 3.4 0.5 3.7 0.4 3.8
1/2" 2.4 2.9 1.9 3.5 1.7 3.9 1.4 4.2 1.2 4.4 1.0 4.6 0.7 4.9 0.5 5.1
3/4" 3.6 4.3 2.9 5.3 2.5 5.9 2.1 6.3 1.8 6.6 1.4 6.9 1.0 7.4 0.8 7.7
1” 4.8 5.8 3.9 7.0 3.3 7.8 2.8 8.4 2.4 8.8 1.9 9.2 1.4 9.8 1.1 10.2
1 1/4" 6.0 7.2 4.8 8.8 4.1 9.8 3.5 10.4 3.0 11.0 2.4 11.5 1.7 12.3 1.3 12.7
1 1/2" 7.2 8.7 5.8 10.5 4.9 11.8 4.2 12.5 3.6 13.1 2.9 13.8 2.0 14.8 1.6 15.3
2” 9.6 11.5 7.8 14.0 6.6 15.7 5.6 16.7 4.8 17.5 3.8 18.3 2.7 19.7 2.1 20.4

No allowance Made in Table for Wastage.

80
 USEFUL NOTES ON CEMENT

1 Ton of Portland cement = 20 Bags.

1 Cubic foot of Portland cement weighs 90 to 94 lbs. when
loosely filled. Average weight of 1:2:4 concrete; Coke
breeze aggregate 100 lbs. per cubic foot; Clinker
aggregate 110 lbs. per cubic foot; Brick aggregate 125 lbs.
per cubic foot; Ballast aggregate 145 lbs. per cubic foot.
Average weight of 1 : 2 : 4 reinforced concrete, 150 lbs. per
cubic foot.
1 Cubic foot of loose Portland Cement paste will make about:
4.1 cu. ft. of concrete mixed 1 : 2 : 4
5.1 cu. ft. of concrete mixed 1 : 2 1/2 : 5
5.8 cu. ft. of concrete mixed 1 : 3 : 6
7.5 cu. ft. of concrete mixed 1 : 4 : 8
1 Cubic foot of loose Portland Cement neat as Cement Paste
will cover about 9.5 sq. feet, 1 inch thick.
1 Cubic foot of loose Portland Cement to 1 of sand will cover
about 16.8 sq. feet, 1 inch thick.
1 Cubic foot of loose Portland Cement to 2 of sand will cover
about 29 sq. feet, 1 inch thick.
1 Cubic foot of loose Portland Cement to 3 of sand will cover
about 35.7 sq. feet, 1 inch thick.
1 Cubic foot of loose Portland Cement to 6 of sand will lay
about 410 bricks with 3/8 inch joints, and 527 bricks with
1/4 inch joints.
81
 Quantities of Materials Required for Mortar and Concrete

Mortar:
1 Cu. Ft. of Loose Portland Cement plus 0.36 Cu. Ft. (=2.25
gallons) of water gives 0.835 cu. Ft. of neat Cement Mortar.
1 Cu. Ft. Loose Cement will cover approximately:
10 Sq. Ft. 1” Thick mixed Neat
17 Sq. Ft. 1” with 1c. ft. of sand
25 Sq. Ft. 1”with 2c. ft. of sand.
34 Sq. Ft. 1” with 3c. ft. of sand.
For Plastering on brickwork one cu. Ft. extra mortar per 100
sq. ft. is required to fill the inequalities and joints.
For Brick work masonry about 30 cu. Ft. cement mortar is
required per 100 cu. Ft. of masonry with ¼” to 3/8” joints,
including wastage.
For rubble masonry about 50 cu. Ft. cement mortar is
required per 100 cu. Ft. of masonry, including wastage.
Concrete:
1 Cu. Ft. of Loose Portland Cement Mixed with sand (40%
voids) and broken stone ballast (45% voids) will give
unmixed with water about:
3.9 Cu. Ft. Solid Dry Concrete if mixed 1 : 2 : 4
4.7 Cu. Ft. Solid Dry Concrete if mixed 1 : 2 1/2 : 5
5.6 Cu. Ft. Solid Dry Concrete if mixed 1 : 3 : 6
7.5 Cu. Ft. Solid Dry Concrete if mixed 1 : 4 : 8
The Final Yield can be calculated by adding to these figures
the specified Volume of water.
82
 LOADS

Structures are designed for the worst combination of dead

and live loads; wherever applicable, wind loads, seismic forces
and secondary effects, such as shrinkage the rise or fall in
temperature, etc. must also be considered.

Dead Loads
The dead weight of a number of materials and structural
item is given in the table No. 1. In using these figures it should
be noted that the density of most materials varies with in
certain well defined limits and this variation can, therefore,
effect the imposed loading. The figure in the table are,
however, sufficiently accurate for normal design purpose.

Live Loads
The live load to be used for the design of floors and roofs in
building are given in table 2 & 3 respectively. They are
considered as uniformly distributed static loads on the plan
area and include the effects of normal impact. They, however,
do not take into consideration special concentrated loads nor
do they cater for loads incidental to construction and special
cases of vibration such as moving machinery, heavy
acceleration from cranes, hoists and the like; such loads
should be dealt with individually in each case.

Wind Pressure
The basic pressure induced by wind loads for various
heights of exposed surface are given in Table No. 4. The

83
figures are based on Table III of the I.S. Code of Practice, No.
875 - 1957, and their application should confirm to the
provisions on contained in clause 4 of the code.

Earth Pressure
The value of the horizontal pressure exerted by a retained
material is obtained from the normal Rankin’s formula, which
for a level fill retained against a vertical surface is expressed
as:
  ∅
p = wh
  ∅
Where:
p = the pressure in kg/m³
w = the unit weight of earth in kg/m³
h = the height of fill in meter
Ø = the angle of repose of the fill in degrees.

The unit weight of earth and the angle of repose, will of

course vary depending upon the degree of saturation of the
retained material.
The pressures exerted on inclined surfaces and due to the
effect of sloping files are also derived from the normal
formulae. For which reference may be made to text-book on
the subject.

Seismic Effects
The forces exerted as a result of seismic effects can be
calculated directly from the formulae given in clause 7 of the
I.S. Code of Practice No. 875 – 1957.
84
 Table No. 1
DEAD WEIGHT OF MATERIAL

Item Weight
Bituminous Substances
Anthracite coal
Peat 1550 kg/m³
Heavy charcoal 750 kg/m³
Coke 530 kg/m³
Graphite 1200 kg/m³
500 kg/m³
Crude oil 880 kg/m³
Pitch 1100 kg/m³
Coaltar 1200 kg/m³

Excavated Materials
Clay ( dry ) 1600 kg/m³
Clay ( damp, plastic ) 1760 kg/m³
Earth ( dry, loose ) 1200 kg/m³
Earth ( packed ) 1520 kg/m³
Sand ( dry, loose ) 1440-1700 kg/m³
Sand ( dry, packed ) 1600-1900 kg/m³

Liquids
Alcohol 780 kg/m³
Gasoline 670 kg/m³
Ice 910 kg/m³
Nitric acid 1500 kg/m³
Sulphuric acid 1800 kg/m³
Vegetable oil 930 kg/m³
Water 1000 kg/m³

85
 Item Weight
Building Materials
Bricks 1600 kg/m³
Cement 1440 kg/m³
Chalk 2200 kg/m³
Glass 2560 kg/m³
Limestone 2650 kg/m³
Sandstone 2800kg/m³
Steel 7800kg/m³
Timber 650-720kg/m²

Structural Items, Ceilings

Finishes, etc.
A.C. sheets 17 kg/m²
Brick masonry 1920 kg/m³
Brick Wall, 6 in. thick 295 kg/m²
Brick Wall, 9 in. thick 440 kg/m²
Cement Plaster, 2.5 cm. thick 44 kg/m²
Concrete 2306 kg/m³
G.I. sheet, 24 gauge 5 kg/m²
G.I. sheet, 16 gauge 10 kg/m²
Manglore tiles with battens 69 kg/m²
Rubble masonry 2100 kg/m³

86
 Table No. 2
LIVE LOADS ON FLOORS

Alternative minimum live load

For Slabs
Minimum
Uniformly For beams
Loading Load
Distributed uniformly
Class Type of Floor Per unit
Over span distributed
No. Area
Per meter over Span
( kg/m² )
Width ( kg )
( kg )
Floor for residential purposes, including dwelling
195a 195 474 1161
houses.
Floors of tenements, hospital wards, bed rooms,
195b and private sitting rooms in hostels, and 195 474 1162
dormitories
Office floors, other than entrance halls, floors of
244 244 – 390 593 – 949 1451 – 2322
light work rooms.
Floors of banking halls, office entrance halls and
293 office floors below entrance halls, and reading 293 711 1742
rooms.

87
 Shop floors used for the display and scale of
merchandise, work rooms generally, floors of
class rooms in school, garages for vehicles not
exceeding 2.54 tonnes gross weight, places of
390 390 949 2322
assembly with fixed seating, churches, chapels,
restaurants, circulation space in machinery halls,
power stations etc. where not occupied by plant
or equipment.
Floors of warehouse, workshops, factories, and
other buildings or parts of building similar,
category for light weight loads, office floors, for
488 488 1186 2903
storages and filling purposes, places of assembly
without fixed seating ( public rooms in hotels,
dances halls, waiting halls etc.)
Floor of warehouses, workshops, factories and For garage floors only 1.5 times
other building or parts of building of similar the maximum wheel load, but
732 category for medium-weight loads; floors of 732 not less than 907 kg. considered
garages for vehicles not exceeding 4.064 tonnes to be distributed over a floor
gross weight. area of 0.762 m square.

88
 Alternative minimum live load
For Slabs
Minimum
Uniformly For beams
Loading Load
Distributed uniformly
Class Type of Floor Per unit
Over span distributed
No. Area
Per meter over Span
( kg/m² )
Width ( kg )
( kg )
Floors of warehouse, workshops, factories, and
other buildings or parts of building similar
976 category for heavy weight loads, floors of book 976
stores, roofs and pavement lights over basement
projecting under the public footpath.
Stairs, corridors, landings and balconies not
liable to overcrowding:
For class 195a loading. 195
For class 195b loading. 293
For all other classes. 488
Balconies liable to overcrowding. 488
The lower value of 244 kg/m² should be taken where separate storage facilities are provided, and the higher
value of 390 kg/m² where such provisions are lacking.

89
 Table No. 3
LIVE LOADS ON ROOFS
Imposed loads other than wind
Type Slope of Roof Snow Load
and snow
Where snow is
147 kg/m² measured on plan subject to a encountered
Roofs other
Flat, sloping or curved minimum of 91 kg uniformly distributed additional
than
with slop up to and over any span of 0.305 m width of the allowance of 15 kg
sheeted
including 10ᵒ roof slab and 726 kg uniformly distributed per meter depth of
roofs
over this span in the case of all beams snow measured on
plan
Sloping or curved roofs
73 kg/m² on plan or 91 kg concentrated
from 10ᵒ to 30ᵒ and -do-
load.
including 30ᵒ
Sloping or curved roofs
nil -do-
greater than 30ᵒ
To provide for loads incidental to
maintenance all roof ( other than glass )
and supporting structure shall be capable
Sheeted Flat, sloping or curved of carrying a load of 82 kg concentrated -do-
on an area 12.7 cm square. This load is
not in addition to wind load and shall be
treated as an occasional load.

90
 Table No. 4
Wind Velocity and Pressure at Various Exposed Heights

Height of exposed
Horizontal wind Horizontal Pressure
surface above mean
Velocity
retarding surface
( km/hr ) ( kg/m² )
(m)
0 80 40
3 96 58
6 108 73
9 115 85
12 123 98
15 128 105
18 133 112
21 137 120
24 141 127
27 144 133
30 147 141
38 155 151
46 160 166
53 165 175
61 169 185
76 175 200
92 181 210
107 186 224
122 191 234

91
ELECTRICAL
 ELECTRICAL ENGINEERING

POWER

1 HP. - 746 W.
1 W. - 1 J/sec.
1 W. - 1 Nm./sec.
1 W. - 0.102 Kgf. m/sec.
1 KW. - 1.34 HP.
1 Kgf. m/sec. - 9.81 Nm./sec.
1 Kgf. m/sec. - 9.81 J/sec.
1 Kgf. m/sec. - 9.81 W.

746 Watts equal one Mechanical Horse-Power.

Generator are rated in Kilowatts = 1000 Watts. The
Kilowatt Hour is the quantity unit for power. 1 Watt = 1
Volt x 1 Ampere. 1 B.H P. = 0.746 kilowatts. 1 Kw. H. =
3413 B.Th.U.I.E.E. 1939 11th edition.
Electrical pressure, potential difference, or elect.
n. o. t. force:

92
93
94
95
96
97
 Comparison between Synchronous Motor
and Induction Motor

Synchronous motor Induction motor

Construction is simpler, particularly in
Construction is complicated
case of cage rotor.
Not self-starting Self-starting
Rotors get excited by the induced
Separate DC source is required for
e.m.f so separate source is not
rotor excitation.
necessary.
The speed is always synchronous The speed is always less than
irrespective of the load. synchronous but never synchronous
Speed control is possible though
Speed control is not possible
difficult
As load increases, load angle
As load increases, the speed keeps on
increases, keeping speed constant
decreasing
at synchronous.
By changing excitation, the motor
It always operates at lagging p.f and
p.f can be changed from lagging
p.f control is not possible
and leading
It can be used as synchronous It cannot be used as synchronous
condenser for p.f improvement condenser
Motor is sensitive to sudden load
Phenomenon of hunting is absent
changes and hunting results
Motor is costly and requires Motor is cheap, especially cage rotors
frequent maintenance and maintenance free
98
 CABLE RATING TABLE
Cable Cross Typical Current Recommended
Sectional Rating Circuit Breaker
Area (mm2) (amps) Rating (amps)
1.5 mm2 7.9 – 15.9A 8A
2.5 mm2 15.9 – 22A 15A
4 mm2 22 – 30A 20A
6 mm2 30 – 39A 30A
10 mm2 39 – 54A 40A
16 mm2 54 – 72A 60A
25 mm2 71 – 93A 80A
50 mm2 117 – 147A 125A
70 mm2 147 – 180A 150A
95 mm2 180 – 216A 200A
120 mm2 216 – 250A 225A
150 mm2 250 – 287A 275A
185mm2 287 – 334A 300A
240mm2 334 – 400A 350A

99
 USEFUL 3-PHASE FORMULAE

h. p. x 746
kW = kVA x Power Factor kW =
1000 x Efficiency

Line Amps x Line Volts x 1.732 x p. f.

kW =
1000

kW h. p. x 746
kVA = kVA =
p. f. 1000 x Eff. x p. f.

Line Amps x Line Volts x 1.732

kVA =
1000

kW x 1000
Line Amps = kVA x 1000
p. f. Line Volts x Line Amps =
1.732 x p. f.  !" #$%& ' 1.732

h. p x 746
Line Amps =
Line Volts x 1.732 x Eff. x p. f

kW x 1000 x Eff. kVA x 1000 x Eff. x p. f.

h. p. = h. p. =
746 746

Line Amps x Line Volts x 1.732 x Eff. x p. f.

h. p. =
746

100
Electrical Energy Consumption Target

Electrical consumption
Area of activity
(kWh / Ton of OPC )
Crushing 1.5
Raw mill 12 - 18
Kiln and Cooler 18
Coal mill 2.5
Cement mill 18
Packing 1
Miscellaneous 3.5
Total 56-62

101
 Transformer Loss

Transformer loss = No load loss + ((% loading/100)2 * full

load copper loss)

The core loss & the full load copper loss for transformers
are specified in the transformer test certificate. The
typical values of no-load and the full load losses are
given in the following table:

Full load loss

kVA rating No-load loss
(Watts) (Watts) at 75oC Impedance
(Watts)
(%)
160 425 3000 5
200 570 3300 5
250 620 3700 5
315 800 4600 5
500 1100 6500 5
630 1200 7500 5
1000 1800 11000 5
1600 2400 15500 5
2000 3000 20000 6

102
 Core loss as a % Loading at which
Transformer type of full load max. Efficiency is
copper loss achieved (%)

Distribution
15-20 % 40-60 %
transformer

Power transformer 25-30 % 60-80 %

As per IS 2026, the maximum permissible tolerance on

the total loss is 10
%.The permissible limit for no-load and full load loss is
+ 15 %.

There will be a little variation in actual no-load and

load loss of transformer. The exact values can be
obtained from the transformer test certificate.

103
 FUSE WIRE TABLE

Fusing Copper Aluminium Platin Old Tin Allo-Tin Lead

Cur-
rent Dia. S.W.G Dia. S.W.G Dia. S.W.G Dia. S.W.G Dia. S.W.G Dia. S.W.G
Amps. In. (app.) In. (app.) In. (app.) In. (app.) In. (app.) In. (app.)

1 .0021 47 .0026 46 .0035 43 .0072 37 .0083 35 .0081 35

2 .0034 43 .0041 42 .0056 39 .0113 31 .0132 29 .0128 30
3 .0044 41 .0054 39 .0074 36 .0149 28 .0173 27 .0168 27
4 .0053 39 .0065 37 .0089 35 .0181 26 .0210 25 .0203 25
5 .0062 38 .0076 36 .0104 33 .0210 25 .0243 23 .0236 23
10 .0098 33 .0120 30 .0164 27 .0334 21 .0386 19 .0373 20
15 .0129 30 .0158 28 .0215 24 .0437 19 .0506 18 .0491 18
20 .0156 28 .0191 25 .0261 23 .0529 17 .0613 16 .0595 17
25 .0181 26 .0222 24 .0303 21 .0614 16 .0711 15 .0690 15
30 .0205 25 .0250 23 .0342 20 .0694 15 .0803 14 .0779 14
35 .0227 24 .0277 22 .0379 20 .0769 14 .0890 13 .0864 13
40 .0248 23 .0303 21 .0414 19 .0840 14 .0973 13 .0944 13
45 .0268 22 .0328 21 .0448 19 .0909 13 .1052 12 .1021 12
50 .0288 22 .0352 20 .0480 18 .0975 13 .1129 11 .1095 12
60 .0325 21 .0397 19 .0542 17 .1101 11 .1275 10 .1237 10
70 .0360 20 .0440 19 .0601 16 .1220 10 .1413 9 .1371 9
80 .0394 19 .0481 18 .0657 16 .1334 10 .1544 8 .1499 9
90 .0426 19 .0520 18 .0711 15 .1443 9 .1671 8 .1621 8
100 .0457 18 .0558 17 .0762 14 .1548 8 .1792 7 .1739 7
120 .0516 17 .0630 16 .0861 13 .1748 7 .2024 6 .1964 6

104
 FULL LOAD CURRENTS FOR A.C. MOTORS IN AMPERES
Split Phase Single Capacitor Single 2-Phase 3-Phase
H.P.B

Volts Volts Volts Volts

100 200 230 400 480 100 200 230 400 480 200 400 200 220 350 400 440 500
1 12.9 6.5 5.5 3.2 2.7 11. 5.9 5.1 2.9 2.4 2.9 1.4 3.4 3.1 2 1.7 1.5 1.4
2 24 12 10. 6 5 6
22 11 9.5 5.4 4.5 5.7 2.9 6.6 6 3.8 3.3 3 2.6
3 35 17 4
15 9 7 31 15 13 7.8 6.5 8.4 4.2 9.8 8.9 5.7 4.9 4.5 3.9
4 45 23 20 11 9.4 40 20 18 10 8.5 11 5.6 13 12 7.5 6.5 6 5.2
5 56 28 25 14 12 51 25 22 13 11 14 6.8 16 14 9.1 7.9 7.2 6.3
6 66 33 29 17 14 60 29 26 15 13 16 8.1 19 17 11 9.4 8.5 7.5
8 87 43 38 22 18 78 39 34 20 16 21 11 25 22 15 13 12 9.8
10 109 54 47 27 23 98 48 42 24 20 26 13 30 27 17 15 14 12
15 159 79 69 40 33 147 73 64 37 31 38 19 44 40 26 22 20 18
20 209 105 91 52 44 193 97 84 48 42 50 25 58 53 34 29 26 23
25 256 128 111 64 53 237 118 103 59 49 62 31 72 66 42 36 33 29
30 306 153 134 77 64 283 142 124 71 59 74 37 86 78 50 43 39 34
40 400 200 174 100 83 370 185 161 93 77 96 48 111 101 64 56 51 45
50 487 244 212 122 102 450 226 196 113 94 118 59 137 124 79 68 62 55
60 586 292 254 147 122 542 270 235 136 113 140 70 162 147 94 81 74 65
75 715 358 310 179 150 662 330 287 166 139 171 86 198 180 114 99 90 79
100 941 471 410 235 196 870 435 380 217 182 228 114 263 239 152 132 120 105
150 - - - - - - - - - - 336 168 388 356 225 194 176 155
200 - - - - - - - - - - 446 223 517 468 299 258 235 207
Single Phase: Three – Phase Star:

..  
Current = Phase Current = Line Current
       .

Three – Phase Delta and Star: Three – Phase Delta:

..  
Line Current = Phase Current = Line Current ÷ 1.732
.   !"#$  %.&. % (&&)*+

105
 ELECTICAL FORMULAS

REACTANCE FORMULAS
1 1

=  =
2 2

XL
=  = 2fL
2

RESONANT FREQUECY FORMULAS

1 159.3
=  =
2√
√

1 25.320
=   =
4 

 

1 25.330

=
 =
4    

L - is in microhenries
Where “ “ is in kHz

C - is in microfarads

106
CONVERSION FACTORS

     
   log  = 0.497

1 meter = 3.28 feet

1 inch = 2.54 centimeters
1 radian = 57.3ᵒ

FREQUECY AND WAVELENGTH FORMULAS

3 x 10 * 3 x 10*
 = $%&'&() =
$%&'&() 

984 984
% = $&&' =
$&&' %

0.625λ = 225ᵒ = 5/8 WAVE

0.5λ = 180ᵒ = HALF WAVE
0.311λ = 112ᵒ
0.25λ = 90ᵒ = QUARTER WAVE

RESISTORS IN SERIES

,'-'./ = ,0 + , + ,2 + ⋯

107
RESISTORS IN PARALLEL
EQUAL RESISTORS
, Where n is the total
,'-'./ =
4 Number of resistor

UNEQUAL RESISTORS
1
,'-'./ =
1 1 1
+ + +⋯
,0 , ,2

,0, ,0,
,'-'./ = ,'-'./ =
,0 + , , − ,0

If the current through a resistor doubles, the power

dissipated quadruples.

IMPEDANCE FORMULAS
SERIES CIRCUIT

7 = 8,  + (/ − : )

PARALLEL CIRCUITS – R & X IN PARALLEL

RX
7=
√,  +  

108
DIRECT POWER FORMULA

P = lR
Where I is the common point or base current in amperes, and R
is the common point or base resistance in ohms.

INDIRECT POWER FORMULA

P = IE(effy)
Where I is the final P.A. current in amperes, E is the final P.A.
voltage in volts, and effy is the transmitter efficiency expressed
in decimal form (79% = 0.79).

SINE WAVE CONVERSION

Effective Value = 0.707 x Peak Value
Average Value = 0.637 x Peak Value
Peak Value = 1.414 x Effective Value (RMS)
Effective Value = 1.11 x Average Value
Peak Value = 1.57 x Average Value
Average Value = 0.9 x Effective Value (RMS)

109
OHM’S LAW FORMULA FOR DC CIRCUITS

ONE CYCLE TIME DURATION

10 kHz = 100µ sec
20 kHz = 50µ sec
100 kHz = 10µ sec
200 kHz = 5µ sec
250 kHz = 4µ sec
1 MHz = 1µ sec
4 MHz = 0.25µ sec
f0 MHz = 0.1µ sec

110
BINARY TO BASE 10 CONVERSION
3
1 (2 ) = 8
2
0 (2 ) = 0
1
1 (2 ) = 2
1 (20) = +1
11

TRANSFORMER TURNS RATIOS

Primary Power = Secondary Power
=> ?> @) 7>
= = = A
=) ?) @> 7)

111
Table: 2 core, 3 core & 4 core copper conductor PVC Sheathed, Unarmoured (YY) / Armoured (YWY & YFY)’ cables – 650 / 1100 Volts.
Unarmoured Armoured In Air In Ground
Nom.
Nom. Cross Approx. Nom. Conductor
No. Thickness Approx. Approx. Approx. PVC HRPVC PVC HRPVC
Sectional Class of Overall Steel Resistance
of Of PVC Overall Overall Weight Insulation Insulation Insulation Insulation
Area Conductor Weight Armour At 20ᵒ C
Cores Insulation Db mm Dia. mm Kg. / km. Amps. Amps. Amps. Amps.
Sq. mm Kg. / km. Size mm Ohm / km
mm
2 4 1 1.0 13.25 264 1.4 15.2 585 4.61 35 43 41 48
2 4 2 1.0 13.95 292 1.4 15.9 632 4.61 35 43 41 48
2 6 1 1.0 14.25 327 1.4 16.2 682 3.08 45 55 50 58
2 6 2 1.0 15.05 368 1.4 17.0 751 3.08 45 55 50 58
2 10 2 1.0 16.95 524 4 x 0.8 17.7 867 1.83 60 73 70 81
2 16 2 1.0 19.60 747 4 x 0.8 20.2 1102 1.15 78 95 90 105
2 25 2 1.2 23.20 1092 4 x 0.8 23.8 1874 0.727 105 123 115 122
2 35 2 1.2 25.60 1394 4 x 0.8 26.2 1891 0.524 125 147 140 145
3 4 1 1.0 14.05 317 1.4 16.00 659 4.61 30 37 36 42
3 4 2 1.0 14.70 351 1.4 16.65 713 4.61 30 37 36 42
3 6 1 1.0 15.05 401 1.4 17.00 770 3.08 39 48 45 53
3 6 2 1.0 15.90 451 1.4 18.15 860 3.08 39 48 45 53
3 10 2 1.0 17.95 657 4 x 0.8 19.00 1000 1.83 52 63 60 69
3 16 2 1.0 20.75 939 4 x 0.8 21.35 1323 1.15 66 81 77 90
3 25 2 1.2 24.70 1405 4 x 0.8 25.30 1874 0.727 90 106 99 105
3 35 2 1.2 27.20 1810 4 x 0.8 27.80 2336 0.524 110 129 120 125
4 4 1 1.0 15.15 385 1.4 17.10 762 4.61 30 37 39 42
4 4 2 1.0 15.90 430 1.4 18.15 828 4.61 30 37 39 42
4 6 1 1.0 16.70 506 1.4 17.40 878 3.08 39 48 45 53
4
4 6 2 1.0 17.20 559 4 x 0.8 18.25 901 3.08 39 48 45 53
4 10 2 1.0 20.00 837 4 x 0.8 20.60 1220 1.83 52 63 60 69
4 16 2 1.0 22.70 1180 4 x 0.8 23.35 1621 1.15 66 81 77 90
4 25 2 1.2 27.05 1767 4 x 0.8 27.65 2293 0.727 90 106 99 105
4 35 2 1.2 30.20 2328 4 x 0.8 30.90 2912 0.524 110 129 120 125
Y = PVC Insulation, W = Steel round wire armour , F = Steel strip armour

112
 SYMBOLS FOR METHOD OF COOLING

COMPLETE DESIGNATION IC 8 A 1 W 7
SIMPLIFIED DESIGNATION IC 8 1 W

Code letters
Circuit arrangement
Primary coolant
Method of movement of primary coolant
Secondary coolant
Method of movement of secondary coolant

CHARACTERISTIC LETTER FOR COOLANT

Characteristic letter Coolant

A Air
F Freon
H Hydrogen
N Nitrogen
C Carbon dioxide
W Water
U Oil
S Any other coolant
Y Coolant not yot selected

113
When the single coolant is air or when in case of two coolant
either one or both are air, these letter(s) “A” stating the
coolant are omitted on the simplified designation.

For the single letter “S”, the coolant shall identified elsewhere,
e.g. in the technical or the commercial documentation.

When the coolant is finally selected, the temporary used letter

“Y” shall be replaced by the appropriate final characteristic
letter.

114
115
1) Cement Plant Formula Hand Book. By G.JAyaraman.
2) Hand Book of Formula Physical Constants.
3) Steel Hand Books.
4) Engineering Diary 1974.
5) NCB Norms Cement Plant Operation
6) Pocket Formula_Bonfiglioli Riduttori.
7) Formulas in Cement Industries.

And Data’s taken from some other different different Hand

books and Study books etc.,,
Note:
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