Welding Calculation

OVERLAY WELD KG & RUN TIME ESTIMATION
TOME REQUIRED FOR RADIOGRAPHY TEST

C/SEAM OR L/SEAM OR T-FRAME (LS/CS/TF)?
LG OF SHELL/NOZZLE=
LOWER THK INCLUDING RAINFORCEMENT
RADIOGRAPHY BY IRIDIUM/COBALT(I/C)?
SPOT RT OR PENOROMIC RT (S/P)?
LG OF SHELL/NOZZLE=
SPOT LENGTH=
NO. OF SPOT=
3000
300
10
LS
TIME REQUIRED FOR RT=
3000
50
I
S
THK=
50
TIME CALCUCATION
SPOT
SPOT FOR FILLET IN T-FRAMES
PEMOROMIC
297503042.xls
IRIDIUM
86.4
691.2
2592.0
COBALT
23.8
113.0
458.2
12/06/2015
864
14.4
0.60
MIN
HRS
DAYS
LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

SINGLE 'V'
RUN TIME TIME REQUIRED FOR

L/SEAM OR C/SEAM (LS/CS)=
LS
HRS/KG
1). SMAW
2). SAW
45
52
R.F.=
R.G.=
PARAMETERS SETTING
PROCESS
KG/SHIFT
THK= 54
LG OF LONG SEAM= 58000
MATERIAL (SS/STEEL)= ss
DENSITY= 0.000008
4
2.00
(C/S)
30
0.27
(L/S)
18
0.44
3).FCAW (1.2 )
6
1.33
4). GTAW
1.6
5.00
5). TWIN HD. (C/S 24 48
0.330.66
SAW **
(L/S) 14.428.8
0.561.11
** WITH 2 OPERATORS
POSITION OF
MULTIPLICATION
WELDING
FACTOR
1). 1G
1
2). 2G
1.6
3). 3G
1.3
ALL DIMENSIONS ARE IN MM

PREHEATING
REQUIRED?
YES
NO
CROSS SEC. AREA TOTAL WELD KG

O/S WELDING=
C/B WELDING=
TOTAL WELDING=
1420.3
298.2
1718.5
LONG SEAM
659.0
138.4
797.4
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN
20%
0.444
1.0
OUT SIDE BALANCE
80%
1.0
CHIP BACK WELDING
100%
1.0
TOTAL =
297503042.xls
MULTIPLICATION
FACTOR
1.15
1
12/06/2015
RUN TIME
(min)
(Hrs)
3514.7
58.6
63264.4
1054.4
16603.5
276.7
83382.6
1389.7
6
12
0.66
1.11
297503042.xls
12/06/2015
LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION

DOUBLE 'V'

PARAMETERS SETTING
PROCESS
KG/SHIFT HRS/KG
ls
45
1). SMAW
2). SAW
36.0
THK= 54
R.F.=
LG OF LONG SEAM= 1364

MATERIAL (SS/STEEL)= steel
15.0
R.G.=
60
DENSITY= 0.00000785
PREHEATING
REQUIRED?
YES
NO

O/S WELDING=
C/B WELDING=
TOTAL WELDING=
710.3
514.4
1224.7
LONG SEAM
7.6
5.5
13.1
MULTIPLICATION
FACTOR
1.15
1
CHIP BACK DEPTH(MM)

THK <= 30
6
THK > 30
12
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN
12%
1.0
1.15
OUT SIDE BALANCE
88%
0.444
1.0
CHIP BACK WELDING
100%
0.444
1.0
TOTAL =
297503042.xls
4
2.00
(C/S)
30
0.27
(L/S)
18
0.44
3).FCAW (1.2 )
6
1.33
4). GTAW
1.6
5.00
5). TWIN HD. (C/S 24 48
0.330.66
SAW **
(L/S) 14.4
0.561.11
28.8
** WITH 2 OPERATORS
POSITION OF
MULTIPLICATION
WELDING
FACTOR
1). 1G
1
2). 2G
1.6
3). 3G
1.3
12/06/2015
RUN TIME
(min)
(Hrs)
120.7
2.0
178.5
3.0
146.9
2.4
446.1
7.4
LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION
0.66
1.11
297503042.xls
12/06/2015

BACKING STRIP
10
PARAMETERS SETTING
PROCESS
KG/SHIFT
cs

1). SMAW
2). SAW
THK= 8
I/D OF SHELL 5486
MATERIAL (SS/STEEL)= STEEL
R.G.=
4
(C/S)
30
(L/S)
18
3).FCAW (1.2 )
6
5). TWIN HD. (C/S) 24 48
SAW **
(L/S) 14.428.8
** WITH 2 OPERATORS
10
DENSITY= 0.00000785
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1

CROSS SEC. AREA
TOTAL WELD KG
O/S WELDING=
119.8
16.2
TOTAL WELDING=
119.8
16.2
CIRC SEAM
OUT SIDE BALANCE
100%
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
0.267
1.6
TOTAL =
297503042.xls
12/06/2015
RUN TIME
(min)
(Hrs)
0.0
0.0
0.0
0.0
ETTING
HRS/KG
48
28.8
2.00
0.27
0.44
1.33
0.330.66
0.561.11
MULTIPLICATION
FACTOR
1.3
MULTIPLICATION
FACTOR
1.15
1
297503042.xls
12/06/2015

J GROOVE

PARAMETERS SETTING
PROCESS
KG/SHIFT HRS/KG
CS
10
1). SMAW
2). SAW
59.0
THK= 80
R= 12
11.0
R.F.=
R.G.=
I/D OF SHELL 379

DENSITY= 0.00000785
10
PREHEATING
REQUIRED?
YES
NO

O/S WELDING=
C/B WELDING=
TOTAL WELDING=
2186.6
486.7
2673.3
CIRC SEAM
24.8
5.5
30.3
MULTIPLICATION
FACTOR
1.15
1
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN
20%
1.0
1.15
OUT SIDE BALANCE
80%
1.0
1.15
CHIP BACK WELDING
100%
1.0
1.15
TOTAL =
297503042.xls
4
2.00
30
0.27
18
0.44
3). FCAW
6
1.33
4). GTAW
1.6
5.00
5). TWIN HD. (C/S) 24 48
0.33
0.66
SAW **
(L/S) 14.428.8
0.56
1.11
** WITH 2 OPERATORS
POSITION OF
MULTIPLICATION
WELDING
FACTOR
1). 1G
1
2). 2G
1.6
3). 3G
1.3
(C/S)
(L/S)
12/06/2015
RUN TIME
(min)
(Hrs)
683.1
11.4
2732.5
45.5
760.3
12.7
4175.9
69.6
6
12

HRS/KG
0.66
297503042.xls
12/06/2015

COMPOUND 'V'

10
45
12
R.F.=
R.G.=
O/S WELDING=
C/B WELDING=
TOTAL WELDING=
738.6
298.2
1036.8
CIRC SEAM
HRS/KG
2.00
(C/S)
0.27
(L/S)
0.44
3).FCAW (1.2 )
1.33
4). GTAW
5.00
THK= 50
I/D OF SHELL= 2600
5). TWIN HD. (C/S) 24 48
0.330.66
SAW **
(L/S) 14.4 28.8
0.56
1.11
** WITH 2 OPERATORS
DENSITY= 0.00000785
POSITION OF
MULTIPLICATION
WELDING
FACTOR
1). 1G
1
2). 2G
1.6
3). 3G
1.3
PREHEATING
REQUIRED?
YES
NO

48.3
19.5
67.8
4
30
18
6
1.6
MULTIPLICATION
FACTOR
1.15
1
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN
20%
1.0
1.15
OUT SIDE BALANCE
80%
0.267
1.0
CHIP BACK WELDING
100%
0.267
1.0
TOTAL =
297503042.xls
PARAMETERS SETTING
PROCESS
KG/SHIFT
1). SMAW
2). SAW
36
CS
12/06/2015
RUN TIME
(min)
(Hrs)
1332.3
22.2
617.9
10.3
311.8
5.2
2262.0
37.7
6
12
HRS/KG
0.66
297503042.xls
12/06/2015
NOZZLE WELD KG & RUN TIME ESTIMATION

SINGLE 'V'
NOZZLE ON SHELL/DEND) (D/S) ?
CFW= 10
INC. ANG=45

DENSITY= 7.85E-006
NOZZLE O/D=
60
OFF SET=
0
THK= 26
SHELL I/D=
4300
R.F.= 2
R.G=
4
NOZ O/D
60
ELLIPSE DIMENSION
MAJOR AXIS=
64.0
MINOR AXIS=
64
LG. OF WELDING= 201.066
WELD KG
WEIGHT
CROSS SEC.
ON SHELL ON D/END
CALCULATION
AREA
O/S WELDING=
338.00
0.53
0.53
C/B WELDING=
56.55
0.09
0.09
TOTAL WELDING=
0.62
0.62
PROCESS
POSITION
HEATING
ON SHELL
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN 20%
1
2.5
1
1.0
Y
1.15
OUT SIDE BALANCE 80%
1
2.5
1
1.0
Y
1.15
CHIP BACK WELDING 100%
1
2.5
1
1.0
Y
1.15
TOTAL =
297503042.xls
PARAMETERS SETTING
PROCESS
KG/SHIFT
1). SMAW
3.2
2). SAW
14.4
3). FCAW (1.2 )
6.0
4). GTAW
1.3
12/06/2015
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1
1.6
1.3
1.15
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
RUN TIME
(min)
(Hrs)
18.4
0.3
73.6
1.2
15.4
0.3
107.4
1.8
TTING
HRS/KG
2.50
0.56
1.33
6.25
MULTIPLICATION
FACTOR
1
1.6
1.3
MULTIPLICATION
FACTOR
1.15
K DEPTH(MM)
6
12
297503042.xls
12/06/2015

BACKING STRIP

CFW= 9
INC. ANG= 15
DENSITY= 0.00000785
NOZZLE O/D=
300
SHELL I/D=
6800
R.G=
10
NOZ O/D
300
CROSS SEC.
AREA
875.44
WELD KG
ON SHELL ON D/END
7.63
7.63
TOTAL WELDING=
ON D/END
BACKING STRIPP DIMENSION

OUTER MAJOR AXIS 358.4
OUTER MINOR AXIS
340.0
WIDTH=
32.3
297503042.xls
PROCESS
CODE
1
2.5
3).FCAW (1.2 )
HRS/KG
2.50
0.56
1.33
6.0
OFF SET=
1100
THK= 50
ELLIPSE DIMENSIO o/d

I/d
MAJOR AXIS=
353.4
303.4
WEIGHT
MINOR AXIS=
353.4 303.377 CALCULATION
LG. OF WELDING= 1110.17
O/S WELDING=
PARAMETERS SETTING
PROCESS
KG/SHIFT
1). SMAW
3.2
2). SAW
14.4
7.63
POSITION
CODE
1
1.0
O/D= 358.4
I/D= 275.4
12/06/2015
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1
1.6
1.3
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
7.63
HEATING
(Y/N)
Y
1.15
TOTAL =
1.15
RUN TIME
(min)
(Hrs)
1316.0
21.9
1316.0
21.9
6
12
DOUBLE 'V'
CFW= 9
INC. ANG= 45
1). SMAW
2). SAW
3).FCAW (1.2 )
4). GTAW
DENSITY= 0.00000785
NOZZLE O/D=
OFF SET=
194
44
THK= 65
R.F.= 2
3020
SHELL I/D=
19
R.G=
NOZ O/D
194
INC. ANG= 35
ELLIPSE DIMENSION
MAJOR AXIS=
MINOR AXIS=
LG. OF WELDING=
197.1
197
619.1137
ON SHELL
OUTSIDE ROOT RUN
WEIGHT
CALCULATION
O/S WELDING=
C/B WELDING=
TOTAL WELDING=
WELD KG
CROSS SEC. AREA ON SHELL ON D/END
1146.50
5.57
5.57
336.45
1.64
1.63
7.21
7.20
PROCESS
POSITION
CODE
(Y/N)
20%
2.50
1.0
1.15
OUT SIDE BALANCE
80%
2.5
1.0
CHIP BACK WELDING
100%
2.5
1.0
TOTAL =
297503042.xls
12/06/2015
3.2
14.4
6.0
1.3
HRS/KG
2.50
0.56
1.33
6.25
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1
CHIP BACK DEPTH(MM)

THK <= 30
6
THK > 30
12
HEATING
CODE
PARAMETERS SETTING
PROCESS
KG/SHIFT
RUN TIME
(min)
(Hrs)
192.2
3.2
668.6
11.1
245.3
4.1
1106.2
18.4

'J' GROOVE
PARAMETERS SETTING
PROCESS
HRS/KG
KG/SHIFT
1). SMAW
2). SAW
DENSITY= 0.00000785 3).FCAW (1.2 )
4). GTAW
NOZZLE LIP O/D=
R.G=
369
3
R.F.= 10
3.2
14.4
6.0
1.3
2.50
0.56
1.33
6.25
OFF SET=
0
R= 12
4644
SHELL I/D=
THK= 80
INC. ANG.= 5
369
INC. ANG.= 5
372.4
372
1169.3
ON SHELL
OUTSIDE ROOT RUN
WEIGHT
CALCULATION
I/S WELDING=
C/B WELDING=
TOTAL WELDING=
CROSS SEC. AREA

1456.86
414.69
PROCESS
WELD KG
ON SHELL ON D/END
13.37
13.37
3.81
3.80
17.18
17.17
POSITION
CODE
HEATING
CODE
(Y/N)
20%
2.5
1.0
1.15
OUT SIDE BALANCE
80%
2.5
1.0
1.15
CHIP BACK WELDING
100%
2.5
1.0
1.15
TOTAL =
297503042.xls
MULTIPLICATION
FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1
NOZ O/D
ELLIPSE DIMENSION
MAJOR AXIS=
MINOR AXIS=
LG. OF WELDING=
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
12/06/2015
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
RUN TIME
(min)
(Hrs)
461.4
7.7
1845.4
30.8
656.6
10.9
2963.4
49.4
6
12
R.F. PAD +SINGLE 'V'
CFW= 9
INC. ANG= 35

DENSITY= 0.00000785
PARAMETERS SETTING
PROCESS
KG/SHIFT
1). SMAW
2). SAW
3).FCAW (1.2 )
4). GTAW
INC. ANG= 5
OFF SET=
HRS/KG
3.2
14.4
6.0
1.3
2.50
0.56
1.33
6.25
0
THK= 16
R.F.PAD
5
NOZZLE O/D=
0
00
=2
D
/
DO
PA
602
THK= 20
NOZ O/D
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
1.15
1
602
FILLET SIZE=30
ELLIPSE DIMENSION
MAJOR AXIS=
MINOR AXIS=
LG. OF WELDING=
4300
SHELL I/D=
R.F.= 2
R.G=
3
WEIGHT
CALCULATION
O/S WELDING=
C/B WELDING=
R.F.PAD WELDING=
TOTAL WELDING=
607.0
605
1903.83
ON SHELL
WELD KG
554.79
8.29
8.28
56.55
0.85
0.84
450.00
22.42
22.42
31.55
31.54
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN
20%
2.5
1.0
OUT SIDE BALANCE
80%
2.5
1.0
CHIP BACK WELDING
100%
2.5
1.0
R.F.PAD WELDING
100%
2.5
1.0
TOTAL =
297503042.xls
12/06/2015
RUN TIME
(min)
(Hrs)
248.7
4.1
995.0
16.6
126.8
2.1
3362.6
56.0
1370.5
22.8
6
12

CFW= 9
INC. ANG= 45
1). SMAW
2). SAW
3).FCAW (1.2 )
10
INC. ANG= 5
PARAMETERS SETTING
PROCESS
KG/SHIFT
DENSITY= 0.00000785
HRS/KG
3.2
14.4
6.0
2.50
0.56
1.33
OFF SET=
330
THK= 90
R.F.PAD
10
NOZZLE O/D=
/D=
DO
A
P
0
10
345
THK= 90
NOZ O/D
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
1.15
1
345
FILLET SIZE=40
2450
SHELL I/D=
R.F.= 2
R.G=
3
WEIGHT
CALCULATION
ELLIPSE DIMENSION o/d
I/d
O/S WELDING=
MAJOR AXIS=
381.2
331.2 R.F.PAD WELDING=
MINOR AXIS=
381.2 331.1593 TOTAL WELDING=
LG. OF WELDING=
1197.447
ON D/END
WELD KG
13984.83
131.46
131.46
800.00
20.26
20.26
151.71
151.71
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUT SIDE BALANCE
100%
0.56
1.0
R.F.PAD WELDING
100%
2.50
1.3
1.15
TOTAL =
BACKING STRIPP DIMENSION
OUTER MAJOR AXIS=
386.2
OUTER MINOR AXIS=
371.0
WIDTH=
25.2
297503042.xls
12/06/2015
RUN TIME
(min)
(Hrs)
4381.9
73.0
4542.3
75.7
8924.1
148.7
6
12

CFW= 9
INC. ANG= 35
5
DENSITY= 0.00000785
OFF SET=
THK= 16
R.F.PAD
PARAMETERS SETTING
PROCESS
KG/SHIFT
HRS/KG
1). SMAW
2). SAW
3).FCAW (1.2 )
4). GTAW
3.2
14.4
6.0
1.3
2.50
0.56
1.33
6.25
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1
545
5
R.F.= 2
NOZZLE O/D=
407
=2
O/D
D
PA
00
THK= 17
NOZ O/D
407
4300
SHELL I/D=
FILLET SIZE=30
R.G=
3
INC. ANG=
35
ELLIPSE DIMENSION
MAJOR AXIS=
MINOR AXIS=
LG. OF WELDING=
424.7
410
1311.309
ON SHELL
WELD KG
WEIGHT
CALCULATION
I/S WELDING=
129.77
0.42
1.36
C/B(O/S) WELDING=
314.68
1.01
3.30
R.F. PAD WELDING
450.00
22.42
22.42
TOTAL WELDING=
23.85
27.07
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN
20%
2.5
1.0
OUT SIDE BALANCE
80%
2.5
1.0
CHIP BACK WELDING
100%
2.5
1.0
R.F.PAD WELDING
100%
2.5
1.0
TOTAL =
297503042.xls
12/06/2015
RUN TIME
(min)
(Hrs)
12.5
0.2
50.1
0.8
151.9
2.5
3362.6
56.0
3577.2
59.6
6
12
297503042.xls
12/06/2015
R.F.PAD + DOUBLE 'V'
CFW= 9
INC. ANG= 60
INC. ANG= 10
10
DENSITY= 0.00000785
THK= 30
R.F.PAD
HRS/KG
1). SMAW
2). SAW
3).FCAW (1.2 )
4). GTAW
3.2
14.4
6.0
1.3
2.50
0.56
1.33
6.25
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1
OFF SET=
10
330
NOZZLE O/D=
345
40
THK= 60
=
O/D
D
PA
20
00
R.F.= 2
18
NOZ O/D
ELLIPSE DIMENSION
MAJOR AXIS=
MINOR AXIS=
LG. OF WELDING=
2450
SHELL I/D=
345
INC. ANG=
45
363.0
348
1117.086
OUTSIDE ROOT RUN
FILLET SIZE=30
R.G=
WEIGHT
CALCULATION
O/S WELDING=
C/B WELDING=
R.F. PAD WELDING
TOTAL WELDING=
WELD KG
4099.95
35.95
35.19
450.00
3.95
3.86
450.00
22.42
22.42
39.90
39.05
PROCESS
ON D/END
POSITION
CODE
CHIP BACK DEPTH(MM)

THK <= 30
THK > 30
HEATING
CODE
(Y/N)
20%
0.56
1.0
OUT SIDE BALANCE
80%
2.5
1.6
1.15
CHIP BACK WELDING
100%
2.5
1.6
1.15
R.F.PAD WELDING
100%
2.5
1.0
1.15
TOTAL =
297503042.xls
PARAMETERS SETTING
PROCESS
KG/SHIFT
12/06/2015
RUN TIME
(min)
(Hrs)
234.6
3.9
7769.2
129.5
1065.9
17.8
3867.0
64.4
12936.7
215.6
6
12

SET ON
NOZZLE IN SHELL/DEND) (D/S) ?
50
35
NOZ I/D
MATERIAL (SS/STEEL)=
19
STEEL
DENSITY= 0.00000785
`
INC. ANG.=
15
CFW= 9
INC. ANG.= 50
3
NOZ I/D
203
NOZ O/D
3400
SHELL
I/D=
THK= 70
273
ELLIPSE DIMENSION
MAJOR AXIS=
MINOR AXIS=
LG. OF WELDING=
238.2
238
748.0
WEIGHT CALCULATION
O/S WELDING=
CROSS SEC. AREA

716.09
WELD KG
ON SHELL ON D/END
4.20
4.20
TOTAL WELDING=
ON SHELL
4.20
3.2
14.4
6.0
1.3
POSITION OF
WELDING
1). 1G
2). 2G
3). 3G
MULTIPLICATION
FACTOR
1
1.6
1.3
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1
4.20
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
OUTSIDE ROOT RUN 20%
6.25
1.0
2.5
1.0
1.15
1.15
TOTAL =
297503042.xls
HRS/KG
1). SMAW
2). SAW
3).FCAW (1.2 )
4). GTAW
2.50
0.56
1.33
6.25
OFFSET=
0
R.F.= 1
R.G.=
PARAMETERS SETTING
PROCESS
KG/SHIFT
12/06/2015
RUN TIME
(min)
(Hrs)
362.6
6.0
580.2
9.7
942.9
15.7
FILLET WELD KG & RUN TIME ESTIMATION

PARAMETERS SETTING
PROCESS
KG/SHIFT
WELD LG (CALCULATED/MANUAL) (C/M?) M

MANUAL LENGTH OF WELDING(MM)=
33615
HRS/KG
1). SMAW
2). SAW
3).FCAW (1.2 )
3.2
14.4
6.0
2.50
0.56
1.33
POSITION OF
WELDING
1). 1F/2F
2) 3F
MULTIPLICATION
FACTOR
1
1.1
PREHEATING
REQUIRED?
YES
NO
MULTIPLICATION
FACTOR
1.15
1

DENSITY= 0.00000785
FOR CALCULATING WELD LENGTH
RADIUS OF WELDING(MM)=
0
INCLUDED ANGLE OF WELDING(DEG)=
0
CALCULATED LENGTH OF WELDING(MM)=
0.000
LENGTH OF WELDING(MM)=
WELD CALCULATION
CROSS SEC. AREA
TOTAL WELDING
18.00
FILLET WELD
297503042.xls
TOTAL WELD KG
4.75
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
2.50
33615.000
1.0
12/06/2015
(min)
712.5
712.5
RUN TIME
(Hrs)
11.9
11.9

DOUBLE SIDE FILLET JOINT
WELDING BY SINGLE OPERATOR/
DOUBLE OPERATOR(S/D)?
WELD LG (CALCULATED/AMNUAL) (C/M?) m
HRS/KG
1). SMAW
2). SAW
3).FCAW (1.2 )
3.2
14.4
6.0
2.50
0.56
1.33
POSITION OF
WELDING
1). 1F/2F
2) 3F
MULTIPLICATION
FACTOR
1
1.1
PREHEATING
REQUIRED?
MULTIPLICATION
FACTOR
YES
1.15
NO
1000
13
DENSITY= 0.00000785
0
0
0.000
LG OF WELDING=
1000.000
13
WELD CALCULATION
FIRST SIDE WELDING
SECOND SIDE WELDING
TOTAL WELDING=
CROSS SEC. AREA

84.50
84.50
TOTAL WELD KG
0.66
0.66
169.00
1.33
DOUBLE OPERATOR
PROCESS
POSITION
CODE
HEATING
CODE
(Y/N)
FIRST SIDE
100%
2.50
1.0
SECOND SIDE SIDE
100%
2.50
1.0
1
1
TOTAL=
297503042.xls
PARAMETERS SETTING
PROCESS
KG/SHIFT
12/06/2015
(min)
99.5
99.5
99.5
RUN TIME
(Hrs)
1.7
1.7
1.7

DOUBLE SIDE FILLET JOINT
WELDING BY SINGLE OPERATOR/
DOUBLE OPERATOR(S/D)?
PARAMETERS SETTING
PROCESS
KG/SHIFT
HRS/KG
1). SMAW
2).FCAW (1.2 )
3.2
6.0
2.50
1.33
POSITION OF
WELDING
1). 1F/2F
2) 3F
MULTIPLICATION
FACTOR
1
1.1
PREHEATING
REQUIRED?
MULTIPLICATION
FACTOR
YES
1.15
NO

SECOND SIDE
20CFW
20CFW
FIRST SIDE
WELD CALCULATION
FIRST SIDE WELDING
SECOND SIDE WELDING
TOTAL WELDING=
DENSITY= 0.00000785
O/D= 400
CROSS SEC. AREA

200.00
200.00
TOTAL WELD KG
1.94
2.01
400.00
3.95
SINGLE OPERATOR
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
FIRST SIDE
100%
2.50
1.0
SECOND SIDE SIDE
100%
2.50
1.0
1.1
1.1
TOTAL=
297503042.xls
12/06/2015
(min)
320.1
331.0
651.1
RUN TIME
(Hrs)
5.3
5.5
10.9

DOUBLE SIDE + FULL PENETATION JOINT
PARAMETERS SETTING
PROCESS
KG/SHIFT
PROCESS? (DOT/ WITH CHIP

BACK/TIG+SMAW) (D/C/T) ?
WELD LG (CALCULATED/AMNUAL) (C/M?) C
20
60
10
RG=
DEG
2
2
20
10000
DENSITY= 0.00000785
1000
360
6283.185
LENGTH OF WELDING(MM)=
6283.185
HRS/KG
1). SMAW
2). SAW (TWIN HEAD)
3).FCAW (1.2 )
4). GTAW+SMAW
3.2
14.4
6.0
1.3
2.50
0.56
1.33
6.25
FOR TIG
POSITION OF
WELDING
1). 1F/2F
2) 3F
MULTIPLICATION
FACTOR
1
1.1
PREHEATING
REQUIRED?
MULTIPLICATION
FACTOR
YES
1.15
NO
CHIP BACK DEPTH(MM)= 6
WELD CALCULATION
FIRST SIDE WELDING
SECOND SIDE WELDING
CROSS SEC. AREA

137.59
194.14
TOTAL WELD KG
6.79
9.58
331.73
16.36
TOTAL WELDING=
WITH CHIP BACK
(INCLUDING CHIP BACK)
PROCESS
POSITION
HEATING
CODE
CODE
(Y/N)
FIRST SIDE
100%
2.63
1.0
1.1
SCOND SIDE SIDE
100%
2.63
1.0
1.1
TOTAL=
297503042.xls
12/06/2015
(min)
1175.7
1658.9
2834.7
RUN TIME
(Hrs)
19.6
27.6
47.2

FORGING
GASKET FACE O/LAY
O/D OF GASKET FACE O/LAY=
BORE OF FLANGE AFTER O/L=
MEAN DIA OF GASKER GROOVE=
DEPTH OF GASKET GROOVE=
WIDTH OF GROOVE AT TOP=
THK OF O/LAY=
GASKET FACE O/LAY=
BORE O/LAY
229
165
200
10
23
8
BORE OF FLANGE AFTER O/LAY=

LENGTH OF FLANGE/FORG=
THK OF O/LAY=
2.423601 KG
BORE O/LAY=
165
1234
8
42.9231 KG
BACK FACE O/LAY

O/D OF LIP =
BORE OF FORG AFTER O/L=
THK OF O/LAY=
BACK FACE O/LAY=
TOTAL O/LAY=
487
381
6
3.46862 KG
48.81532 KG
KG
PROCESS
GASKET FACE OVER LAY
2.4
2.00
1.00
BORE OVER LAY
42.9
1.14
1.15
BACK FACE (PROFILE) OVER LAY
3.5
1.33
CODE
(Y/N)
1.00
TOTAL=
297503042.xls
RUN TIME
HEATING
(min)
291
3385
277
3953.1
12/06/2015
(Hrs)
4.8
56.4
4.6
65.9
PARAMETERS SETTING
PROCESS
KG/SHIFT
1). SMAW
2).FCAW (1.2 )(M/C)
3). FCAW (MANUAL)
HRS/KG
4
7
6
2.00
1.14
1.33
PREHEATING
REQUIRED?
YES
MULTIPLICATION
FACTOR
1.15
NO

FLANGE
GASKET FACE O/LAY
O/D OF GASKET FACE O/LAY=
BORE OF FLANGE AFTER O/L=
DIA OF GASKER GROOVE=
DEPTH OF GASKET GROOVE=
WIDTH OF GROOVE AT TOP=
THK OF O/LAY=
BORE O/LAY
483
381
450
0
0
7
BORE OF FLANGE AFTER O/LAY=

LENGTH OF FLANGE=
THK OF O/LAY=
GASKET FACE O/LAY=
3.876072 KG
TOTAL O/LAY=
13.68025 KG
KG
BORE O/LAY=
PROCESS
HEATING
CODE
(Y/N)
GASKET FACE OVER LAY
3.9
2.00
1.00
BORE OVER LAY
9.8
1.14
1.00
9.804182 KG
RUN TIME
TOTAL=
297503042.xls
381
168
6
(min)
465
672
1137.4
12/06/2015
(Hrs)
7.8
11.2
19.0
PARAMETERS SETTING
PROCESS
KG/SHIFT
1). SMAW
2).FCAW (1.2 )(M/C)
3). FCAW (MANUAL)
PREHEATING
REQUIRED?
YES
NO
4
7
6
HRS/KG
2.00
1.14
1.33
MULTIPLICATION
FACTOR
1.15
1

ELBOW
I/D O/LAY
BORE OF ELBOW AFTER O/LAY=
RADIUS OF ELBOW
INCLUDED ANGLE OF ELBOW=
THK OF O/LAY=
BORE O/LAY=
448
1176
90
8
1). SMAW
2). FCAW (MANUAL)
PREHEATING
REQUIRED?
YES
NO
169.3643 KG
BORE OVER LAY
297503042.xls
PARAMETERS SETTING
PROCESS
KG/SHIFT
KG
PROCESS
HEATING
(Y/N)
169.4
CODE
1.33
1.00
12/06/2015
4
6
2.00
1.33
MULTIPLICATION
FACTOR
1.15
1
RUN TIME
(min)
13549
HRS/KG
(Hrs.)
225.8

PIPE
I/D O/LAY
BORE OF PIPE AFTER O/LAY=
LENGTH OF PIPE=
THK OF O/LAY=
BORE O/LAY=
381
463
6
1). SMAW
2).FCAW (1.2 )(M/C)
3). FCAW (MANUAL)
27.01986 KG
KG
BORE OVER LAY
297503042.xls
PARAMETERS SETTING
PROCESS
KG/SHIFT HRS/KG
27.0
PREHEATING
REQUIRED?
YES
NO
PROCESS
HEATING
CODE
(Y/N)
1.14
1.15
12/06/2015
4
7
6
MULTIPLICATION
FACTOR
1.15
1
RUN TIME
(min)
2131
2.00
1.14
1.33
(Hrs.)
35.5

CIRC. SEAM/ LONG SEAM OVERLAY
I/D OF SHELL=
THK OF O/LAY=
CLAD STRIP ANG.=
THK OF CLAD=
CALCULATION
WIDTH OF O/LAY=
R.F. WIDTH=
AREA OF O/LAY=
3400
6
45
5
THK=
I/S INC. ANG.=
I/S 'V' HEIGHT=
CLAD STRIPPING=
ROOT GAP=
LG OF CEAM=
65
78
364.5095
C/SEAM O/LAY=
PARAMETERS SETTING
PROCESS
KG/SHIFT
70
35
47
15
3
10697.12
1). SMAW
2).FCAW (1.2 )(M/C)
3). FCAW (MANUAL)
PREHEATING
REQUIRED?
YES
NO
30.60874
THK=
C/SEAM OR L/SEAM (LS/CS)?
70
47
35
5
R.G.=
3
5
15
45
O/L THK=
6
35
I/D OF SHELL= 3400
KG
CIRC. SEAM OVER LAY
297503042.xls
30.6
PROCESS
HEATING
CODE
(Y/N)
2.00
1.15
12/06/2015
RUN TIME
(min)
4224
(Hrs.)
70.4
4
7
6
HRS/KG
2.00
1.14
1.33
MULTIPLICATION
FACTOR
1.15
1
CS
SHELL ESSC OVERLAY WELD KG & RUN TIME ESTIMATION
SHELL ESSC OVERLAY

I/D OF SHELL BEFORE O/LAY=
LENGTH OF SHELL=
THK OF O/LAY=
BORE O/LAY=
PARAMETERS SETTING
PROCESS
KG/SHIFT
4500
2250
8
1) ESSC (60 WD)

2) ESSC (90WD)
3) ESSC (120 WD)
2032.133 KG
KG
PROCESS
CODE
I/D OVER LAY(WITH 2 OPERATOR)
297503042.xls
2032.1
0.18
RUN TIME
(min)
44337
12/06/2015
(Hrs.)
739.0
44
66
84
HRS/KG
0.18
0.12
0.10

Welding Calculation

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Welding Calculation

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Welding Calculation

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What welding processes are discussed in the document?

What welding processes are discussed in the document?

What parameters are considered for estimating weld time?

What parameters are considered for estimating weld time?

OVERLAY WELD KG & RUN TIME ESTIMATION

TOME REQUIRED FOR RADIOGRAPHY TEST

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

RUN TIME TIME REQUIRED FOR

ALL DIMENSIONS ARE IN MM

CROSS SEC. AREA TOTAL WELD KG

CHIP BACK DEPTH(MM)

OUTSIDE ROOT RUN

OUT SIDE BALANCE

CHIP BACK WELDING

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION

RUN TIME TIME REQUIRED FOR

LG OF LONG SEAM= 1364

ALL DIMENSIONS ARE IN MM

CROSS SEC. AREA TOTAL WELD KG

CHIP BACK DEPTH(MM)

OUTSIDE ROOT RUN

OUT SIDE BALANCE

CHIP BACK WELDING

LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

RUN TIME TIME REQUIRED FOR

ALL DIMENSIONS ARE IN MM

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

RUN TIME TIME REQUIRED FOR

I/D OF SHELL 379

ALL DIMENSIONS ARE IN MM

CROSS SEC. AREA TOTAL WELD KG

CHIP BACK DEPTH(MM)

OUTSIDE ROOT RUN

OUT SIDE BALANCE

CHIP BACK WELDING

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

RUN TIME TIME REQUIRED FOR

CROSS SEC. AREA TOTAL WELD KG

CHIP BACK DEPTH(MM)

OUTSIDE ROOT RUN

OUT SIDE BALANCE

CHIP BACK WELDING

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

NOZZLE WELD KG & RUN TIME ESTIMATION

NOZZLE ON SHELL/DEND) (D/S) ?

MATERIAL (SS/STEEL)= STEEL

CHIP BACK DEPTH(MM)

NOZZLE WELD KG & RUN TIME ESTIMATION

NOZZLE WELD KG & RUN TIME ESTIMATION

NOZZLE ON SHELL/DEND) (D/S) ?

MATERIAL (SS/STEEL)= STEEL

BACKING STRIPP DIMENSION

ELLIPSE DIMENSIO o/d

CHIP BACK DEPTH(MM)