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7/21/2019 Weld Kgs Formulae http://slidepdf.com/reader/full/weld-kgs-formulae 1/32 OVERLAY WELD KG & RUN TIME ESTIMATION 300506216.xls 01/13/2016 TOME REQUIRED FOR RADIOGRAPHY TEST C/SEAM OR L/SEAM OR T-FRAME (LS/CS/TF)? LS LG OF SHELL/NOZZLE= 3000 TIME REQUIRED FOR RT !"# MIN LOWER THK INCLUDING RAINFORCEENT $0 %## HRS I 0"0 DAYS S LG OF SHELL/NOZZLE= 3000 THK= 50 S!OT LENGTH= 300 NO. OF S!OT= 10 TIME CALCUCATION IRIDIUM CO'ALT S!OT "6.# 23." S!OT FOR FILLET IN T$FRAES 6%1.2 113.0 !EOROIC 25%2.0 #5".2 RADIOGRA!H& '& IRIDIU/CO'ALT(I/C)? S!OT RT OR !ENOROIC RT (S/P)?

Weld Kgs Formulae

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Weld Kgs Formulae

Text of Weld Kgs Formulae

  • OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    TOME REQUIRED FOR RADIOGRAPHY TEST

    C/SEAM OR L/SEAM OR T-FRAME (LS/CS/TF)? LSLG OF SHELL/NOZZLE= 3000 TIME REQUIRED FOR RT= 864 MIN

    LOWER THK INCLUDING RAINFORCEMENT 50 14.4 HRSI 0.60 DAYSS

    LG OF SHELL/NOZZLE= 3000 THK= 50SPOT LENGTH= 300NO. OF SPOT= 10

    TIME CALCUCATIONIRIDIUM COBALT

    SPOT 86.4 23.8SPOT FOR FILLET IN T-FRAMES 691.2 113.0PEMOROMIC 2592.0 458.2

    RADIOGRAPHY BY IRIDIUM/COBALT(I/C)?SPOT RT OR PENOROMIC RT (S/P)?

  • FILLET WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    PARAMETERS SETTINGM PROCESS KG/SHIFT HRS/KG

    1). SMAW 3.2 2.50MANUAL LENGTH OF WELDING(MM)= 24000 2). SAW 14.4 0.56

    6.0 1.33MATERIAL (SS/STEEL)= STEEL

    15DENSITY= 0.00000785

    FOR CALCULATING WELD LENGTHRADIUS OF WELDING(MM)= 4500

    INCLUDED ANGLE OF WELDING(DEG)= 36015 CALCULATED LENGTH OF WELDING(MM)= 28274.334 1). 1F/2F 1

    2) 3F 1.1LENGTH OF WELDING(MM)= 24000.000

    WELD CALCULATION CROSS SEC. AREA TOTAL WELD KGTOTAL WELDING 112.50 21.20 YES 1.15

    NO 1

    FILLET WELDPROCESS POSITION HEATING RUN TIME

    CODE CODE (Y/N) (min) (Hrs)1 2.50 1 1.0 N 1.1 3497.2 58.3

    3497.2 58.3

    WELD LG (CALCULATED/MANUAL) (C/M?)

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    SINGLE 'V' CS PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG1). SMAW 4 2.00

    15 THK= 17

    2). SAW (C/S) 30 0.27 70 (L/S) 18 0.44

    6 1.334). GTAW 1.6 5.00

    R.F.= 2 I/D OF SHELL= 1200 5). TWIN HD. (C/S 24 0.33 MATERIAL (SS/STEEL)= SS 14.4 0.56

    R.G.= 3 ** WITH 2 OPERATORSDENSITY= 0.000008

    1). 1G 12). 2G 1.63). 3G 1.3

    ALL DIMENSIONS ARE IN MM

    CROSS SEC. AREA TOTAL WELD KGYES 1.15

    O/S WELDING= 280.6 8.6 NO 1C/B WELDING= 92.5 2.8TOTAL WELDING= 373.1 11.4 CHIP BACK DEPTH(MM)

    THK 30 12

    CIRC SEAM PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2 1 1.0 N 1 206.0 3.4OUT SIDE BALANCE 80% 1 2 1 1.0 N 1 823.8 13.7

    CHIP BACK WELDING 100% 1 2 1 1.0 N 1 339.7 5.7TOTAL = 1369.5 22.8

    RUN TIME TIME REQUIRED FOR L/SEAM OR C/SEAM (LS/CS)=

    3).FCAW (1.2 )

    SAW ** (L/S)

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    4828.8

    0.661.11

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    .

    0.661.11

  • LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    DOUBLE 'V' LS PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG 65 1). SMAW 4 2.00

    30.0

    THK= 45

    2). SAW (C/S) 30 0.27 (L/S) 18 0.44

    6 1.334). GTAW 1.6 5.00

    R.F.= 2 LG OF LONG SEAM= 967 5). TWIN HD. (C/S 24 0.33

    13.0MATERIAL (SS/STEEL)= STEEL 14.4 0.56

    ** WITH 2 OPERATORS 60 DENSITY= 0.00000785

    R.G.= 3 1). 1G 1ALL DIMENSIONS ARE IN MM 2). 2G 1.6

    3). 3G 1.3

    CROSS SEC. AREA TOTAL WELD KG

    YES 1.15O/S WELDING= 793.0 6.0 NO 1C/B WELDING= 416.8 3.2TOTAL WELDING= 1209.8 9.2 CHIP BACK DEPTH(MM)

    THK 30 12

    LONG SEAM PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 5 0.556 1 1.0 Y 1 40.1 0.7OUT SIDE BALANCE 80% 4 5 1 1.0 Y 1.15 1661.5 27.7

    CHIP BACK WELDING 100% 4 ERROR 1 1.0 Y 1.15 #VALUE! #VALUE!TOTAL = #VALUE! #VALUE!

    RUN TIME TIME REQUIRED FOR L/SEAM OR C/SEAM (LS/CS)=

    3).FCAW (1.2 )

    SAW ** (L/S)

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    4828.8

    0.661.11

  • LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    0.661.11

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    BACKING STRIP cs PARAMETERS SETTINGPROCESS KG/SHIFT 12 1). SMAW 4

    THK= 12

    2). SAW (C/S) 30 (L/S) 18

    65). TWIN HD. (C/S) 24

    I/D OF SHELL 2800 14.4R.G.= STEEL ** WITH 2 OPERATORS

    18DENSITY= 0.00000785

    1). 1G 12). 2G 1.63). 3G 1.3

    ALL DIMENSIONS ARE IN MM

    CROSS SEC. AREA TOTAL WELD KGYES 1.15

    O/S WELDING= 292.7 20.3 NO 1

    TOTAL WELDING= 292.7 20.3

    CIRC SEAM PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUT SIDE BALANCE 100% 2 0.267 1 1.0 Y 1 324.8 5.4

    TOTAL = 324.8 5.4

    RUN TIME TIME REQUIRED FOR L/SEAM OR C/SEAM (LS/CS)=

    3).FCAW (1.2 )

    SAW ** (L/S)MATERIAL (SS/STEEL)=

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    4828.8

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    PARAMETERS SETTINGHRS/KG

    2.000.270.441.33

    0.330.56

    1.3

    1.151

    MULTIPLICATION FACTOR

    MULTIPLICATION FACTOR

    4828.8

    0.661.11

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    J GROOVE CS PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG 1

    74.1

    THK= 86

    1). SMAW 4 2.002). SAW (C/S) 30 0.27 (L/S) 18 0.44

    3). FCAW 6 1.334). GTAW 1.6 5.00

    I/D OF SHELL 4500 5). TWIN HD. (C/S) 24 0.33R= 12

    11.9MATERIAL (SS/STEEL)= STEEL 14.4 0.56

    ** WITH 2 OPERATORSR.F.= 0 DENSITY= 0.00000785

    R.G.= 2 1). 1G 1ALL DIMENSIONS ARE IN MM 2). 2G 1.6

    3). 3G 1.3

    CROSS SEC. AREA TOTAL WELD KGYES 1.15

    O/S WELDING= 2303.9 260.6 NO 1C/B WELDING= 298.2 33.7TOTAL WELDING= 2602.1 294.3 CHIP BACK DEPTH(MM)

    THK 30 12

    CIRC SEAM PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2 1 1.0 Y 1.15 7191.7 119.9OUT SIDE BALANCE 80% 2 0.267 1 1.0 Y 1 3335.3 55.6

    CHIP BACK WELDING 100% 2 0.267 1 1.0 Y 1 539.6 9.0TOTAL = 11066.6 184.4

    RUN TIME TIME REQUIRED FOR L/SEAM OR C/SEAM (LS/CS)=

    SAW ** (L/S)

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    4828.8

    0.661.11

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    HRS/KG

    0.66

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    COMPOUND 'V' CS PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG 10

    36

    THK= 50

    1). SMAW 4 2.002). SAW (C/S) 30 0.27 (L/S) 18 0.44

    6 1.33 45 4). GTAW 1.6 5.00

    12I/D OF SHELL= 2600 5). TWIN HD. (C/S) 24 0.33

    MATERIAL (SS/STEEL)= STEEL 14.4 0.56** WITH 2 OPERATORS

    R.F.= 2 DENSITY= 0.00000785

    R.G.= 3 1). 1G 1ALL DIMENSIONS ARE IN MM 2). 2G 1.6

    3). 3G 1.3

    CROSS SEC. AREA TOTAL WELD KGYES 1.15

    O/S WELDING= 738.6 48.3 NO 1C/B WELDING= 298.2 19.5TOTAL WELDING= 1036.8 67.8 CHIP BACK DEPTH(MM)

    THK 30 12

    CIRC SEAM PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2 1 1.0 Y 1.15 1332.3 22.2OUT SIDE BALANCE 80% 2 0.267 1 1.0 Y 1 617.9 10.3

    CHIP BACK WELDING 100% 2 0.267 1 1.0 Y 1 311.8 5.2TOTAL = 2262.0 37.7

    RUN TIME TIME REQUIRED FOR L/SEAM OR C/SEAM (LS/CS)=

    3).FCAW (1.2 )

    SAW ** (L/S)

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    4828.8

    0.661.11

  • LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    HRS/KG

    0.66

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    SINGLE 'V' NOZZLE ON SHELL/DEND) (D/S) ? S PARAMETERS SETTINGPROCESS KG/SHIFT

    CFW= 10 MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2INC. ANG=45 2). SAW 14.4

    DENSITY= 7.85E-006 6.04). GTAW 1.3

    NOZZLE O/D= OFF SET=

    THK= 32

    708 0

    R.F.= 2 1). 1G 1

    SHEL

    L I/D

    =17

    78

    2). 2G 1.6R.G= 3). 3G 1.3

    4 NOZ O/D708

    YES 1.15ELLIPSE DIMENSION WELD KG NO 1MAJOR AXIS= 732.5 ON SHELLON D/ENDMINOR AXIS= 712 O/S WELDING= 500.00 8.91 8.78 CHIP BACK DEPTH(MM)LG. OF WELDING= 2269.22 C/B WELDING= 226.19 4.03 3.97 THK 30

    ON SHELLPROCESS POSITION HEATING

    CODE CODE (Y/N) RUN TIMEOUTSIDE ROOT RUN 20% 1 2.5 1 1.0 Y 1.15 (min) (Hrs)OUT SIDE BALANCE 80% 1 2.5 1 1.0 Y 1.15 307.3 5.1

    CHIP BACK WELDING 100% 1 2.5 1 1.0 Y 1.15 1229.1 20.5695.1 11.6

    TOTAL = 2231.5 37.2

    3). FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    WEIGHT CALCULATION

    CROSS SEC. AREA

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    PARAMETERS SETTINGHRS/KG

    2.500.561.336.25

    11.61.3

    1.151

    CHIP BACK DEPTH(MM)6

    12

    MULTIPLICATION FACTOR

    MULTIPLICATION FACTOR

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    BACKING STRIP NOZZLE ON SHELL/DEND) (D/S) ? d PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG

    MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.50CFW= 9 2). SAW 14.4 0.56

    INC. ANG= 15 DENSITY= 0.00000785 6.0 1.33

    NOZZLE O/D= OFF SET=

    THK= 50

    300 1100

    1). 1G 1

    SHEL

    L I/D

    =68

    00

    2). 2G 1.6R.G= 3). 3G 1.3

    10 NOZ O/D300

    YES 1.15ELLIPSE DIMENSIO o/d I/d NO 1MAJOR AXIS= 353.4 303.4 WELD KGMINOR AXIS= 353.4 303.377 ON SHELL ON D/END CHIP BACK DEPTH(MM)LG. OF WELDING= 1110.17 O/S WELDING= 875.44 7.63 7.63 THK 30 12TOTAL WELDING= 7.63 7.63

    ON D/END PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUT SIDE BALANCE 100% 1 2.5 1 1.0 Y 1.15 1316.0 21.9

    TOTAL = 1316.0 21.9

    BACKING STRIPP DIMENSIONOUTER MAJOR AXIS 358.4 O/D= 358.4OUTER MINOR AXIS 340.0 I/D= 275.4WIDTH= 32.3

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    WEIGHT CALCULATION

    CROSS SEC. AREA

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    DOUBLE 'V' NOZZLE ON SHELL/DEND) (D/S) ? s PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG

    CFW= 9 MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.50INC. ANG= 45 2). SAW 14.4 0.56

    DENSITY= 0.00000785 6.0 1.334). GTAW 1.3 6.25

    NOZZLE O/D= OFF SET=

    THK= 74

    60 653 500

    R.F.= 2

    121). 1G 12). 2G 1.6

    SHEL

    L I/D

    =24

    50

    3). 3G 1.3R.G= NOZ O/D

    3 653

    INC. ANG= 35 YES 1.15ELLIPSE DIMENSION NO 1

    CROSS SEC. AREAWELD KG

    MAJOR AXIS= 736.6 ON SHELL ON D/END CHIP BACK DEPTH(MM)MINOR AXIS= 656 O/S WELDING= 2026.50 34.86 32.78 THK 30 12

    TOTAL WELDING= 40.24 37.84

    ON SHELL PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 2 0.56 1 1.0 Y 1 232.4 3.9OUT SIDE BALANCE 80% 1 2.5 2 1.6 Y 1 6692.7 111.5

    CHIP BACK WELDING 100% 1 2.5 2 1.6 Y 1 1290.5 21.5TOTAL = 8215.6 136.9

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    WEIGHT CALCULATION

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    'J' GROOVE NOZZLE ON SHELL/DEND) (D/S) ? s PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG

    MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.502). SAW 14.4 0.56

    R.G= NOZZLE LIP O/D= DENSITY= 0.00000785 6.0 1.333 369 4). GTAW 1.3 6.25

    THK= 170

    R.F.= 5 OFF SET=0

    R= 12

    1). 1G 1

    SHEL

    L I/D

    =45

    14

    2). 2G 1.63). 3G 1.3

    INC. ANG.= 5 NOZ O/D369

    INC. ANG.= 10YES 1.15

    ELLIPSE DIMENSION NO 1CROSS SEC. AREA WELD KG

    MAJOR AXIS= 372.4 ON SHELL ON D/END CHIP BACK DEPTH(MM)MINOR AXIS= 372 I/S WELDING= 4720.64 43.33 43.31 THK 30 12

    TOTAL WELDING= 46.27 46.25

    ON SHELL PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2.5 1 1.0 Y 1.15 1495.0 24.9OUT SIDE BALANCE 80% 1 2.5 1 1.0 Y 1.15 5979.8 99.7

    CHIP BACK WELDING 100% 1 2.5 1 1.0 Y 1.15 507.4 8.5TOTAL = 7982.2 133.0

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    WEIGHT CALCULATION

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    R.F. PAD +SINGLE 'V' NOZZLE ON SHELL/DEND) (D/S) ? S PARAMETERS SETTINGCFW= 9 PROCESS KG/SHIFT HRS/KG

    INC. ANG= 35 5 MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.50DENSITY= 0.00000785 2). SAW 14.4 0.56

    INC. ANG= 5 6.0 1.33OFF SET= 4). GTAW 1.3 6.25

    0THK= 16

    R.F.PAD 5MULTIPLICATION FACTOR

    THK= 20

    NOZZLE O/D= 1). 1G 1602 2). 2G 1.6

    NOZ O/D 3). 3G 1.3602

    R.F.= 2 FILLET SIZE=30MULTIPLICATION FACTOR

    SHEL

    L I/D

    =43

    00

    R.G= YES 1.153 NO 1

    CROSS SEC. AREAWELD KG

    ON SHELL ON D/END CHIP BACK DEPTH(MM)ELLIPSE DIMENSION O/S WELDING= 554.79 8.29 8.28 THK 30 12MINOR AXIS= 605 R.F.PAD WELDING= 450.00 22.42 22.42LG. OF WELDING= 1903.83 TOTAL WELDING= 31.55 31.54

    ON SHELL PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2.5 1 1.0 N 1 248.7 4.1OUT SIDE BALANCE 80% 1 2.5 1 1.0 N 1 995.0 16.6

    CHIP BACK WELDING 100% 1 2.5 1 1.0 N 1 126.8 2.1R.F.PAD WELDING 100% 1 2.5 1 1.0 N 1 3362.6 56.0

    TOTAL = 1370.5 22.8

    3).FCAW (1.2 )

    POSITION OF WELDING

    PREHEATING REQUIRED?

    WEIGHT CALCULATION

    PADO/D

    =2000

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    R.F. PAD +SINGLE 'V' NOZZLE ON SHELL/DEND) (D/S) ? D PARAMETERS SETTINGCFW= 9 PROCESS KG/SHIFT HRS/KG

    INC. ANG= 45 MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.5010 2). SAW 14.4 0.56

    INC. ANG= 5 DENSITY= 0.00000785 6.0 1.33OFF SET=

    330THK= 90

    R.F.PAD 10MULTIPLICATION FACTOR

    THK= 90

    NOZZLE O/D= 1). 1G 1345 2). 2G 1.6

    NOZ O/D 3). 3G 1.3345

    R.F.= 2 FILLET SIZE=40MULTIPLICATION FACTOR

    SHEL

    L I/D

    =24

    50

    R.G= YES 1.153 NO 1

    CROSS SEC. AREAWELD KG

    ON SHELL ON D/END CHIP BACK DEPTH(MM)ELLIPSE DIMENSION o/d I/d O/S WELDING= 13984.83 131.46 131.46 THK 30 12MINOR AXIS= 381.2 331.1593 TOTAL WELDING= 151.71 151.71LG. OF WELDING= 1197.447

    ON D/END PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUT SIDE BALANCE 100% 2 0.56 1 1.0 Y 1 4381.9 73.0

    R.F.PAD WELDING 100% 1 2.50 3 1.3 Y 1.15 4542.3 75.7TOTAL = 8924.1 148.7

    BACKING STRIPP DIMENSIONOUTER MAJOR AXIS= 386.2OUTER MINOR AXIS= 371.0

    WIDTH= 25.2

    3).FCAW (1.2 )

    POSITION OF WELDING

    PREHEATING REQUIRED?

    WEIGHT CALCULATION

    PADO/D

    =1000

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    R.F. PAD +SINGLE 'V' NOZZLE ON SHELL/DEND) (D/S) ? S PARAMETERS SETTINGCFW= 9 PROCESS KG/SHIFT HRS/KG

    MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.50INC. ANG= 35 5 2). SAW 14.4 0.56

    DENSITY= 0.00000785 6.0 1.33OFF SET= 4). GTAW 1.3 6.25

    THK= 16 545R.F.PAD 5

    R.F.= 2 NOZZLE O/D=

    THK= 17

    407 1). 1G 12). 2G 1.6

    NOZ O/D 3). 3G 1.3407

    SHEL

    L I/D

    =

    4300

    FILLET SIZE=30

    R.G=3 YES 1.15

    INC. ANG= NO 135

    CROSS SEC. AREAWELD KG

    ELLIPSE DIMENSION ON SHELL ON D/END CHIP BACK DEPTH(MM)MAJOR AXIS= 424.7 O/S WELDING= 129.77 0.42 1.36 THK 30 12LG. OF WELDING= 1311.309 R.F. PAD WELDING 450.00 22.42 22.42

    TOTAL WELDING= 23.85 27.07

    ON SHELL PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2.5 1 1.0 N 1 12.5 0.2OUT SIDE BALANCE 80% 1 2.5 1 1.0 N 1 50.1 0.8

    CHIP BACK WELDING 100% 1 2.5 1 1.0 N 1 151.9 2.5R.F.PAD WELDING 100% 1 2.5 1 1.0 N 1 3362.6 56.0

    TOTAL = 3577.2 59.6

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    WEIGHT CALCULATION

    PADO/D

    =2000

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    PADO/D

    =2000

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    R.F.PAD + DOUBLE 'V' NOZZLE ON SHELL/DEND) (D/S) ? D PARAMETERS SETTINGCFW= 9 PROCESS KG/SHIFT HRS/KG

    INC. ANG= 60 MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.50INC. ANG= 10 10 2). SAW 14.4 0.56

    DENSITY= 0.00000785 6.0 1.334). GTAW 1.3 6.25

    THK= 30 OFF SET=R.F.PAD 10 330

    NOZZLE O/D=

    THK= 30

    20 345 1). 1G 12). 2G 1.6

    R.F.= 2 3). 3G 1.38 NOZ O/D

    345

    SHEL

    L I/D

    =24

    50

    R.G= FILLET SIZE=30 YES 1.153 NO 1

    INC. ANG=CROSS SEC. AREA

    WELD KG45 ON SHELL ON D/END CHIP BACK DEPTH(MM)

    ELLIPSE DIMENSION O/S WELDING= 1961.49 17.20 16.83 THK 30 12MINOR AXIS= 348 R.F. PAD WELDING 450.00 22.42 22.42LG. OF WELDING= 1117.086 TOTAL WELDING= 18.68 18.29

    ON D/END PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 2 0.56 1 1.0 Y 1 112.2 1.9OUT SIDE BALANCE 80% 1 2.5 2 1.6 Y 1.15 3716.9 61.9

    CHIP BACK WELDING 100% 1 2.5 2 1.6 Y 1.15 400.5 6.7R.F.PAD WELDING 100% 1 2.5 1 1.0 Y 1.15 3867.0 64.4

    TOTAL = 8096.7 134.9

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

    WEIGHT CALCULATION

    PADO/D

    =2000

  • NOZZLE WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    SET ON NOZZLE IN SHELL/DEND) (D/S) ? S PARAMETERS SETTINGPROCESS KG/SHIFT HRS/KG

    60 19.5 NOZ I/D MATERIAL (SS/STEEL)= STEEL 1). SMAW 3.2 2.502). SAW 14.4 0.56

    19.5 DENSITY= 0.00000785 6.0 1.33` 4). GTAW 1.3 6.25

    INC. ANG.= 10 OFFSET=R.F.= 1 0

    CFW= 9INC. ANG.= 60

    R.G.= 3 1). 1G 1

    THK= 602). 2G 1.6

    NOZ I/D 3). 3G 1.3

    1776

    21NOZ O/D

    60

    YES 1.15ELLIPSE DIMENSION

    WEIGHT CALCULATIONCROSS SEC. AREA WELD KG NO 1

    ON SHELL ON D/ENDMAJOR AXIS= 40.5 O/S WELDING= 395.40 0.39 0.39MINOR AXIS= 40.5

    LG. OF WELDING= 127.2 TOTAL WELDING= 0.39 0.39

    ON SHELL PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)OUTSIDE ROOT RUN 20% 1 2.5 2 1.6 n 1 19.0 0.3OUT SIDE BALANCE 80% 1 2.5 1 1.0 y 1.15 54.5 0.9

    TOTAL = 73.5 1.2

    3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    SHEL

    L I/D

    =

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • FILLET WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    DOUBLE SIDE FILLET JOINTPARAMETERS SETTING

    S PROCESS KG/SHIFT HRS/KG1). SMAW 3.2 2.50m 2). SAW 14.4 0.56

    6.0 1.33MANUAL LENGTH OF WELDING(MM)= 10000

    6MATERIAL (SS/STEEL)= STEEL

    DENSITY= 0.00000785FOR CALCULATING WELD LENGTH

    6 RADIUS OF WELDING(MM)= 2500 1). 1F/2F 1INCLUDED ANGLE OF WELDING(DEG)= 120 2) 3F 1.1

    CALCULATED LENGTH OF WELDING(MM)= 5235.988LG OF WELDING= 10000.000

    WELD CALCULATION CROSS SEC. AREA TOTAL WELD KGFIRST SIDE WELDING 18.00 1.41SECOND SIDE WELDING 18.00 1.41 YES 1.15TOTAL WELDING= 36.00 2.83 NO 1

    SINGLE OPERATORPROCESS POSITION HEATING RUN TIME

    CODE CODE (Y/N) (min) (Hrs)FIRST SIDE 100% 1 2.50 1 1.0 N 1.1 233.1 3.9

    SECOND SIDE SIDE 100% 1 2.50 1 1.0 N 1.1 233.1 3.9TOTAL= 466.3 7.8

    WELDING BY SINGLE OPERATOR/ DOUBLE OPERATOR(S/D)?

    WELD LG (CALCULATED/AMNUAL) (C/M?)3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • FILLET WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    DOUBLE SIDE FILLET JOINTPARAMETERS SETTING

    S PROCESS KG/SHIFT HRS/KG1). SMAW 3.2 2.506.0 1.33

    MATERIAL (SS/STEEL)= STEELSECOND SIDE

    20CFW DENSITY= 0.00000785

    20CFW 1). 1F/2F 1FIRST SIDE O/D= 400 2) 3F 1.1

    WELD CALCULATION CROSS SEC. AREA TOTAL WELD KGFIRST SIDE WELDING 200.00 1.94SECOND SIDE WELDING 200.00 2.01 YES 1.15TOTAL WELDING= 400.00 3.95 NO 1

    SINGLE OPERATORPROCESS POSITION HEATING RUN TIME

    CODE CODE (Y/N) (min) (Hrs)FIRST SIDE 100% 1 2.50 1 1.0 N 1.1 320.1 5.3

    SECOND SIDE SIDE 100% 1 2.50 1 1.0 N 1.1 331.0 5.5TOTAL= 651.1 10.9

    WELDING BY SINGLE OPERATOR/ DOUBLE OPERATOR(S/D)?

    2).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • FILLET WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    DOUBLE SIDE + FULL PENETATION JOINTPARAMETERS SETTING

    C PROCESS KG/SHIFT HRS/KG1). SMAW 3.2 2.5020 C 2). SAW (TWIN HEAD) 14.4 0.56

    MANUAL LENGTH OF WELDING(MM)= 10000 6.0 1.33MATERIAL (SS/STEEL)= STEEL 4). GTAW+SMAW 1.3 6.25

    FOR TIG

    1060 DEG DENSITY= 0.00000785

    FOR CALCULATING WELD LENGTHRG= 2 RADIUS OF WELDING(MM)= 1000

    2 INCLUDED ANGLE OF WELDING(DEG)= 36020 CALCULATED LENGTH OF WELDING(MM)= 6283.185 1). 1F/2F 1

    LENGTH OF WELDING(MM)= 6283.185 2) 3F 1.1CHIP BACK DEPTH(MM)= 6

    WELD CALCULATION CROSS SEC. AREA TOTAL WELD KGFIRST SIDE WELDING 137.59 6.79SECOND SIDE WELDING 194.14 9.58 (INCLUDING CHIP BACK) YES 1.15TOTAL WELDING= 331.73 16.36 NO 1

    WITH CHIP BACK PROCESS POSITION HEATING RUN TIMECODE CODE (Y/N) (min) (Hrs)FIRST SIDE 100% 4 2.63 1 1.0 N 1.1 1175.7 19.6

    SCOND SIDE SIDE 100% 4 2.63 1 1.0 N 1.1 1658.9 27.6TOTAL= 2834.7 47.2

    PROCESS? (DOT/ WITH CHIP BACK/TIG+SMAW) (D/C/T) ?

    WELD LG (CALCULATED/AMNUAL) (C/M?)3).FCAW (1.2 )

    POSITION OF WELDING

    MULTIPLICATION FACTOR

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    FORGING

    GASKET FACE O/LAY BORE O/LAY PARAMETERS SETTINGO/D OF GASKET FACE O/LAY= 229 BORE OF FLANGE AFTER O/LAY= 165 PROCESS KG/SHIFT HRS/KGBORE OF FLANGE AFTER O/L= 165 LENGTH OF FLANGE/FORG= 1234 1). SMAW 4 2.00MEAN DIA OF GASKER GROOVE= 200 THK OF O/LAY= 8 7 1.14DEPTH OF GASKET GROOVE= 10 3). FCAW (MANUAL) 6 1.33WIDTH OF GROOVE AT TOP= 23THK OF O/LAY= 8

    GASKET FACE O/LAY= 2.423601 KG BORE O/LAY= 42.9231 KGYES 1.15

    BACK FACE O/LAY NO 1O/D OF LIP = 487BORE OF FORG AFTER O/L= 381THK OF O/LAY= 6

    BACK FACE O/LAY= 3.46862 KG

    TOTAL O/LAY= 48.81532 KG

    KG PROCESS HEATING RUN TIME

    CODE (Y/N) (min) (Hrs)GASKET FACE OVER LAY 2.4 1 2.00 N 1.00 291 4.8

    BORE OVER LAY 42.9 2 1.14 Y 1.15 3385 56.4BACK FACE (PROFILE) OVER LAY 3.5 3 1.33 N 1.00 277 4.6

    TOTAL= 3953.1 65.9

    2).FCAW (1.2 )(M/C)

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    FLANGE

    GASKET FACE O/LAY BORE O/LAY PARAMETERS SETTINGO/D OF GASKET FACE O/LAY= 483 BORE OF FLANGE AFTER O/LAY= 381 PROCESS KG/SHIFT HRS/KGBORE OF FLANGE AFTER O/L= 381 LENGTH OF FLANGE= 168 1). SMAW 4 2.00DIA OF GASKER GROOVE= 450 THK OF O/LAY= 6 7 1.14DEPTH OF GASKET GROOVE= 0 3). FCAW (MANUAL) 6 1.33WIDTH OF GROOVE AT TOP= 0THK OF O/LAY= 7

    GASKET FACE O/LAY= 3.876072 KG BORE O/LAY= 9.804182 KGYES 1.15

    TOTAL O/LAY= 13.68025 KG NO 1

    KG PROCESS HEATING RUN TIME

    CODE (Y/N) (min) (Hrs)GASKET FACE OVER LAY 3.9 1 2.00 N 1.00 465 7.8

    BORE OVER LAY 9.8 2 1.14 N 1.00 672 11.2TOTAL= 1137.4 19.0

    2).FCAW (1.2 )(M/C)

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    ELBOW

    I/D O/LAY PARAMETERS SETTINGBORE OF ELBOW AFTER O/LAY= 448 PROCESS KG/SHIFT HRS/KGRADIUS OF ELBOW 1176 1). SMAW 4 2.00INCLUDED ANGLE OF ELBOW= 90 2). FCAW (MANUAL) 6 1.33THK OF O/LAY= 8

    BORE O/LAY= 169.3643 KGYES 1.15NO 1

    KG PROCESS HEATING RUN TIME

    CODE (Y/N) (min) (Hrs.)BORE OVER LAY 169.4 2 1.33 N 1.00 13549 225.8

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    PIPE

    I/D O/LAY PARAMETERS SETTINGBORE OF PIPE AFTER O/LAY= 470 PROCESS KG/SHIFT HRS/KGLENGTH OF PIPE= 500 1). SMAW 4 2.00THK OF O/LAY= 6 7 1.14

    3). FCAW (MANUAL) 6 1.33

    BORE O/LAY= 35.88955 KG

    YES 1.15NO 1

    KG PROCESS HEATING RUN TIME

    CODE (Y/N) (min) (Hrs.)BORE OVER LAY 35.9 2 1.14 Y 1.15 2830 47.2

    2).FCAW (1.2 )(M/C)

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    CIRC. SEAM/ LONG SEAM OVERLAYPARAMETERS SETTING

    I/D OF SHELL= 4300 THK= 17 PROCESS KG/SHIFT HRS/KGTHK OF O/LAY= 6 I/S INC. ANG.= 0 1). SMAW 4 2.00CLAD STRIP ANG.= 45 I/S 'V' HEIGHT= 0 7 1.14THK OF CLAD= 3 CLAD STRIPPING= 9 3). FCAW (MANUAL) 6 1.33CALCULATION ROOT GAP= 3WIDTH OF O/LAY= 23 LG OF CEAM= 13518.27R.F. WIDTH= 34AREA OF O/LAY= 118.5 C/SEAM O/LAY= 12.57504

    YES 1.15

    THK=17

    NO 1

    C/SEAM OR L/SEAM (LS/CS)? CS0 0

    3R.G.=

    3 95 O/L THK= 45

    60

    I/D OF SHELL= 4300

    KG PROCESS HEATING RUN TIME

    CODE (Y/N) (min) (Hrs.)CIRC. SEAM OVER LAY 12.6 3 1.33 N 1.00 1006 16.8

    2).FCAW (1.2 )(M/C)

    PREHEATING REQUIRED?

    MULTIPLICATION FACTOR

  • SHELL ESSC OVERLAY WELD KG & RUN TIME ESTIMATION

    300506216.xls 01/13/2016

    SHELL ESSC OVERLAY PARAMETERS SETTINGI/D OF SHELL BEFORE O/LAY= 4500 PROCESS KG/SHIFT HRS/KGLENGTH OF SHELL= 2250 1) ESSC (60 WD) 44 0.18THK OF O/LAY= 8 2) ESSC (90WD) 66 0.12

    3) ESSC (120 WD) 84 0.10

    BORE O/LAY= 2032.133 KG

    KG PROCESS RUN TIME

    CODE (min) (Hrs.)I/D OVER LAY(WITH 2 OPERATOR) 2032.1 1 0.18 44337 739.0

    RTFILLETSINGLELSSINGLEVLSDOUBLEVLSBACKINGSTRIPLSJGROOVELSCOMPOUNDNOZSINGLEVNOZBACKINGSTRIPNOZDOUBLEVNOZJGROOVENOZRFSINGLEVNOZRFSVBACKINGSTRIPNOZRFINSIDEVNOZRFDOUBLEVNOZSETONFILLETDOUBLEINTFLGFILLETFILLETDOUBLEVFPFORGOVERLAYFLGOVERLAYELBOWOVERLAYPIPEOVERLAYSEAMOVARLAYESSC