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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

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

0.66
1.11

297503042.xls

12/06/2015

LONG SEAM/ CIRC SEAM WELD KG & RUN TIME ESTIMATION


DOUBLE 'V'

RUN TIME TIME REQUIRED FOR


L/SEAM OR C/SEAM (LS/CS)=

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

ALL DIMENSIONS ARE IN MM

PREHEATING
REQUIRED?
YES
NO

CROSS SEC. AREA TOTAL WELD KG


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

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION


BACKING STRIP
10

PARAMETERS SETTING
PROCESS
KG/SHIFT

cs

RUN TIME TIME REQUIRED FOR


L/SEAM OR C/SEAM (LS/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

ALL DIMENSIONS ARE IN MM


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

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

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

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION


J GROOVE

RUN TIME TIME REQUIRED FOR


L/SEAM OR C/SEAM (LS/CS)=

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


MATERIAL (SS/STEEL)= STEEL
DENSITY= 0.00000785

10

ALL DIMENSIONS ARE IN MM

PREHEATING
REQUIRED?
YES
NO

CROSS SEC. AREA TOTAL WELD KG


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

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION


HRS/KG

0.66

297503042.xls

12/06/2015

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION


COMPOUND 'V'

RUN TIME TIME REQUIRED FOR


L/SEAM OR C/SEAM (LS/CS)=
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
MATERIAL (SS/STEEL)= STEEL
0.56
1.11
** WITH 2 OPERATORS
DENSITY= 0.00000785
POSITION OF
MULTIPLICATION
WELDING
FACTOR
1). 1G
1
ALL DIMENSIONS ARE IN MM
2). 2G
1.6
3). 3G
1.3
PREHEATING
REQUIRED?
YES
NO

CROSS SEC. AREA TOTAL WELD KG


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

LONG SEAM/CIRC SEAM WELD KG & RUN TIME ESTIMATION

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

MATERIAL (SS/STEEL)= STEEL


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

NOZZLE WELD KG & RUN TIME ESTIMATION

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

NOZZLE WELD KG & RUN TIME ESTIMATION


BACKING STRIP

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

MATERIAL (SS/STEEL)= STEEL


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
OUT SIDE BALANCE 100%

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

NOZZLE WELD KG & RUN TIME ESTIMATION

DOUBLE 'V'

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

CFW= 9
INC. ANG= 45

MATERIAL (SS/STEEL)= STEEL

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

NOZZLE WELD KG & RUN TIME ESTIMATION


'J' GROOVE

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

PARAMETERS SETTING
PROCESS
HRS/KG
KG/SHIFT

MATERIAL (SS/STEEL)= STEEL

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

NOZZLE WELD KG & RUN TIME ESTIMATION

R.F. PAD +SINGLE 'V'

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

CFW= 9
INC. ANG= 35

MATERIAL (SS/STEEL)= STEEL


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

MULTIPLICATION FACTOR
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
CROSS SEC. AREA ON SHELL ON D/END
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

NOZZLE WELD KG & RUN TIME ESTIMATION


R.F. PAD +SINGLE 'V'

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

CFW= 9
INC. ANG= 45

MATERIAL (SS/STEEL)= STEEL

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

MULTIPLICATION FACTOR
1
1.6
1.3

PREHEATING
REQUIRED?
YES
NO

MULTIPLICATION FACTOR
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
CROSS SEC. AREA ON SHELL ON D/END
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

NOZZLE WELD KG & RUN TIME ESTIMATION


R.F. PAD +SINGLE 'V'

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

CFW= 9
MATERIAL (SS/STEEL)= STEEL
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
CROSS SEC. AREA ON SHELL ON D/END
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

NOZZLE WELD KG & RUN TIME ESTIMATION

297503042.xls

12/06/2015

NOZZLE WELD KG & RUN TIME ESTIMATION

R.F.PAD + DOUBLE 'V'

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

CFW= 9
INC. ANG= 60

MATERIAL (SS/STEEL)= STEEL

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
CROSS SEC. AREA ON SHELL ON D/END
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

NOZZLE WELD KG & RUN TIME ESTIMATION


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

OUT SIDE BALANCE 80%

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

MATERIAL (SS/STEEL)= STEEL


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

FILLET WELD KG & RUN TIME ESTIMATION


DOUBLE SIDE FILLET JOINT
WELDING BY SINGLE OPERATOR/
DOUBLE OPERATOR(S/D)?
WELD LG (CALCULATED/AMNUAL) (C/M?) m
MANUAL LENGTH OF WELDING(MM)=

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

MATERIAL (SS/STEEL)= STEEL

13

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
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

FILLET WELD KG & RUN TIME ESTIMATION


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

MATERIAL (SS/STEEL)= STEEL


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

FILLET WELD KG & RUN TIME ESTIMATION


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
MANUAL LENGTH OF WELDING(MM)=
MATERIAL (SS/STEEL)= STEEL

20

60

10
RG=

DEG

2
2
20

10000

DENSITY= 0.00000785
FOR CALCULATING WELD LENGTH
RADIUS OF WELDING(MM)=
1000
INCLUDED ANGLE OF WELDING(DEG)=
360
CALCULATED LENGTH OF WELDING(MM)=
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

OVERLAY WELD KG & RUN TIME ESTIMATION


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

OVERLAY WELD KG & RUN TIME ESTIMATION


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

OVERLAY WELD KG & RUN TIME ESTIMATION


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

OVERLAY WELD KG & RUN TIME ESTIMATION


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

OVERLAY WELD KG & RUN TIME ESTIMATION


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