117463233 weld calculation

Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001

Magnatech Pipe Welding Systems

INTRODUCTION The purpose of this program is to allow quick calculation of arc times, weld times, and filler metal requirements for manual, semiautomatic, and mechanized pipe welding projects. Four of the most common pipe joint preparations can be used in the calculations. A guide to approximate deposition rates for different processes is given. Attention: these are for welding pipe in the fixed position only and are not representative of higher rates achievable when the pipe can be rolled. Although deposition rates and duty cycles have been taken from a wide range of industry sources, they are to be used a guidelines only. Individual applications, welder skills, and whether the welding is to be done in a fabrication facility or during field erection can make these assumptions inaccurate. We encourage each user to check the standard assumptions against actual company productivity data and use this actual data for any calculations. Certain applications, for example welding materials requiring strict control of interpass temperature, markedly affect the duty cycle, whether the welding is done manually or with mechanized equipment. We encourage you to check calculated times for future projects against actual welding rates achieved. This Calculator allows a quick comparison between manual and mechanized techniques and provides realistic information on the productivity improvements that can be achieved using mechanized welding. However, it should be used as a guide only. Given the many workplace variables, Magnatech can assume no liability or responsibility for the accuracy of this Calculator to predict actual arc times and weld times for all circumstances. MAGNATECH LIMITED PARTNERSHIP 6 Kripes Road P.O. Box 260 East Granby, CT 06026 USA Phone: (860)653-2573 Fax: (860)653-0486 Web: www.magnatech-lp.com E-Mail: [email protected]

welding pipe in the fixed position only and are not representative of higher rates achievable when the

assumptions inaccurate. We encourage each user to check the standard assumptions against actual

This Calculator allows a quick comparison between manual and mechanized techniques and provides

Magnatech can assume no liability or responsibility for the accuracy of this Calculator to predict actual



WELD CALCULATION ASSUMPTIONS A. GENERAL All assumptions based on welding in fixed 5G position. The torch must be moved around stationary pipe. B. DEFINITIONS 1. Deposition Rate - Weld Metal Deposited Assuming 100% "Arc On"/Duty Cycle Time >Manual or Mechanized Orbital GTAW - 1lb/hr (0.45 kg/hr) >Manual SMAW - 6 lbs/hr (2.27 kg/hr) >Semiautomatic GMAW/FCAW - 8 lbs/hr (3.6 kg/hr) >Mechanized Orbital GMAW/FCAW - 8 lbs/hr (3.6 kg/hr) 2. Efficiency Factor - Percentage of Actual "Arc On"/Duty Cycle Time >Manual SMAW or GTAW - 15-25% >Semiautomatic GMAW/FCAW - 20-40% >Mechanized Orbital GTAW or GMAW/FCAW - 70-80% 3. Arc Time >Time to weld the joint assuming 100% duty cycle 4. Weld Time >Time to weld the joint assuming realistic duty cycle.



TYPICAL JOINT DETAILS 1. GENERAL Typical ranges of dimensions are given below as a guide only - use specific dimensions, if available. 2. TYPICAL DIMENSIONS (Angles Are for Each Pipe End. Included Angle = 2 x Angle) V = Bevel: A = Bevel Angle: 37.5° (ASME) or 30° (API) L = Land Thickness: 0.062 - 0.125" (1.5 - 3mm) G = Gap: 0.062 - 0.125" (1.5 - 3mm) C = Cap Height 0.125" (3mm) Compound V-Bevel: A1 = Primary Bevel Angle: 37.5° (Angle closest to ID) A2 = Secondary Bevel Angle: 10% (Angle closest to OD) L = Land Thickness: 0.062 - 0.125" (1.5 - 3mm) G = Gap: 0.062 - 0.125" (1.5 - 3mm) H = Dimension to A2: 0.75" (19mm) (Dimension from pipe ID at which bevel angle changes) C = Cap Height: 0.125" (3mm) J-Bevel: A = Bevel Angle: 20° L = Land Thickness: 0.050" - 0.062" (1.3 - 1.5mm) E = Land Extension: 0.030 - .050" (.75 - 1.3mm) C = Cap Height: 0.125" (3mm) R = Radius: 0.094" (2.4mm) Compound J-Bevel: A1 = Primary Bevel Angle: 37.5° (Angle closest to ID) A2 = Secondary Bevel Angle: 10% (Angle closest to OD) L = Land Thickness: 0.050 - 0.062" (.75 - 1.5mm) E = Land Extension: 0.030 - 0.050" (.75 - 1.3mm) H = Dimension to A2: 0.75" (19mm)(Dimension from pipe ID at which bevel angle changes) C = Cap Height: 0.125" (3mm) R = Radius: 0.094" (2.4mm)



Joint Details Production Details

Diameter in Inches (D) 10.75 Deposition Rate in lbs/hr 8.00

Wall Thickness (T) 0.594 Efficiency Factor in % 70%

Land Thickness (L) 0.15 # of Weld Joints 1

Bevel Angle (A) 30 Hours per Shift 8

Root Gap (G) 0.125 Shifts per Day 1

Cap Height (C) 0.125 Days per Week 5

Total No of Welding Systems 1 0.444 T-L 0.637687 0.188067

Volume Calculations Time Calculations Time Calculations

0.27 0.31

8.79 0.44

0.28 26.66

2.49 2.49

0.31

0.44

0.06

0.06

0.01

Time Calculations Multiple Systems

0.31

0.44

0.01

Cross Section Area (in2)

Volume of weld (in3)

Weight of Steel (lbs per in3)

Weld Metal joint (lbs)

Arc Time per/joint

Weld Time per/joint (hr.)

Weld Time per/joint (min.)

Total Weld Weight

Welding Duration in hrs

Welding Duration in Shifts

Welding Duration in Days

Welding Duration in Weeks

Total ArcTime (Hours)

Total Weld Time (Hours)

Total ArcTime (Hours)

Total Weld Weeks


Weld Volume /Filler Metal Weight Calculator Copyright Magnatech 2001


Diameter in Inches (D) 36.000 Production Details

Wall Thickness (T) 0.625

Radius (R) 0.094 Deposition Rate in lbs/hr 1.00

Land Extension (E) 0.030 Efficiency Factor in % 70%

Land Height (L) 0.060 # of Weld Joints 110

Bevel Angle (A) 20 Hours per Shift 8

Cap Height (C) 0.10 Shifts per Day 1

Days per Week 5

0.565 0.471 Total No of Welding Systems 1

Volume Calculations Time Calculations

0.22 8.76

30.938 12.51

0.283 750.47

8.76 963.10

963.10

0.590542 0.275949 1375.86

171.98

171.98

34.40


963.10

1375.86

34.40

Cross Section Area ( in2)

Volume of Weld (in3)

Weight of Steel (lbs per in3) Weld Time per/joint (min.)

Weld Metal Joint (lbs)

Arc Time per/joint


Total Weld Weight

Total Arc Time (Hours)




Arc Time per/joint



Total Weld Weeks




Diameter in Inches D 18.000 Deposition Rate in lbs/hr 8.00

Wall Thickness T 2.000 Efficiency Factor in % 70%

Land Height L 0.150 # of Weld Joints

Bevel Angle 1 A1 30.000 Hours per Shift 8

Bevel Angle2 A2 20.000 Shifts per Day 1

Root Gap G 0.125 Days per Week 5

Cap Height C 0.125 Total No of Welding Systems 1

dist to Angle 2 H 0.750


1.893 3.98

112.611 5.69

0.283 341.45

31.869 0.00

0.00

e16 1.7277 0.60 e14 0.00

f16 2.10854 1.25 e15 0.00

0.00

0.00


0.00

0.00

0.00




Weld Metal Joint (lbs)

Arc Time per/joint

Total Weld Weight






Total Weld Time (hours)




Total Weld Weeks




Diameter in Inches D 1.750 Deposition Rate in lbs/hr 4.60

Wall Thickness T 0.250 Efficiency Factor in % 80%

Radius R 0.093 # of Weld Joints 1

Land Extension E 0.030 Hours per Shift 8

Land Thickness L 0.050 Shifts per Day 1

Bevel Angle1 A1 20 Days per Week 5

Bevel Angle 2 A2 0 Total No of Welding Systems 1

Cap Height C 0.10

Dist to Angle 2 H 0.00

0.200 0.107 -0.14 0.250 0.026907 0.141905


0.027 0.01

0.2 0.02

0.283 0.97

0.059 0.06

0.01

0.02

0.00

0.00

0.00


0.01

0.02

0.00




Weld Metal Joint (lbs.)




Arc Time per/joint

Total Weld Weight






Total Weld Time (hours)

Total Weld Weeks

0.04110

117463233 weld calculation

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