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Welding of Plates

Welding of Plates

(OP)
Hi All,

I would like to know a few details about welding of plates (for pressure vessel and storage tanks)

01.How long would it take approximately for welding 1 linear meter (Please consider 10 mm thk for plate and skilled welder). How we can apply the factor when thickness increases? (Material can be A36 for example)
02.How to calculate the consumable (Quantity can be taken by calculating the area of weld deposit but it depends on weld gap). I need to know how effectively we can calculate this during tender stage?

I know the question is general but I can be specific once we start the thread.


I have some serious issues in calculating the welding time required for fabrication of pressure vessels and storage tanks (Welder productivity). Please help

Thanks in advance
Best Regards,

RE: Welding of Plates

1. Depends on the welding process (SMAW, FCAW, SAW) and welder experience with the process.

2. Lincoln, ESAB, and other filler metal manufacturers have information in regards to consumable deposition rates.

RE: Welding of Plates

Are you bound to some Codes?

Probably should be. Maybe you have other aspects of the welding, like welder certification, weld prep, and NDT requirements covered, but NDT can really slow down completion of multi-pass welds.

RE: Welding of Plates

(OP)
Hi Gents,

Thanks alot for the response.

I work in tendering dept. All I need is thumb rule to calculate the man hours required along with welding electrode/filler wire consumption.

Lets put it in this way. I will give an example using which you can explain the calculation method.

Note: I have some methods for my calculations. But its purely theoretical. It would be great if someone who has real experience, can give me some thumb rule for the calculations

Consider the below (Just as an example):

Pressure Vessel
Material - SA516 Gr60
Shell thickness - 8 mm
Dish End thickness - 10 mm (Ellipsoidal 2:1)
Dimensions - 6 Meter (T-T) length and 2.5 Meter Dia
NDT Requirements: 100% LPT, MPT and RT where T joints
U stamping is not required
Welding process - SMAW

As per the above, please let me know how many welders required to complete the welding involved or it would be fine if can provide welder productivity per linear meter.

What if, the thickness of the shell becomes 10 mm? How the productivity and welding consumption get affected? what are the factors to be considered.


Kindly share with me your experience and knowledge on the above.

Thank you so much for your time and effort.

Best Regards,

RE: Welding of Plates

If the bulk of the welding can be done in the flat position, figure about 1Kg/hr deposited weld metal. You can figure out the volume and weight per lineal meter.

RE: Welding of Plates

There are no rules of thumb as the variables change considerably per joint. Process, Joint Design, Access, backing, preheat, filler metal class, and other factor all contribute to how MUCH weld can be deposited in a period of time.

Some formulas and concepts that may be of great help can be learned about in ESAB's book

If you are the adventourous type, I have some old basic code that may be helpful calculating weld volumes and also comparing the costs of two different processes but you will need an older compliler or the ability to convert the subs/functions to a modern language/version.

I am sure there are some new apps out there to help with some of these things.

Have a good day.

Gerald Austin
www.weldingdata.com
Greeneville Tennessee

RE: Welding of Plates

(OP)
Hi Gents,

Thanks all of you for the response.

Mr. Gerald, I have gone through ESAB and found it useful. I have also tried your old book codes mentioned above but found noway to compile it. The language used, looks unfamiliar to me. Anyway, thanks alot for the support shown.


Best Regards,

RE: Welding of Plates

Greetings to every one. I am stuck. Pls help me out.

A per ASME Section-I, the EP for Bi thickness drum for longitudinal welds shall be Fig PW 9.1(a)(attached).
The taper is supposed to be build by weld itself as per the ASME code.
However during the NDT of weld as quoted by the vendors, the profile of the weld being tapered is not feasible for a UT or RT as it requires a straight section.
I have attached a sketch of the bi thickness drum plate weld detail with yellow tapered part.
This yellow part will be subjected to NDT(RT or UT)
Did any one have a similar issue and they came out of it. How shall i go about it.
Feedbacks are requested.

Thanks in advance

RE: Welding of Plates

PakchikpakRajababu,
You should start another thread not "highjack" someone elses thread!!!

RE: Welding of Plates

The language is BASIC and you can get a free compiler titled FreeBasic. I don't know what's involved in compiling... but programming syntax appears to be OK.

Check with SourceForge or something of that ilk for downloading free BASIC compilers.

Dik

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