Magnatech Pipe Welding Systems Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001

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: info@magnatech-lp.com

e when the

ainst actual

nd provides

redict actual

Magnatech Pipe Welding Systems Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001
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.

Magnatech Pipe Welding Systems Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001
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)

Magnatech Pipe Welding Systems Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001
Joint Details Diameter in Inches Wall Thickness Land Thickness Bevel Angle Root Gap Cap Height (D) (T) (L) (A) (G) (C) 10.75 0.594 0.15 30 0.125 0.125 Production Details Deposition Rate in lbs/hr Efficiency Factor in % # of Weld Joints Hours per Shift Shifts per Day Days per Week Total No of Welding Systems
0.444 T-L 0.637687 0.188067

8.00 70% 1 8 1 5 1

Volume Calculations
Cross Section Area (in2) Volume of weld (in3) Weight of Steel (lbs per in3) Weld Metal joint (lbs)

Time Calculations Time Calculations 0.27 8.79 0.28 2.49

Arc Time per/joint Weld Time per/joint (hr.) Weld Time per/joint (min.) Total Weld Weight Total ArcTime (Hours) Welding Duration in hrs Welding Duration in Shifts Welding Duration in Days Welding Duration in Weeks

0.31 0.44 26.66 2.49 0.31 0.44 0.06 0.06 0.01 0.31 0.44 0.01

Time Calculations Multiple Systems

Total ArcTime (Hours) Total Weld Time (Hours) Total Weld Weeks

Magnatech Pipe Welding Systems Weld Volume /Filler Metal Weight Calculator
Joint Details Diameter in Inches Wall Thickness Radius Land Extension Land Height Bevel Angle Cap Height (D) (T) (R) (E) (L) (A) (C) 0.565 Volume Calculations Cross Section Area ( in2) Volume of Weld (in3) Weight of Steel (lbs per in3) Weld Metal Joint (lbs)
0.590542

Copyright Magnatech 2001

Production Details 36.000 0.625 0.094 0.030 0.060 20 0.10 0.471 Production Details Deposition Rate in lbs/hr Efficiency Factor in % # of Weld Joints Hours per Shift Shifts per Day Days per Week Total No of Welding Systems Time Calculations Arc Time per/joint Weld Time per/joint (hr.) Weld Time per/joint (min.) 1.00 70% 110 8 1 5 1 8.76 12.51 750.47 963.10 963.10 1375.86 171.98 171.98 34.40 963.10 1375.86 34.40

0.275949

0.22 30.938 0.283 8.76 Total Weld Weight Total Arc Time (Hours) Welding Duration in hrs Welding Duration in Shifts Welding Duration in Days Welding Duration in Weeks Time Calculations Multiple Systems Total Arc Time (Hours) Arc Time per/joint Total Weld Weeks

Magnatech Pipe Welding Systems Weld Volume/Filler Metal Weight Calculator

Joint Details Diameter in Inches Wall Thickness Land Height Bevel Angle 1 Bevel Angle2 Root Gap Cap Height dist to Angle 2 D T L A1 A2 G C H 18.000 2.000 0.150 30.000 20.000 0.125 0.125 0.750 Production Details

Copyright Magnatech 2001

Deposition Rate in lbs/hr Efficiency Factor in % # of Weld Joints Hours per Shift Shifts per Day Days per Week Total No of Welding Systems

8.00 70% 8 1 5 1

Volume Calculations Cross Section Area ( in2) Volume of Weld (in3) Weight of Steel (lbs per in3) Weld Metal Joint (lbs) e16 f16 1.7277 0.60 2.10854 1.25

Time Calculations 1.893 Arc Time per/joint 112.611 Weld Time per/joint (hr.) 0.283 Weld Time per/joint (min.) 31.869 Total Weld Weight Total Arc Time (Hours) e14 Welding Duration in hrs e15 Welding Duration in Shifts Welding Duration in Days Welding Duration in Weeks Time Calculations Multiple Systems Total Arc Time (Hours) Total Weld Time (hours) Total Weld Weeks

3.98 5.69 341.45 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Magnatech Pipe Welding Systems Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001
Joint Details Diameter in Inches Wall Thickness Radius Land Extension Land Thickness Bevel Angle1 Bevel Angle 2 Cap Height Dist to Angle 2 D T R E L A1 A2 C H 1.750 0.250 0.093 0.030 0.050 20 0 0.10 0.00 0.200 Production Details Deposition Rate in lbs/hr Efficiency Factor in % # of Weld Joints Hours per Shift Shifts per Day Days per Week Total No of Welding Systems 4.60 80% 1 8 1 5 1

Volume Calculations Cross Section Area ( in2) Volume of Weld (in3) Weight of Steel (lbs per in3) Weld Metal Joint (lbs.)

0.107 -0.14 0.250 0.026907 0.141905 Time Calculations 0.027 Arc Time per/joint 0.01 0.2 Weld Time per/joint (hr.) 0.02 0.283 Weld Time per/joint (min.) 0.97 0.059 Total Weld Weight 0.06 Total Arc Time (Hours) 0.01 0.02 Welding Duration in hrs 0.00 Welding Duration in Shifts 0.00 Welding Duration in Days 0.00 Welding Duration in Weeks Time Calculations Multiple Systems 0.01 Total Arc Time (Hours) 0.02 Total Weld Time (hours) 0.00 Total Weld Weeks

0.04110