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Strip Cladding

The document provides calculations to determine the costs of using a strip cladding method for welding overlays on the shell and dish sections of a pressure vessel. It outlines the production schedule, material costs, labor costs, and non-destructive testing costs to arrive at a total cost per ton of plates for applying strip cladding. Dimensions, welding parameters, production times, and cost figures are provided for both the shell and dish sections in the example calculations.

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Renny Devassy
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© © All Rights Reserved
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Download as xlsx, pdf, or txt
100 views8 pages

Strip Cladding

The document provides calculations to determine the costs of using a strip cladding method for welding overlays on the shell and dish sections of a pressure vessel. It outlines the production schedule, material costs, labor costs, and non-destructive testing costs to arrive at a total cost per ton of plates for applying strip cladding. Dimensions, welding parameters, production times, and cost figures are provided for both the shell and dish sections in the example calculations.

Uploaded by

Renny Devassy
Copyright
© © All Rights Reserved
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
Download as xlsx, pdf, or txt
Download as xlsx, pdf, or txt
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PERFECT INTERNATIONAL (FZC)

,Manufacturer of Pressure Vessels


Heat Exchangers & Process Equipments

STRIP CLADDING OF SHELL


Objective:
To arrive the weld overlay costs for shell by strip cladding method.
STRIP WELD OVERLAY : Shell Section
Diameter of Vessel (before overlay) in mm Di =
Length of Vessel in mm TL/TL =
Width of Weld Overlay w =
Weld overlay thickness t =
Weld overlay density rho =
No of Welding Equipment running at the same time N =
Equipment Welding Speed tr =
Average production time per day ( 2 shift) M =
Percentage of Weld Overlay repairs a =
PRODUCTION SCHEDULE
Length of Weld Overlay Travel per circumference seam C pi.Di
No of Strip Weld Overlay per TL/TL n TL-TL/W
Additional increase of repair r =a.n
Total Length of Strip Overlay Travel L = (n+r).C
Total Welding time T =L/tr

No of days per equipment Days = =

COST OF STRIP WELD OVERLAY PER TON OF PLATES


STRIP WELD OVERLAY MATERIAL COST : Inconel 625
Cost of Strip Weld Overlay =
Weight of strip weld overlay wt of strip with 2% wastage
Cost of Strip Weld Overlay flux
Percentage of Strip Weld Overlay Flux = 100%
Cost of Weld Overlay and flux =
MANPOWER COST No of workmen
Cost of Manpower =
Total welder HRS = 2 PERSON/
Total Welder Cost
ULTRASONIC EXAMINATION COST
Cost of UT =
Total UT cost =
100% DPT COST =
TOTAL COST
Total Cost including Weldoverlay + NDT =
PERFECT INTERNATIONAL (FZC)
,Manufacturer of Pressure Vessels
Heat Exchangers & Process Equipments

STRIP CLADDING OF SHELL

Prepared By:-
IONAL (FZC)
e Vessels
Equipments

L Date:- 25-09-2011

2,012 mm
6,000 mm
60 mm
5.5 mm
8900 kg/m3
1
115 mm/minute
22 hrs
10%

6,320.88 mm
105.35 mm
10.53
732,482.30 mm
6,369.41 minute
106 hrs
5 days

AED 265.00 Aed/Kg


2194 Kg
AED 35.00 Aed/Kg
2194 kg
AED 658,297.95
2
AED 26.00 AED/HR
231 HRS
AED 6,006.00 AED

AED 15.00 AED/Mtr


AED 10,987.23
AED 10,987.23

AED 686,278.42
IONAL (FZC)
e Vessels
Equipments

L Date:- 25-09-2011
PERFECT INTERNATIONAL (FZC)
,Manufacturer of Pressure Vessels
Heat Exchangers & Process Equipments

STRIP CLADDING OF DISH


Objective:
To arrive the weld overlay costs for dish heads by strip cladding method.
STRIP WELD OVERLAY : HEAD Section
Diameter of Vessel Head Di =
Straight Flange SF =
Head Qty Qty =
Width of Weld Overlay w =
Weld overlay thickness t =
Weld overlay density rho =
No of Welding Equipment running at the same time N =
Equipment Welding Speed tr =
Average production time per day M =
Percentage of Weld Overlay repairs a =
PRODUCTION SCHEDULE
Area of 2:1 Ellipsoidal Head A =1.084*Di^2
Area of 2:1 Ellipsoidal Head at S.F C =P.I*Di*SF
Additional increase of repair r =a.(A+C)
Total Area of Strip Overlay L =QTY*(A+C+r)/W
Total Welding time T =L/tr

No of days per equipment Days = =

COST OF STRIP WELD OVERLAY PER TON OF PLATES


STRIP WELD OVERLAY MATERIAL COST : Inconel 625
Cost of Strip Weld Overlay =
Weight of strip weld overlay wt of strip with 2% wastage
Cost of Strip Weld Overlay flux
Percentage of Strip Weld Overlay Flux = 100%
Cost of Weld Overlay and flux =
MANPOWER COST No of workmen
Cost of Manpower =
Total welder HRS = 2 PERSON/SHIFT
Total Welder Cost
ULTRASONIC EXAMINATION COST
Cost of UT =
Total UT cost =
100% DPT COST =
TOTAL COST
Total Cost =
PERFECT INTERNATIONAL (FZC)
,Manufacturer of Pressure Vessels
Heat Exchangers & Process Equipments
Prepared By:-
NAL (FZC)
els
ments

Date:- 25-09-2011

2,012 mm
50 mm
2
60 mm
5.5 mm
8900 kg/m3
1
115 mm/minute
22 hrs
10%

4,388,188.10 mm
316,044.22 mm
470,423.23
172,488.52 mm
1,499.90 minit
25 hrs
1 days

AED 260.00 Aed/Kg


517 Kg
AED 30.00 Aed/Kg
517 kg
AED 149,851.92 AED
2
26 AED/HR
46.2 HRS
AED 1,201.20 AED

15 AED/Mtr
AED 2,587.33
AED 2,587.33

AED 156,227.77
NAL (FZC)
els
ments

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