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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

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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

Production Details
(D)
(T)
(L)
(A)
(G)
(C)

10.75
0.594
0.15
30
0.125
0.125

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

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

8.00
70%
1
8
1
5
1

0.637687 0.188067

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

Time Calculations Multiple Systems


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

0.31
0.44
0.01

Magnatech Pipe Welding Systems


Weld Volume /Filler Metal Weight Calculator
Joint Details

Production Details

Diameter in Inches
Wall Thickness
Radius
Land Extension
Land Height
Bevel Angle
Cap Height

(D)
(T)
(R)
(E)
(L)
(A)
(C)

36.000
0.625
0.094
0.030
0.060
20
0.10

0.565

0.471

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

0.2759487

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.)

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

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

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

Production Details
D
T
L
A1
A2
G
C
H

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

Copyright Magnatech 2001

1.7277 0.60
2.10854
1.25

18.000
2.000
0.150
30.000
20.000
0.125
0.125
0.750

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
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

8.00
70%
8
1
5
1

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

Production Details
D
T
R
E
L
A1
A2
C
H

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

1.750
0.250
0.093
0.030
0.050
20
0
0.10
0.00
0.200

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

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