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