ESTIMATING WELD METAL DEPOSITION COSTS

MATERIAL COST

ELECTRODE
SHIELDING GAS

FIXED COST

Joint Preparation
Fixturing Tacking

Preheating
Cleaning Inspection

Rs

COSTING

POWER & EQUIP. ELECTRODE COST

Power & Equipment

2-5%

Electrode Cost 8-15 % Labour & 80-85 % Overhead Cost

LABOUR & OVERHEAD

INCREASED WELDING PRODUCTIVITY

REDUCED WELDING COST

ELECTRODE EFFICIENCY & STUB END LOSS

DATA ON EFFECT OF STUB END LOSSES TYPE -E7018 ELECTRODES EFFICIENATY AT 50 mm EFFICIENATY AT 75 mm EFFICIENATY AT 100 mm EFFICIENATY AT 125 mm EFFICIENATY AT 150 mm STUB STUB STUB STUB STUB LOSS -70 % LOSS -64.5% LOSS -59.1% LOSS -54.5% LOSS -49.1%

450 mm

WELD METAL COST FORMULAS

1 Labour & Overhead = Labour & Overhead Cost/Hr ---------------------------------------Deposition Operating Rate (Kg/Hr) X Factor Electrode Cost / Kg --------------------------------Deposition Efficiency Gas Flow Rate Cu.Meters/ Hr. X Gas Cost / litre -----------------------------------Deposition Rate (Kg/Hr)

Electrode:

Gas

Flux

Flux Cost/kg X 1.4 ------------------------------------Deposition Efficiency

Power Cost

Cost Rs/KWH x Volts x Am ps ---------------------------------1000 X Deposition Rate (kg/Hr)

T otal Cost per kg of Deposited Weld Metal

= Sum of 1-5 , Above

WELD METAL COST WORKSHEET

FCAW AS COMPARED TO SMAW CALCULATING COST PER KG DEP. WELD - WELDING POSITION - FLAT COST CAL SMAW E 7018 / 5mm AT 250 A/28 V FCAW Vs. SMAW * COST RED.-

COST CAL.
FCAW E 71T-1 / 1.6 DIA. AT 300 A/28 V

Labour & Overhead Electrode: Gas

150/5X0.45 150/0.87 990 x 0.04 /5

66.67 150/2.5 X0.30 172.4 60 /0.65 7.92 NA 4 x 250 x 28 / 6.72 1000 x 2.5 253.7 Total Variable
Cost/kg Deposite

200 92.3

-133.33 80.4 7.92

Power Cost 4 x 300 x 28 /

1000 x 5

11.2 304
:

-4.48 -49.29

Sum of the Above Rework COST

Total Variable cost/kgDeposite

at 3% 253.72 /0.97

at 15% 261.56 303.51 /0.85

= =

357

-95.54

Basic Cost Saving per Kg with 49.29 FCAW Actual Cost Saving pr Kg with 95.54 FCAW

HOW WELDING SMARTER SAVED 120,000 MAN-HOURS

Walking Dragline - 12,000 MT Weight Boom Height : 95 M Hoist Depth : 55 M Bucket Load :325 MT Cylindrical Steel Base 32 M Dia. 2.5 M Wide & 140 MT Weight Replacement of the Base Estimated 160,000 Man- Hour with SMAW(80 Months) Estimated 40,000 Man- Hour with FCAW (20 Months)

Wedge Shaped Segments Make Up Dragon Base

2.5M

32M

150 mm

SS FCAW TO RESCUE OF ASPRIN MAKERS HEAD ACHE

SS Half Coil Reactor Found Leaking. Leak Spots HALF COIL Identified as likely restart points in OH Position. Small Dia. SS FCAW made it possible to reduce restart points Better approach made improved Fusion Possible.

ONE MINUTE WELD VERTICAL UP POSITION-6MM FILLET

FCAW

GMAW

One Minute Welds made using SMAW 3.2mm 70mm, GMAW-0.9mm 105 mm FCAW 1.2mm 300 mm Cost aspect based on above productivity.
LABOUR &OVERHEAD-RS.500

COST IN RS.

SMAW

2900 1300 900 FCAW GMAW SMAW DEP. COST PER KG

PROCESS SHARE FOR VARIOUS COUNTRIES

GTAW 2% GMAW 60% SMAW 30%
GTAW SMAW

GTAW 2%

GTAW

SMAW SMAW 20%SAW

SAW

GMAW

EUROPE GMAW
10%
GTAW 2% SMAW 80% SAW 8%

SAW 8%

GMAW 70%

GMAW

SAW8%

JAPAN
SAW8% SMAW 35%

GMAW 55%

GTAW2%

INDIA

USA

GLOBAL PROCESS SHARE OF WELD METAL

JAPAN
SMAW SAW GTAW GMAW 20% 8% 2% 70%

EUROPE USA
30% 8% 2% 60% 35% 8% 2% 55%

INDIA
80% 8% 2% 10%

PROCESS SHARE IN GLOBAL PERSPECTIVE

Steady Increase in Solid & Core Wire Consumption Covered Electrode Consumption will Decline & Stabilise around 30% In Developed Countries, CO2 Welding Accounts for more than 50% In Developing Countries like China & Korea CO2 Process Share is already around 15%

THANK YOU