Master in Fabrication Layout Development PDF

MASTER IN
FABRICATION
LAYOUT
DEVELOPMENT
Using Geometrical and
Numerical Methods with
Practical Example
Solution
By
Mr. Imran Pinjara
Founder and CEO of
Let’sFab Educational Services.
1
We are Continuously Working to Digitize Fabrication Techniques, we had
Developed many Digital Product such as eBook’s, E-learning, Video Courses,
Excel Utilities, Mobile Applications etc. that can be used in daily fabrication
activity to increase accuracy, efficiency and save time of fabrication engineers.
website: www.letsfab.in email: supports@letsfab.in
2
Dedicated To
To my Sweet Wife Saniya
3
Contents
Preface: Master in Fabrication Layout Development 5
1. Pipe or Shell Layout Development 06

2. Truncated Pipe Layout Development 14
3. Pipe to Pipe Intersection with Equal Diameters 25
4. Pipe to Pipe Intersection with Unequal Diameters 36
5. Pipe to Pipe Intersection with Offset Centres 47
6. Pipe to Cone Intersection Perpendicular to Axis 59
7. Pipe to Cone Intersection Parallel to Axis 71
8. Full Cone Layout Development 82
9. Truncated Cone Layout Development 94
10. Multi Levels Cone Layout Development 106
11. Eccentric Cone Layout Development 123
12. Multi Levels Eccentric Cone Layout Development 144
13. Tori Cone with Knuckle Radius at Large End 173
14. Tori Cone with Knuckle Radius at Both Ends 185
15. Square to Round or Rectangular to Round Layout 198
16. Round to Square or Round to Rectangular Layout 212
17. Pyramid Layout Development 225
18. Truncated Pyramid Layout Development 236
19. Sphere Petal Layout Development 247
20. Dish Ends Petal Layout Development 259
21. Miter Bend Layout Development 271
22. Screw Flight Layout Development 286
Acknowledgement 294
About Authors 295
Recommended Tools for fabrication 296
Vote of Thanks 299
4
Preface
Master in Fabrication Layout Development
Welcome to Let’sFab where we Learn, Guide and Digitize Fabrication Techniques.
We are very happy to see you that you had taken one step ahead to learn most useful
concept used in fabrication. In this book you will learn Fabrication Layout development of All
types of Shapes used in fabrications such as Pipe or Shell, Pipe or Shell Intersections, Full
Cone, Half Cone or Truncated Cone, Eccentric Cone, Multi Levels Cone, Tori Cones, Square
to Round or Rectangular to Round, Round to Square or Round to Rectangular, Pyramid,
Truncated Pyramid, Sphere, Dish Ends, Miter Bend, Screw Flight etc. This Concept of
Fabrication Layout helps you to Increase your Accuracy of Fabrication Works, Increase your
Efficiency by Making Fabrication Layout Process Faster and Easy and Save your time of
Fabrication Layout by shifting you to use numerical tools for layout development or numerical
calculation method of Layout so that you will not require to draw layout actually on plate or on
Auto Cad by Geometrical Method. We had explained fabrication layouts development
methods in very detailed and simple way so that you can learn whole layouting process in easy
and faster way. We had explained both Geometrical and Numerical Methods of Fabrication
Layout of all Shapes and also take one practical Example of each Fabrication layout Shapes so
that you can learn how to use our method to get final fabrication layout. We had provided
detailed explanations in step by step method with descriptive images of each step so that you
can learn quickly. We tried our best to make you Master in Fabrication Layout Development
and we hope that at last you will definitely feel that you get valuable knowledge in Fabrication
layout development which help you in real fabrication field.
We are Let’sFab Educational Services continuously working to digitize fabrication
techniques so that you can increase accuracy, efficiency and save time of fabrication and
become faster and dominant partner of your clients. We had developed many digital products
such as eBooks, E-Learning, Video Courses, Excel utilities, Mobile Applications, Software etc.
that can help you in your daily working fabrication activities. You can visit our website get
details of tools and products and if you are facing any problem in your fabrication activity and
you are looking for any other product that will help all fabrication community to minimize and
make faster by such tool, you can share your ideas with us so that will work on it to make this
digital tool and make it available for all those who are working in Fabrication Field.
We thank you to giving us an opportunity to help to increase your knowledge in
fabrication and improve your skills in fabrication with us.
5
1. Pipe or Shell Layout
Development
Pipe or Shell is very simple and widely used shape in fabrication. This is very basic shape in
fabrication most people’s working in this fields knows the layouting development or Flat
Pattern Layout of this shape even though we starting with shape just because those who is just
starting their journey in fabrication field and it also help you to learn fabrication layout
development from simple level to difficult level in Fabrication Layout Development.
We are going to explain this layout in both Geometrical and Numerical Methods and
at the end of learning this Methods we have taken one practical Example of Pipe or Shell
Layout Development to understand use of this method for layout Development, at the end of
this Example Solution. We had also provided you example solution checking method using our
tool so that you can verify your calculation with some tested tools and make you confident in
fabrication layout. You can Practice this method taking more examples yourself and verify your
answer by our tools and become expert in shell or Pipe Layout Development.
Geometrical Method for Pipe or Shell Layout
Geometrical Method of Pipe or Shell Layout Development is also called Graphical

Methods, in this layouting Method layout marking are developed using direct measuring of
Geometrical shape of Pipe or Shell. This Method is Basic Method for fabrication Layout but it
required much time to draw the geometry of actual size and it also has limitation for Bigger
Size pipe or Shell to avoid this limitation you have to use computerized tool Such as Auto Cad
Software and to developed layout using this software also required skilled manpower to
generate layout it cost us more in terms of extra skilled manpower and extra time for drawing
layout. If fabrication layout shape is complex then it is not economical.
Now, we will move towards learning Pipe or Shell Layout Development using
Geometrical Method in Step by Step.
Step 1: Draw Elevation and Top View of Pipe or Shell.
We recommend you that always use mean dimensions for layout development
it gives more Accuracy of fabrication Layout.
6
Pipe or Shell Elevation and Top View drawn in required size with dimensions as shown
below
Elevation View Top View
Step 2: Measure Circumference of the Top View Circle and Height of the Pipe or Shell.
Step 3: Draw the Flat Pattern Layout of the Shell or Pipe Using Measured Values of
Circumference and Height in Previous Step.
7
Numerical Method for Pipe or Shell Layout
Numerical Method for Pipe or Shell Layout Development is very faster and time saving
method for layouting, you can calculate the values of layout dimension by solving manually on
scientific calculator or you can use any computerized tool for solving such as MS excel or any
other tool for Calculates Values in faster way.
Now we will move towards learning Numerical Method of Pipe or Shell Layout
Development.
Step 1: Define Pipe or Shell Generalised Diagram for fabrication Layout Development.
Step 2: Define variables for layout development.
Let,
D = Diameter of Pipe or Shell.
H = Height of the Pipe or Shell.
W = Flat Plate Width of Shell or Pipe.
OD
ID ==Inside Diameter
Outside Diameter
of Shell
of Shell
or Pipe.
or Pipe.
T = Thickness of Pipe or Shell.
We recommend you that use Mean Diameter for Layout if you are making pipe or shell
using plate rolling process.
8
Step 3: Calculate Plate Width W for Layout Development.
Plate Width W = TI X D
If you have input diameter is Inner Diameter (ID) then use following Formula.
Plate Width W = It x (ID + T )
Or if you have input diameter is Outside Diameter (OD) then use following Formula.
Plate Width W = It x (OD — T )
After Calculating Plate Width W from using any one formula then go to Next Step.
Step 4: Mark Final Flat Pattern Layout of Pipe or Shell Using Calculated Values in
Previous Steps.
Plate Width (W)
This is Final layout of Shell or Pipe using Numerical Methods. If you want make shell or
Pipe more than one joint due to sheet limitations then divide plate width in to equal no of
Parts you want to make in your required no of Joints Or if you want to make Pipe or Shell in
more than one Joint height wise or you have make shell in more than one part Vertically then
Divide Height of the Shell or Pipe in to equal no of Parts you are wishing to fabricated. In
above Two Methods we learn How to Layout Pipe or Shell Using Geometrical and Numerical
Methods, now we will see one Practical Example Solution Using Numerical Method so that we
can understand in better layouting by practicing it Practically.
Practical Example Solution by Numerical
Method
Example: Generate Fabrication Layout Development or Flat Pattern of Pipe or Shell
having Following Dimensions:
Mean Diameter 294 mm, Shell or Pipe Thickness 6 mm and Height 500 mm. Or
Outside Diameter 300 mm, Shell or Pipe Thickness 6 mm and Height 500 mm. Or
Inside Diameter 288 mm, Shell or Pipe Thickness 6 mm and Height 500 mm.
Solution:
Given Data:
D = 294 mm.
OD = 300 mm.
ID = 288 mm.
T = 6 mm.
H = 500 mm.
Calculation on the Basis of Mean Diameter:
��
��ℎ
��= ��× ��
10
Plate Width W = TI X 294 = 923.62 mm.
Calculation on the Basis of Outside Diameter:
Plate Width W = It x (OD — T)
Plate Width W = It x (300 – 6) = 923.62 mm
Calculation on the Basis of Inside Diameter:
Plate Width W = It x (ID + T)
Plate Width W = It x (288 + 6) = 923.62 mm
Fabrication layout or Flat Plate Layout Marking of Shell or Pipe Will Be:
Plate Size = 923.62 x 500 x 6. Thk
Plate Width (W) = 923.62

ſ
This is Final Plate Layout Marking of Pipe or Shell by practicing numerical method you will
become more confident in fabrication layout Development of Shell or Pipe.
11
Example Solution Checking for Pipe or Shell
We are providing this example solution Checking Method to you so that you can easily
verify your calculated values with some standard tested tool so that become more confident
while layouting and easily practice to use this method till you become expert in layouting by
Numerical method. We had already tested is Tool with advanced Computer Tool so that you
can trust on this tool and become more accurate in calculating values.
Now we will see example solution checking Method, First You have to Download
our Mobile Application from Our Website.
Download Website: www.letsfab.in/our-apps
Mobile Application Name: Branch Pipe Layouts
Application Icon:
Solution Checking Process: Download above Mobile Application to your mobile check
example Result Values with App results Value. Follow below Screen Shots for Better
Understanding of Checking Methods.
Step 1: Select Pipe Option from Application Main Menu
12
Step 2: Enter Input data of Diameter and Height in input Fields and Press Calculate
Button.
Step 3: Check Result Values with your Calculated Values if your calculated values Match
with this Result Page Value then you are correct if your values is not matching with result page
values then recheck your calculation and Find out Correct values for Accurate Result.
This Checking Method is discussed with you so that you can verify your Fabrication layout
Development Dimension and also verify it so that you can Build trust on your calculated
values once you verify that you can calculate results accurately then you can say that you
become master in fabrication layout development of Pipe or Shell.
13
2. Truncated Pipe Layout
Development
Truncated Pipe Fabrication Layout development is useful in Fabrication Field where Pipe
is Cut at an angle with horizontal Plane. Truncated Pipe is nothing but simple pipe having
section cut at an angle on any one side or both side of pipe which depend upon use of this
shape in fabrication field. In this Chapter we are covering all the Points related to Truncated
pipe layout so that you can learn in depth and used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Truncated Pipe or
Truncated Shell Layout Development to understand use of this method for layout
Development, at the end of this Example Solution. We had also provided you example
solution checking method using our tool so that you can verify your calculation with some
tested tools and make you confident in fabrication layout. You can Practice this method taking
more examples yourself and verify your answer by our tools and become expert in shell or Pipe
Layout Development.
Geometrical Method for Truncated Pipe Layout

Geometrical Method of Truncated Pipe or Truncated Shell Layout Development is also
called Graphical Methods, in this layouting Method layout marking are developed using direct
measuring of Geometrical shape of Truncated Pipe or Shell. This Method is Basic Method for
fabrication Layout but it required much time to draw the geometry of actual size and it also has
limitation for Bigger Size pipe or Shell to avoid this limitation you have to use computerized
tool Such as Auto Cad Software and to developed layout using this software also required
skilled manpower to generate layout it cost us more in terms of extra skilled manpower and
extra time for drawing layout. If fabrication layout shape is complex then it is not economical.
Now, we will move towards learning Truncated Pipe or Shell Layout Development
using Geometrical Method in Step by Step process.
We recommend you that always use mean dimensions for Fabrication layout
development it gives more Accuracy of fabrication Layout Marking Compared to
Outside or Inside Dimensions.
14
Step 1: Draw Elevation View of Truncated Pipe or Truncated Shell for Fabrication Layout.
Step 2: Draw Half Circle View of Truncated pipe and Divide it in to equal No. of Parts as
shown in below figure.
We had Highlighted Half Circle and Divided Parts in red colour for better understanding
and given numbers to each divided part for Identification.
15
Step 3: Project Vertical lines from Divided Points of half Circle of Truncated Pipe as
shown below figure.
Step 4: Mark Development Lines and Measure length of 1’-1’’, 2’-2”, 3-3”, 4-4”, 5-5”, 6-6”,
7-7” as shown in below figure.
We had Highlighted development marking Lines by Red Colour for understanding and
note down the length of each development lines.
16
Step 5: Mark Layout Using Measured Length 1’-1”, 2’-2”, 3’-3”, 4’-4”, 5-5”, 6’-6”, 7’-7” as
shown in figure given Below.
In this way we can generate fabrication layout of Truncated Pipe using Geometrical
Method or Graphical Method of Fabrication Layout Development.
Numerical Method for Truncated Pipe Layout

Numerical Method for Truncated Pipe or Shell Layout Development is very faster and time
saving method for layouting, you can calculate the values of layout dimension by solving
manually on scientific calculator or you can use any computerized tool for solving such as MS
excel or any other tool for Calculates Values in faster way.
Now we will move towards learning Numerical Method for Truncated Pipe or Shell
Fabrication Layout Development.
Step 1: Define Truncated Pipe Generalised Diagram for fabrication Layout Development.
17
Step 2: Define Variables used in fabrication layout development of Truncated Pipe.
Let,
d = Pipe Diameter.
L1 = Large Height o:
L2 = Small Height.
& = Pipe Truncated Angle. Yº
N = No. Of Parts to Divide Base Circle.
º
C = Part Length.
Step 3: Calculate Required Unknown Values of 0, 6), C etc. by using Numerical formulae.
Step 4: Calculate development Marking lengths 1'-1”, 2’-2”, 3’-3”, 4'-4”, 5'-5", 6'-6°, 7-7”
and so on for next parts.
1'-1” = L1 – ((R – R x cos(0 × 0)) x tan & )

2’-2” = L1 – ((R – R x cos(1 x 0)) x tan & )
3’-3” = L1 – ((R – R x cos(2 × 0)) x tan & )
4'-4” = L1 – ((R – R x cos(3 × 0)) x tan & )
5’-5’ = L1 – ((R – R x cos(4 × 0)) x tan & )
6'-6" = L1 – ((R – R x cos(5 × 0)) x tan & )
7°-7” = L1 – ((R – R x cos(6 x 0)) x tan & )
Here we had make this layout in 12 Parts so that we had taken this formula up to 7-7°
markings lengths. If you want to make layout in 24 Parts then you have to take this formula up
to 13'-13” or if you want to make layout in 36 Parts then then you have to take this formula up
to 19°-19°. By using this formula, you can calculate layout marking for any no. of parts but you
to make changes in Cos Multiplying factor by increasing to next number than previous. So
then Generalised Formula for this will Become.
18
Ln = ��
− ((��− ��× ��((��
− ��)× Θ)) × ��α
)
By using this generalised Formula, you can calculate development marking lengths of any
no. of parts.
Step 4: Mark Layout Using Calculated Length 1’-1”, 2’-2”, 3’-3”, 4’-4”, 5-5”, 6’-6”, 7’-7” as
shown in given Figure.
So, by using these Numerical Formulae you can generate fabrication Layout Development
of Truncated Pipe or Truncated Shell in very faster and efficient way.
In above Two Methods we learn How to Layout Truncated Pipe or Shell Using
Geometrical and Numerical Methods, now we will see one Practical Example Solution Using
Numerical Method so that we can understand in better layouting by practicing it Practically.
19
Method
Example: Generate Fabrication Layout Development Markings for Truncated pipe or
Shell for Following Sizes:
Solution:
Step 1: Note Down the Given Data of the Example.
Given Data:
d = 500
L1 = 800
L2 = 600
N = 12
α = Pipe Truncated Angle.
C = Part Length.
20
Step 2: Calculate 0, G), C etc.
& = tant"( aft ) = tant"( º ) = 21.8

e = ** = , = 30
C = ** =*=130.89
R = : * = 250
F
Step 3: Calculate development Marking lengths 1'-1”, 2’-2”, 3’-3”, 4'-4”, 5'-5", 6'-6°, 7-7”.
1°-1” = L1 – ((R – R × cos(0 × 0)) × tan & )

1?-1” = 800 – ((250 — 250 × cos(0 × 30)) × tan 21.8)
12–122 = 800
2’-2” = L1 – ((R – R × cos(1 × 0)) × tan & )

2’-2” = 800 – ((250 — 250 × cos(1 x 30)) x tan 21.8)
22–2” = 786.6
3’-3” = L1 – ((R – R x cos(2 × 0)) x tan & )

3’-3” = 800 – ((250 — 250 × cos(2 x 30)) x tan 21.8)
3’-3” = 750
42-4” = L1 – ((R – R × cos(3 × 0)) × tan & )

42-4” = 800 – ((250 — 250 × cos(3 × 30)) × tan 21.8)
42-4” = 700
21
5’-5’ = L1 – ((R – R × cos(4 × 0)) × tan & )
5’-5’ = 800 – ((250 — 250 × cos(4 × 30)) x tan 21.8)
5’-5’’ = 650
6'-6" = L1 – ((R – R × cos(5 × 0)) × tan & )

6'-6" = 800 – ((250 — 250 × cos(5 x 30)) x tan 21.8)
6?–6” E 613.41
7°-7” = L1 – ((R – R x cos(6 × O)) x tan & )

7°-7” = 800 – ((250 — 250 × cos(6 x 30)) x tan 21.8)
72–7” = 600
Step 5: Mark Layout Using Calculated Length 1'-1”, 2’-2”, 3’-3’’, 4'-4”, 5-5”, 6'-6°, 7-7”.
in 1" in
3.2 2 3"
7. 6" in 6" 7.
C= 130.89
7. 6' 5' 4' 3' 2' 1. 2' 3' 4' 5' 6' 7.
This is Final Fabrication Layout Markings for Given Example solved by using Numerical
Method. You can Get Marking for any size and using any no. of parts by using this method,
you have practice this method to become master in this type of layouting and after practicing
you will have confidence in your layouting and in latter part after become expert you reduce
your work by using method with the help of computerizes numerical tools, for increase your
accuracy and save time of calculations.
Now we will see this example Solution checking process so that you can assured
about your calculation and verify your result with some standard tested reference.
22
Example Solution Checking for Truncated Pipe
Application Icon:
Step 1: Select Truncated Pipe Option from Application Main Menu
23
Step 2: Enter Input data of Diameter and Large End and Small End Height in input Fields
and Press Calculate Button.
In this Result Page it has taken 24 Parts for layout but our example has taken 12 Parts
layouts so you to keep in mind while checking result with this values that either you check your
values with alternate value such as L0, L2, L4, L6, L8, L10, L12 with your calculated values or
You Can Solve this example using 24 Parts and check your values with this Result Page Values.
become master in fabrication layout development of Truncated Pipe or Shell.
24
3. Pipe to Pipe Intersection
with Equal Diameters
Pipe to Pipe Intersection with equal diameters is mostly used piping fabrication and it also
has wide application in Process Equipment Manufacturing for making branch Connection of
Nozzles Pipe or Shells. So, in this Chapter we are covering all the Points related to Pipe to Pipe
Intersection with Equal Diameters Fabrication Layout Development so that you can learn in
depth and used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Pipe to Pipe
Intersection with equal Diameters Layout Development to understand use of this method for
layout Development, at the end of this Example Solution. We had also provided you example
more examples yourself and verify your answer by our tools and become expert in Pipe to Pipe
intersection with equal diameters layout Development.
Geometrical Method for Pipe to Pipe

Intersection
Geometrical Method of Pipe to Pipe to Intersection with equal diameters is also called
Graphical Method of Layout, in this layouting Method layout marking are developed using
direct measuring of Geometrical shape of Pipe to Pipe to Intersections of Equal Diameters.
This Method is Basic Method for fabrication Layout but it required much time to draw the
Geometry of actual size and it also has limitation for Bigger Sizes to avoid this limitation you
have to use computerized tool Such as Auto Cad Software and to developed layout using this
software also required skilled manpower to generate layout it cost us more in terms of extra
skilled manpower and extra time for drawing layout. If fabrication layout shape is complex
then it is not economical.
Now, we will move towards learning Pipe to Pipe to Intersections with Equal
Diameters Layout Development using Geometrical Method in Step by Step process.
25
Step 1: Draw Elevation View for Pipe to Pipe Intersection with equal Diameters as shown
in Figure below.
Step 2: Draw Half Circle View of Branch Pipe and Divide in to equal No. of Parts as
shown in figure below.
Half Circle and Divided Parts lines geometry is Highlighted in Red Colour for better
understanding. Please follow the same process for Practicing this Method.
26
Step 3: Project lines from Divided Points of half Circle as shown in figure and Projected
Lines Highlighted in Green Colours.
Step 4: Mark Development Lines of Branch Pipe and Measure length of 1-1’, 2-2’, 3-3’, 4
4’, 5-5’, 6-6’, 7-7’ as shown in figure given below
Measure Green highlighted Lines and note down the length of measured lines so that it can
be used to Mark in next step.
27
Step 5: Mark Layout Using Measured Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’ as shown
in figure given below.
In this way we can generate fabrication layout of Pipe to Pipe Intersection using
Geometrical Method or Graphical Method of Fabrication Layout Development.
Numerical Method for Pipe to Pipe Intersection

Numerical Method for Pipe to Pipe Intersection with equal Diameters Layout
Development is very faster and time saving method for layouting, you can calculate the values
of layout dimension by solving manually on scientific calculator or you can use any
computerized tool for solving such as MS excel or any other tool for Calculates Values in faster
way.
Now we will move towards learning Numerical Method for Pipe to Pipe Intersection
with equal diameters Fabrication Layout Development.
Step 1: Define Pipe to Pipe intersection at 900 with Equal diameter Generalised Diagram.
28
Step 2: Define Variables for Pipe to Pipe Intersection layout.
Let,
D = Pipe Diameter.
C = Centre to End Distance
& = Part Angle.

P = Part Length.
Step 3: Calculate Q, P, R required in fabrication layout marking calculations.
_ 360
0. F —
P = —
TIX "a
}
R=-
2
Step 4: Calculate development Marking lengths 1-1’, 2-2’, 3-3', 4–4, 5-5, 6-6, 7–7 by using
below Formulae.
1-1’ = C – (R × cos(0 × 0.) )

2-2' = C – (R × cos(1 × 2) )
3-3’ = C – (R × cos(2 × 0.) )
4-4* = C – (R × cos(3 × 0.) )
5-5’ = 3-32
6-6’ = 2-2”
7–7 = 1-12
You can Calculate Marking length for any no parts of Development by using these
formulae but you have to make slight Changes for calculating next lengths. Here we had make
this layout in 12 Parts so that we had taken this formula up to 7-7° markings lengths. If you
29
want to make layout in 24 Parts then you have to take this formula up to 13-13” or if you want
to make layout in 36 Parts then then you have to take this formula up to 19-19”. By using this
formula, you can calculate layout marking for any no. of parts but you to make changes in Cos
Multiplying factor by increasing to next number than previous. So then Generalised Formula
for this will Become.
Ln = ��− (�� − ��)×

× ��((�� α) )
no. of parts.
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’ as shown
in given figure.
So, by using Numerical Formulae you can generate fabrication Layout Development of Pipe to
Pipe intersection with equal diameters in very faster and efficient way.
In above Two Methods we learn How to Layout Pipe to Pipe

Intersection with equal diameters Using Geometrical and Numerical Methods, now we will see
one Practical Example Solution Using Numerical Method so that we can understand in better
layouting by practicing it Practically.
30
Method
Example: Generate Fabrication Layout Development Markings for Pipe to Pipe

Intersection with equal diameters for Following Sizes:
500
3.
300
Solution:
Given Data:
D = 300
C = 500
& = Part Angle.

N = 12
P = Part Length.
Step 2: Calculate Q, P, R required for layout marking length calculations.
_ 360 360
* ...
=&
_ TIX ** -
P == 12 78.53
31
– D – 300 —
R= ,= 2 = 150
Step 4: Calculate development Marking lengths 1-1’, 2-2, 3-3', 4–4, 5-5, 6–6, 7-7.
1-1’ = C – (R × cos(0 × 0.) )

1-1'= 500 – (150 x cos(0 × 30).)
1-12- 350
2-2' = C – (R × cos(1 × 0.) )

2-2' = 500 – (150 × cos(1 × 30) )
2–22 = 370
3-3’ = C – (R × cos(2 × 0.) )

3-3’ = 500 – (150 x cos(2 x 30).)
3–3?= 425
4-4* = C – (R × cos(3 × 0.) )

4–4 = 500 – (150 x cos(3 x 30).)
4-4” = 500
5-5’ = 3-32 = 425
6–6’ = 2–2? = 370
7–72 = 1-12 = 350
32
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’.
This is Final Fabrication Layout Markings of pipe to Pipe intersections with Equal
Diameters for Given Example solved by using Numerical Method. You can Get Marking for
any size and using any no. of parts by using this method, you have practice this method to
become master in this type of layouting and after practicing you will have confidence in your
layouting and in latter part after become expert you reduce your work by using method with
the help of computerizes numerical tools, for increase your accuracy and save time of
calculations.
Now we will see this example Solution checking process so that you can assured about
your calculation and verify your result with some standard tested reference.
Example Solution Checking for Pipe to Pipe

Intersection with Equal Diameters
33
Application Icon:
Step 1: Select Pipe to Pipe Intersection with Equal Diameters Option from Application
Menu
Step 2: Enter Input data of Diameter and Centre Distance in input Fields and Press
Calculate Button.
34
Step 3: Check Result Values with your Calculated Values if your calculated values Match with
this Result Page Value then you are correct if your values is not matching with result page
become master in fabrication layout development of Pipe to Pipe Intersection.
35
with Unequal Diameters
Pipe to Pipe Intersection with unequal diameters is same as Pipe to Pipe intersection but
only Difference is that in this Branch Pipe and Main Pipe Diameters is Different. Pipe to Pipe
Intersection with unequal diameters is mostly used piping fabrication and it also has wide
application in Process Equipment Manufacturing for making branch Connection of Nozzles
Pipe or Shells. So, in this Chapter we are covering all the Points related to Pipe to Pipe
Intersection with unequal Diameters Fabrication Layout Development so that you can learn in
depth and used this method in daily fabrication activity.
Intersection with unequal Diameters Layout Development to understand use of this method
for layout Development, at the end of this Example Solution. We had also provided you
example solution checking method using our tool so that you can verify your calculation with
some tested tools and make you confident in fabrication layout. You can Practice this method
taking more examples yourself and verify your answer by our tools and become expert in Pipe
to Pipe intersection with unequal diameters Layout Development.

Intersection
Geometrical Method of Pipe to Pipe to Intersection with unequal diameters is also called
Graphical Method of Layout, in this layouting Method layout marking are developed using
direct measuring of Geometrical shape of Pipe to Pipe to Intersections of unequal Diameters.
This Method is Basic Method for fabrication Layout but it required much time to draw the
Now, we will move towards learning Pipe to Pipe to Intersections with unequal Diameters
Layout Development using Geometrical Method in Step by Step process.
36
Step 1: Draw Elevation View for Pipe to Pipe Intersection with unequal Diameters.
Step 2: Draw Half Circle View of Branch Pipe and Divide in to equal No. of Parts as
shown in Figure given below.
In this Figure Half Circle and Divided Parts are Highlighted by Red Colour for better
understanding.
37
Step 3: Project lines from Divided Points of half Circle as shown in figure.
Projected Lines are Highlighted using Green Colour.

Step 4: Mark Development Lines and Measure length of 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7
7’
Measure Green Colour Highlighted lines and note down the distance of this lines for
marking layout in next step.
38
Step 5: Mark Layout Using Measured Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’ as shown in
figure given below.
In this way we can generate fabrication layout of Pipe to Pipe Intersection with unequal
Diameters using Geometrical Method or Graphical Method of Fabrication Layout
Development.

Numerical Method for Pipe to Pipe Intersection with unequal Diameters Layout
way.
with unequal diameters Fabrication Layout Development.
Step 1: Define Pipe to Pipe intersection at 900 with unequal diameter Generalised Diagram.
39
Step 2: Define Variables for Pipe to Pipe Intersection with unequal diameters layout.
Let,
D = Main Pipe Diameter
d = Branch Pipe Diameter
& = Part Angle.

P = Part Length.
Step 3: Calculate Q, P, R, r etc required in fabrication layout marking calculations.
_ 360
O. = —
P = —
TX 'a
}
R =;
d
f E —
2
Step 4: Calculate development Marking lengths 1-1’, 2-2’, 3-3', 4–4, 5-5, 6-6, 7-7.
1-1 = C – VR2 – (rx sin(0 × 2)?

2-2' = C – VR2 – (rx sin(1 × 2)?
3-3 = C – VR2 – (rx sin(2 × 2))?
4–4 = C – VR2 – (rx sin(3× 2)”
5-5’ = 3-32
6–6’ = 2–2?
7-7 = 1-12
40
this layout in 12 Parts so that we had taken this formula up to 7-7” markings lengths. If you
to make layout in 36 Parts then then you have to take this formula up to 19-19”. By using this
Ln = ��− √��
− (��×sin((��− ��)× α))��
no. of parts.
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’ as shown
in given figure.
So, by using Numerical Formulae you can generate fabrication Layout Development of
Pipe to Pipe intersection with unequal diameters in very faster and efficient way.

Intersection with unequal diameters Using Geometrical and Numerical Methods, now we will
see one Practical Example Solution Using Numerical Method so that we can understand in
better layouting by practicing it Practically.
41
Method
Intersection with unequal diameters for Following Sizes:
600
500
Solution:
Given Data:
D = 500
d = 300
C = 600
N = 12
Step 2: Calculate Q, P, R, r etc. required for layout marking length calculations.
rº,
12-5-2s.
"jºi. 2 2
42
1-1 = C – VR2 – (rx sin(0 × 2))?

1-1 = 600 – V2502 – (150x sin(0x30)?
1–12 = 350
2-2' = C – VR4 – (rx sin(1 × 2))”

2-2 = 600 – V2502 – (150 x sin(1x30)?
2-2' = 361.51
3-3 = C – VR4 – (rx sin(2 × 2))”

3-3 = 600 – V2502 – (150 x sin(2 x 30)?
3-3’ = 386.45
4–4 = C – VR2 – (rx sin(3 × 2))”

4–4 = 600 – V2502 – (150x sin(3×30)?
4-4” = 400
5-5’ = 3-3”
6-6’ = 2–2”
7-7 = 1-12
Step 5: Mark Final Layout Using Calculated Length 1-1’, 2-2, 3-3', 4–4, 5-5, 6–6, 7-7°
§
78.53
This is Final Fabrication Layout Markings of pipe to Pipe intersections with unequal Diameters
for Given Example solved by using Numerical Method. You can Get Marking for
43
any size and using any no. of parts by using this method, you have practice this method to
calculations.

Intersection with unequal Diameters
Application Icon:
example Result Values with App results Value. Follow below Steps of Checking Solution of
Pipe to Pipe Intersection with unequal diameters we had also added Screen Shots for Better
Understanding of this Checking Methods.
44
Step 1: Select Pipe to Pipe Intersection with unequal Diameters Option from Application
Menu
Step 2: Enter Input data of Main Pipe Diameter, Branch Pipe Diameter and Centre
Distance in input Fields and Press Calculate Button.
Put offset distance as 0 in the above input field because we are taking Pipe to Pipe intersection
without offset so put zero value in offset distance.
45
Step 3: Check Result Values with your Calculated Values if your calculated values Match with
this Result Page Value then you are correct if your values is not matching with result page
In this Result Page it has taken 24 Parts for layout but our example has taken 12 Parts layouts
so you to keep in mind while checking result with this values that either you check your values
with alternate value such as L0, L2, L4, L6, L8, L10, L12 with your calculated values or You
Can Solve this example using 24 Parts and check your values with this Result Page Values. This
Checking Method is discussed with you so that you can verify your Fabrication layout
become master in fabrication layout development of Pipe to Pipe Intersection with unequal
diameters.
46
with offset Centres
Pipe to Pipe Intersection with offset centres having equal or unequal diameters. Pipe to
Pipe Intersection with offset centres is most widely fabrication Shape and it is majorly used
piping fabrication and it also has wide application in Process Equipment Manufacturing for
making branch Connection of Nozzles Pipe or Shells. So, in this Chapter we are covering all
the Points related to Pipe to Pipe Intersection with offset centres having equal or unequal
Diameters Fabrication Layout Development so that you can learn in depth and used this
method in daily fabrication activity.
Intersection with offset Centres Layout Development to understand use of this method for
more examples yourself and verify your answer by our tools and become expert in Pipe to Pipe
intersection with offset centres layout Development.

Intersection with Offset Centres
Geometrical Method of Pipe to Pipe to Intersection with offset centres having equal or
unequal diameters is also called Graphical Method of Pipe to Pipe Intersection with offset
centres layout, in this layouting Method layout marking are developed using direct measuring
of Geometrical shape of Pipe to Pipe to Intersections with offset centres. This Method is Basic
Method for fabrication Layout but it required much time to draw the Geometry of actual size
and it also has limitation for Bigger Sizes to avoid this limitation you have to use computerized
Now, we will move towards learning Pipe to Pipe to Intersections with offset Centres
Layout Development using Geometrical Method in Step by Step process.
47
Step 1: Draw Elevation View & Plan View for Pipe to Pipe Intersection with offset
centres.
Elevation View Top View or Plan View
Step 2: Draw Circle of Branch Pipe in Top View or Plan View and Divide in to equal No.
of Parts.
In this Figure Branch Pipe Circle and Divided Parts are Highlighted by Red Colour for
better understanding.
48
Step 3: Project lines from Divided Points of Circle as shown in figure.
7’, 8-8’, 9-9’, 10-10’, 11-11’, 12-12’.
Measure Green Colour Highlighted lines and note down the distance of this lines for marking
layout in next step.
49
Step 5: Mark Layout Using Measured Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’, 8-8’, 9-9’, 10
10’, 11-11’, 12-12’.
In this way we can generate fabrication layout of Pipe to Pipe Intersection with offset centres
using Geometrical Method or Graphical Method of Fabrication Layout Development.

with offset Centres
Numerical Method for Pipe to Pipe Intersection with offset centres Layout Development is
very faster and time saving method for layouting, you can calculate the values of layout
dimension by solving manually on scientific calculator or you can use any computerized tool
for solving such as MS excel or any other tool for Calculates Values in faster way.
with offset centres of fabrication layout development.
Step 1: Define Pipe to Pipe intersection with offset Centres Generalised Diagram.
50
Step 2: Define Variables for Pipe to Pipe Intersection with offset Centres layout
Let, C
D = Main Pipe Diameter

O = Offset Distance.
& = Part Angle.

P = Part Length.
\LA—I:
Step 3: Calculate Q, P, R, r etc. required in fabrication layout marking calculations.
_ 360
O. = —
P = —
TX "a
B"
R =#
d
f E —
2
51
Step 4: Calculate development Marking lengths 1-1’, 2-2, 3-3', 4–4, 5-5, 6-6, 7-7’, 8-8, 9
9', 10-10°, 11–11’, 12-12’.
1-1 = C – VR2 = ( 0 – (rx sin(0 × 2)))?

2-2' = C – VR2 — (O - (rx sin(1 × 2)))?
3-3 = C – VR2 — (O - (rx sin(2 × 2)))?
4–4 = C – VR2 = (0 – (rx sin(3 x 2)))?
5-5’ = C – VR2 = (0 – (rx sin(4 × 2)))?
6-6 = C – VR2 – ( 0 – (rx sin(5 × 2)))?
7-7 = C – VR2 – ( 0 – (rx sin(6 × 2)))?
8-8 = C – VR2 — (O - (rx sin(7× 2)))?
9-9 = C – VR2 = (0 – (rx sin(8 × 2)))?
10-10 = c – VR2 = ( 0 – (rx sin(9 × 2)))?
11-11 = C – VR2 = ( 0 – (rx sin(10 × 2)))?
12-12' = C – VR2 = ( 0 – (rx sin(11 × 2)))?
this layout in 12 Parts so that we had taken this formula up to 12-12 markings lengths. If you
want to make layout in 24 Parts then you have to take this formula up to 24-24’ or if you want
to make layout in 36 Parts then then you have to take this formula up to 36-36’. By using this
Ln = C – VR2 – (O - (rx sin((n − 1) × 2)))”

no. of parts.
52
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’, 8-8’, 9-9’,
10-10’, 11-11’, 12-12’.
Pipe to Pipe intersection with offset centres in very faster and efficient way.

Intersection with offset Centres Using Geometrical and Numerical Methods, now we will see
one Practical Example Solution Using Numerical Method so that we can understand in better
53
Method
Intersection with offset Centres for Following Sizes:
800
§
LA—
Solution:
Given Data:
D = 650
d = 500
C = 800
O = 75
N = 12
Step 2: Calculate Q, P, R, r etc. required for layout marking length calculations.
360 360
- = − = 30
Step 3: Calculate development Marking lengths 1-1’, 2-2’, 3-3', 4–4, 5-5, 6–6, 7–7, 8–8’, 9-9.,
10-10°, 11–11’, 12-12’.
1-1 = c – VR2 – Co - (rx sin(0x2)))?

1-1 = 800 – V3252 – (75 – (250× sin(0x30)))?
1–12 = 483.77
2-2' = c – VR2 – Go - (rx sin(1xx)))?

2-2 = 800 – V3252 – (75 – (250× sin(1x30)))?
2–22 = 478.87
3-3 = C – VR2 = (0 – (rx sin(2 × 2)))?

3-3 = 800 – V3252 – (75 – (250× sin(2x30)))?
3-32 = 507.42
4–4 = c – VR2 = Co - (rx sin(3x2)))?

4–4 = 800 – V3252 – (75 – (250× sin(3 x 30)))?
4-4” = 526.13
5-5’ = c – VR2 = Co - (rx sin(4x2)))?

5-5 = 800 – V3252 – (75 – (250× sin(4 x 30)))?
5-5’ = 507.42
6-6 = c – VR2 = (0 – (rx sin(5× 2)))?

6-6 = 800 – V3252 – (75 – (250× sin(5x30)))?
6-6’ = 478.87
7-7 = c – VR2 – Go – (rx sin(6x2)))?

7-7 = 800 – V3252 – (75 – (250× sin(6x30)))?
7–7 = 483.77
8-8 = c – VR2 – Go – (rx sin(7x2)))?

8-8 = 800 – V3252 – (75 – (250× sin(7x30)))?
8-8’ = 543.82
9-9 = c – VR2 – Go - (rx sin(8 × 2)))?

9-9 = 800 – V3252 – (75 – (250× sin(8 x 30)))?
9-9° = 656.30
55
10-10 = c – VR2 = Co - (rx sin(9xx)))?
10-10 = 800 – V3252 – (75 – (250× sin(9 × 30).)?
10-10’ = 800
11-11 = c – VR2 = Co - (rx sin(10x2)))?

11-11 = 800 – V3252 – (75 – (250× sin(10 x 30)))?
11-11” = 656.30
12-12 = c – VR2 – Co - (rx sin(11 × 2)))?

12-12 = 800 – V3252 – (75 – (250× sin(11 × 30)))?
12–12? = 543.82
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2, 3-3', 4–4, 5-5, 6–6, 7–7, 8–8’, 9-9.,
10-10°, 11–11’, 12-12’.
y/N
1 2 3. 4
-
6 7 8'
N-| N-| CN
CO
CN | N-|
|
N
Co 3|3| 3
'I OO -
is oſ St| X| St| ol is : 3 $3
g| go|| > | {{{| S] go| g| $#| Cô CO
Cºl S.
*F|
$2| S] $2|
< | LO
S. &
10| < | ºf
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1 2 3 4 5 6 7 8 9 10 11 12 1
This is Final Fabrication Layout Markings of Pipe to Pipe intersections with offset centre
for Given Example solved by using Numerical Method. You can Get Marking for any size and
using any no. of parts by using this method, you have practice this method to become master
in this type of layouting and after practicing you will have confidence in your layouting and in
latter part after become expert you reduce your work by using method with the help of
computerizes numerical tools, for increase your accuracy and save time of calculations.
56
Intersection with Offset Centres
Application Icon:
Pipe to Pipe Intersection with offset centres we had also added Screen Shots for Better
Step 1: Select Pipe to Pipe Intersection with offset centres Option from Application Menu
57
Step 2: Enter Input data of Main Pipe Diameter, Branch Pipe Diameter and Centre Distance
and offset centres in input Fields and Press Calculate Button.
In this Result Page it has taken 24 Parts for layout but our example has taken 12 Parts layouts
so you to keep in mind while checking result with this values that either you check your values
with alternate value such as L0, L2, L4, L6, L8, L10, L12, L14, L16, L18, L20, L22, L24 with
your calculated values or You Can Solve this example using 24 Parts and check your values
with this Result Page Values. This Checking Method is discussed with you so that you can
verify your Fabrication layout Development Dimension and also verify it so that you can Build
trust on your calculated values once you verify that you can calculate results accurately then
you can say that you become master in fabrication layout development of Pipe to Pipe
Intersection with offset diameters.
58
6. Pipe to Cone Intersection
Perpendicular to Axis
Pipe to Cone Intersection perpendicular to Axis Geometry is useful in equipment

fabrication where Nozzle Pipe is to be fitted on Conical Shape and it has many other
application where such types of geometrical problem is arises then we had make this type
layout for fabrication of this Joints Connection in Piping Industry it also has widely used
connections. So, in this Chapter we are covering all the Points related to Pipe to Cone
Intersection Perpendicular to Axis Connection Fabrication Layout Development so that you
can learn in depth and used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Pipe to Cone
Intersection perpendicular to Axis Layout Development to understand use of this method for
more examples yourself and verify your answer by our tools and become expert in Pipe to
Cone intersection Perpendiculars to Axis Fabrications layout Development.
Geometrical Method for Pipe to Cone

Intersection Perpendicular to Axis
Geometrical Method of Pipe to Cone Intersection Perpendicular to Axis is also called
Graphical Method of Pipe to Cone Intersection perpendicular to Axis, in this layouting
Method layout marking are developed using direct measuring of Geometrical shape of Pipe to
Cone Intersections perpendicular to Axis. This Method is Basic Method for fabrication Layout
but it required much time to draw the Geometry of actual size and it also has limitation for
Bigger Sizes to avoid this limitation you have to use computerized tool Such as Auto Cad
Now, we will move towards learning Pipe to Cone Intersections Perpendicular to Axis
Connection layout Development using Geometrical Method in Step by Step process.
59
Step 1: Draw Elevation View & Plan View for Pipe to Cone Intersection at Perpendicular
Axis.
Step 2: Draw Half Circle for Pipe in Elevation View and Divide in to equal No. of Parts
better understanding.
60
Step 3: Project lines from Divided Points of Circle as shown in figure
7’, 8-8’, 9-9’, 10-10’, 11-11’, 12-12’.
61
Step 5: Mark Layout Using Measured Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’, 8-8’, 9-9’, 10
10’, 11-11’, 12-12’.
In this way we can generate fabrication layout of Pipe to Cone Intersection perpendicular to
Axis using Geometrical Method or Graphical Method of Fabrication Layout Development.
Numerical Method for Pipe to Cone

Numerical Method for Pipe to Cone Intersection Perpendicular to Axis layout
way.
Now we will move towards learning Numerical Method for Pipe to Cone Intersection
Perpendicular to Axis of fabrication layout development.
Step 1: Define Pipe to Cone intersection Perpendicular to Axis Generalised Diagram
62
Step 2: Define Variables for Pipe to Cone Intersection Perpendicular to Axis.
Let,
D1 = COne Base Diameter

D2 = Cone Top Diameter
H = Cone Height
h = Cone Base Pipe Centre distance
C = Cone Centre to Pipe End Distance
T = Cone Overall Height.
Q = Cone Angle.
© = Part Angle.
P = Part Length.
Step 3: Calculate Q, P, T, r etc required in fabrication layout marking calculations.
360
(S) = -
P = —
TX 'a
D1–D2
tan Oz F
2×H
_ D1/2
tan 0.
1 F d
63
Step 4: Calculate development Marking lengths 1-1’, 2-2’, 3-3', 4–4, 5-5, 6–6, 7-7,8-8’, 9-9.,
10-10°, 11–11’,12–12?
1-1 = C – V((T- (h – r > cos(0 × O))) x tan & )” – (rx sin(0 × O))”
2-2' = C – VC (T = (h – r x cos(1 × O))) x tan & )? – (rx sin(1 × O))”
3-3 = C – VC (T = (h – r x cos(2 × O))) x tan & )? – (rx sin(2 × 0))”
4–4 = C – VC (T = (h – r x cos(3× O))) x tan & )? – (rx sin(3× O))”
5-5’ = C – V((T – (h – rx cos(4 × O))) x tan & )” – (rx sin(4 × O))”
6-6 = C – V((T – (h – rx cos(5 × O))) x tan & )” – (rx sin(5 × O))”
7-7 = C – V((T – (h – rx cos(6 × O))) x tan & )” – (rx sin(6 × O))”

8–8? = 6–6?
9–92 = 5-5°
10-10’ = 4-4”
11-11” = 3-3”
12–12? = 2–2?
this layout in 12 Parts so that we had taken this formula up to 12-12 markings lengths. If you
Ln = C –
V((T- (h-rx cos((n − 1) x 0))) & tang)? – (rx sin((n-1) x 0))?
no. of parts.
64
10-10’, 11-11’, 12-12’.
Pipe to Cone intersection perpendicular to Axis in very faster and efficient way.
In above Two Methods we learn How to Layout Pipe to Cone

Intersection perpendicular to Axis. Using Geometrical and Numerical Methods, now we will
see one Practical Example Solution Using Numerical Method so that we can understand in
better layouting by practicing it Practically.

Method
Intersection perpendicular to Axis for Following Sizes:
65
Solution:
Given Data:
D1 = 500
D2 = 150
H = 375
d = 200
h = 185
C = 350
N = 12
Step 2: Calculate Q, P, R, r etc required for layout marking length calculations.
360 360
e =# =#=30
_ Itxd
P= -
Itx200 = 52.35
N N
tan OZ =
D1–D2 _ 500–150
; F ===== 0.4667
_ D1/2 500/2
T tan & T 0.4667 T 535.67
d 200
r = 7 –-- 100
Step 3: Calculate development Marking lengths 1-1’, 2-2’, 3-3', 4–4, 5-5, 6-6, 7–7, 8-8, 9
9', 10-10°, 11–11’, 12-12’.
1-1 = c – VC (T = (h-r cos(0 × 6))) & tang)” – (rx sin(0x6)?
1-1 = 350 – VOC535.67 – (185–100x cos(0x0)× 0.4667)? – (100x sin(0x0)?

1–1 = 139.67
66
2-2' = c – V((T = (h-rcos(1 x 0))); tanz)? - (rx sin(1 x 0))?
2-2' = 350 —
V((535.67 – (185–100x cos(1x30)× 0.4667)? – (100x sin(1 x 30)?

2–22 = 152.14
3-3 = c – VC (T- (h-rcos(2 x 0))); tang)? – (rx sin(2 x 9))”

3-3’ = 350 —
VC (535.67 – (185–100x cos(2x30))) & 0.4667)? - (100x sin(2x30)?

3-32 = 184.27
4–4 = c – VCCT= (h-rcos(3× 6))) & tanz)? – (rx sin(3× 6)?

4-4” = 350 —
V((535.67 – (185–100x cos(3x30)× 0.4667)? – (100x sin(3 x 30)?

4-4” = 220.44
5-5 = c – VCCT= (h-rcos(4 × 6)×tanz)? – (rx sin(4 × 6)?

5-5’ = 350 —
VC (535.67 – (185–100x cos(4x30))) & 0.4667)? - (100x sin(4×30)?

5-5’ = 239.58
6-6 = c – VCCT= (h-rcos(5× 6))) & tanz)? – (rx sin(5x6)?

6-6’ = 350 —
V((535.67 – (185–100x cos(5x30)× 0.4667)? – (100x sin(5x30))?

6-6’ = 237.35
7-7 = c – VCCT= (h-rcos(6 x 6))) & tanz)? – (rx sin(6x6)?

7–7 = 350 —
VC (535.67 – (185–100x cos(6x30))) & 0.4667)? - (100x sin(6x30)?

7–7 = 233
8-8’ = 6-6’;
9-9' = 5-5';
10-10' = 4-4';
67
11-11’ = 3-3’
12-12’ = 2-2’
10-10’, 11-11’, 12-12’.
This is Final Fabrication Layout Markings of Pipe to Cone intersections perpendicular to

Axis for Given Example solved by using Numerical Method. You can Get Marking for any
size and using any no. of parts by using this method, you have practice this method to become
master in this type of layouting and after practicing you will have confidence in your layouting
and in latter part after become expert you reduce your work by using method with the help of
Example Solution Checking for Pipe to Cone

68
Application Icon:
Pipe to Pipe Intersection Perpendicular to Axis. we had also added Screen Shots for Better
Step 1: Select Pipe to Cone Intersection Perpendicular to Axis Option from Application
Menu
Step 2: Enter Input data of Cone Large End Diameter, Small End Diameter, Cone Hight,
Nozzle Diameter, Centre to End Distance, Nozzle Height in the input Fields and Press
Calculate Button.
69
become master in fabrication layout development of Pipe to Cone Intersection perpendicular
to Axis.
70
7. Pipe to Cone Intersection
Parallel to Axis
Pipe to Cone Intersection Parallel to Axis Geometry is useful in equipment fabrication

where Nozzle Pipe is to be fitted on Conical Shape and it has many other application where
such types of geometrical problem is arises then we had make this type layout for fabrication of
this Joints Connection in Piping Industry it also has widely used connections. So, in this
Chapter we are covering all the Points related to Pipe to Cone Intersection parallel to Axis
Connection Fabrication Layout Development so that you can learn in depth and used this
at the end of learning this Methods, we have taken one practical Example of Pipe to Cone
Intersection parallel to Axis Layout Development to understand use of this method for layout
more examples yourself and verify your answer by our tools and become expert in Pipe to
Cone intersection Parallel to Axis Fabrication layout Development.
Geometrical Method for Pipe to Cone

Intersection Parallel to Axis
Geometrical Method of Pipe to Cone Intersection Parallel to Axis is also called Graphical
Method of Pipe to Cone Intersection Parallel to Axis, in this layouting Method layout marking
are developed using direct measuring of Geometrical shape of Pipe to Cone intersection
parallel to Axis. This Method is Basic Method for fabrication Layout but it required much time
to draw the Geometry of actual size and it also has limitation for Bigger Sizes to avoid this
limitation you have to use computerized tool Such as Auto Cad Software and to developed
layout using this software also required skilled manpower to generate layout it cost us more in
terms of extra skilled manpower and extra time for drawing layout. If fabrication layout shape
is complex then it is not economical.
Now, we will move towards learning Pipe to Cone Intersections Parallel to Axis
Connection layout Development using Geometrical Method in Step by Step process.
71
Step 1: Draw Elevation View & Plan View for Pipe to Cone Intersection at Parallel to
Axis.
Step 2: Draw Half Circle for Pipe in Elevation View and Divide in to equal No. of Parts
72
better understanding of this step.
Step 3: Project lines from Divided Points of Circle as shown in figure
Step 4: Mark Development Lines and Measure length of 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’
etc.
73
Step 5: Mark Layout Using Measured Length 1-1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’.
In this way we can generate fabrication layout of Pipe to Cone Intersection Parallel to Axis
Numerical Method for Pipe to Cone

Numerical Method for Pipe to Cone Intersection Parallel to Axis layout Development is
Now we will move towards learning Numerical Method for Pipe to Cone Intersection
Parallel Axis fabrication layout development.
to
Step 1: Define Pipe to Cone intersection at Parallel to Axis Generalised Diagram
74
Step 2: Define Variables for Pipe to Cone Intersection Parallel to Axis.
Let,
D1 = COne Base Diameter

D2 = Cone Top Diameter
H = Cone Height
h = Cone Base Pipe End distance
C = Cone Centre to Pipe Centre Distance
T = Cone Overall Height.
Q = Cone Angle.
© = Part Angle.
P = Part Length.
Step 3: Calculate Q, P, T, r etc required in fabrication layout marking calculations.
360
(S) = -
N
TIXd
P = —
N
D1–D2
tan OZ =
2×H
_ D1/2
tan 0.
1 F d
T2
1-1’ = h – (T – (G/[GTF × cos (0 × 0) )* + (rx sin(0 × 0))” )/tana)

2-2' = h – (T – (C/CTFx cos (1 × 0) )* + (rx sin(1 × 0))” )/tana)
75
3–3’ = h – (t–(G/(CTFxcos(2 × 0))2 + (rx sin(2 × 0))?
4–4 = h -(T-(
= (T – ((V(C + r x cos (3× O))2 + (rx sin(3× O))?
5-5’ = h – (t–(G/(CTFxcos(4x6) )2 + (rx sin(4 × O))?

6-6 = h = (T = ((V(C + r x cos (5 × 0))2 + (rx sin(5 × 0))?
7-7 = h – (T – (G/(CTF × cos (6 x 0))” + (rx sin(6 x 0))”

want to make layout in 24 Parts then you have to take this formula up to 13-13'or if you want
to make layout in 36 Parts then then you have to take this formula up to 19-19'. By using this
Ln = h – (T-((MCTFxcos(n=TX6) )2 + (rx sin((n − 1) × O))? )/tana)

no. of parts.
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2’, 3-3', 4–4, 5-5, 6-6, 7-7.
1 2 3 4 5 6 7 6 5 4 3 2
76
Pipe to Cone intersection Parallel to Axis in very faster and efficient way.
In above Two Methods we learn How to Layout Pipe to Cone

Intersection Parallel to Axis. Using Geometrical and Numerical Methods, now we will see one
Practical Example Solution Using Numerical Method so that we can understand in better

Method
Intersection Parallel to Axis for Following Sizes:
Solution:
Given Data:
D1 = 500
D2 = 150
H = 375
d = 100
h = 395
C = 165
N=1
77
Step 2: Calculate Q, P, R, r etc required for layout marking length calculations.
360 — 360 —
e ======30
P = ** = tº -26.18
tang =#=#= 0.4667
= P1/* = 30% = 535.67
tang T 04667
1-1 = h = (T-((V(C + r x cos(0x6))2+ (rx sin(0 × 6)? )/tan & )
1-1 = 395 – (535.67–((\ſ(165+ 50x cos(0x0))3 + (50x sin(0x0)? )/0.4667)

1–12 = 320
2-2' = h = (T = ((V(C-Frx cos(1x oy)2+ (rx sin(1× 6)? )/tan & )
2-2 = 395 – (535.67 – ((V(165+ 50x cos(1x30))3 + (50 x sin(1x30)? )/0.4667)

2-2' = 308.86
3-3 = h = (T-((V(C + r x cos(2 × 6))2+ (rx sin(2 × 6)? )/tan & )
3-3 = 395 – (535.67 – ((V(165+ 50x cos(2x30))3 + (50x sin(2x30)? )/0.4667)

3-32 = 276.88
4–4 = h = (T = ((V(C-Frx cos(3× 6))2+ (rx sin(3× 6)? )/tan & )
4–4 = 395 – (535.67 – ((V(165+ 50x cos(3×30))3 + (50 x sin(3×30)? )/0.4667)

4-4” = 228.75
78
5-5 = h = (T-((V(C + r x cos(4 × 6))2+ (rx sin(4 × 6)?)/tan & )
5-5 = 395 – (535.67 – ((V(165+ 50x cos(4×30))3 + (50 x sin(4×30)? )/0.4667)

5-5’ = 173.32
6-6 = h = (T = ((V(C-Frx cos(5x O)2+ (rx sin(5× 6)? )/tan & )
6-6 = 395 – (535.67 – ((V(165+ 50x cos(5x30))3 + (50 x sin(5x30)? )/0.4667)

6-6’ = 125.53
7-7 = h = (T-((V(C + r x cos(6 x 6))2+ (rx sin(6x6)?)/tan & )
7-7 = 395 – (535.67 – ((V(165+ 50x cos(6x30))3 + (50x sin(6x30)? )/0.4667)

7–7 = 105.74
Step 5: Mark Layout Using Calculated Length 1-1’, 2-2’, 3-3', 4–4, 5-5, 6-6, 7-7°
1.
|->
s
§
::
26.18
1 2 3 4 5 6 7 6 5 4 3 2 1
This is Final Fabrication Layout Markings of Pipe to Cone intersections Parallel to Axis for
Given Example solved by using Numerical Method. You can Get Marking for any size and
using any no. of parts by using this method, you have practice this method to become master
in this type of layouting and after practicing you will have confidence in your layouting and in
latter part after become expert you reduce your work by using method with the help of
79
Example Solution Checking for Pipe to Cone
Application Icon:
Pipe to Pipe Intersection Parallel to Axis diameters we had also added Screen Shots for Better
Understanding of this Checking Methods
.
Step 1: Select Pipe to Cone Intersection Parallel to Axis Option from Application Menu
80
Step 2: Enter Input data of Cone Large End Diameter, Small End Diameter, Cone Hight,
Nozzle Diameter, Nozzle Centre Distance, Nozzle Height in the input Fields and Press
Calculate Button.
become master in fabrication layout development of Pipe to Cone Intersection Parallel to Axis.
81
8. Full Cone Layout
Development
Full Cone is very common shape in fabrication industry as it is most frequently used shape
in fabrication so it is very necessary that every fabrication engineer or professionals in
fabrication field must have knowledge of Cone layout Development if you have detailed
knowledge of cone fabrication it is very useful to you while working in fabrication daily
activities. So, in this Chapter we are covering all the Points related to Full Cone Fabrication
Layout Development so that you can learn in depth and used this method in daily fabrication
activity.
at the end of learning this Methods, we have taken one practical Example of Full Cone
Fabrication Layout Development to understand use of this method for layout Development, at
the end of this Example Solution. We had also provided you example solution checking
method using our tool so that you can verify your calculation with some tested tools and make
you confident in fabrication layout. You can Practice this method taking more examples
yourself and verify your answer by our tools and become expert in Full Cone Fabrication
Layout Development.
Geometrical Method for Full Cone Layout

Geometrical Method of Full Cone Fabrication Layout Development is also called
Graphical Method of Full Cone Layout Development, in this layouting Method layout marking
are developed using direct measuring of Geometrical shape of Full Cone. This Method is Basic
Now, we will move towards learning Full Cone Fabrication Layout Development using
Geometrical Method in Step by Step process.
82
Step 1: Draw Elevation View & Plan View for Full Cone Shape.
Step 2: Divide Top View Circle of Cone in equal no. of Parts
Step 3: Measure Slant Height of the Cone in elevation view.
83
Step 4: Draw Development Circle with Radius as Slant Height
Step 5: Measure Dividing Distance (L) From the Top view of Divided Circle.
84
Step 6: Mark the Development Circle with Dividing Distance (L) in to equal no of parts in
top view.
Step 7: Trim the remaining part to get layout of the Full Cone.
In this way we can generate fabrication layout of Full Cone using Geometrical Method or
Graphical Method of Fabrication Layout Development.
85
Numerical Method for Full Cone Layout
Numerical Method for Full Cone layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Full Cone fabrication
layout development in this Method We are Discussing Two Cases for Layout Development.
Case 1: Cone Angle and Cone Diameter Given

Step 1: Define Generalised Diagram of Full Cone Layout Development
Step 2: Define Variables for Full Cone Layout
Let,
D = Base Mean Diameter of Cone.

α = Cone Angle
β = Cone Included Angle.
R = Development Radius.
Θ = Development Angle.
X = Cone Cord Length.
86
Step 3: Calculate Development Radius R of Full Cone.
If x is given then,
D/2
Cos (c.)
If B is given then,
D/2
Sin (#)
Step 4: Calculate Development Angle ().
e = ** - 360
Step 4: Calculate Cone Cord Length X
X = 2* R + sin (O/2)
Step 5: Development of Cone Layout
In this way we can develop fabrication Layout when we had problem like case-1 where
Cone angle and Cone Diameter is Given.
Now we will see Case-2 type problem of fabrication layout Development.
87
Case 2: Cone Diameter and Cone Height Given
Step 1: Define Generalised Diagram for Full Cone Layout Development.
——
Step 2: Define Variables for Full Cone Layout
Let,
D = Base Mean Diameter of Cone.

H = Cone Height. -
R = Development Radius.
() = Development Angle.
X = Cone Cord Length.
—
Step 3: Calculate Development Radius R.
R = WCH3TCD72)?
Or,
a = tan-"(+)
(#)
D/2
Cos (c.)
88
Step 4: Calculate Development Angle Θ.
��/��
Θ= ∗ ��
Step 5: Calculate Cone Cord Length X.
X = 2* R * ��(
Θ/2)
Step 6: Development of Cone Layout
So, by using Numerical Formulae you can generate fabrication Layout Development of Full
Cone in very faster and efficient way.
In above Two Methods we learn How to Layout Full Cone Using

89
Method
Example: Generate Fabrication Layout Development Markings of Full Cone for

Following Sizes:
500
Solution:
Given Data:
D = 500
H = 750.
Step 2: Calculate Development Radius R
R = y/(H2 + (D/2)?
R = \ſ(7502I (500/2)?
R = 790.56
Step 3: Calculate Development Angle C)
(S) —
= D/2
R
_
+ 360 = 500/2
790.56 + 360 = 113.84
-
90
Step 4: Calculate Cone Cord Length X
X = 2* R * ��(
Θ/2) = 2* 790.56* ��(
113.84) = 1324.83
Step 4: Mark Development Layout Using Above Dimensions.
This is Final Fabrication Layout Markings of Full Cone for Given Example solved by using
Numerical Method. You have practice this method to become master in this type of layouting
and after practicing you will have confidence in your layouting and in latter part after become
expert you reduce your work by using method with the help of computerizes numerical tools,
for increase your accuracy and save time of calculations.
Example Solution Checking for Full Cone

91
Mobile Application Name: Cones Calculators
Application Icon:
Full Cone Layouts we had also added Screen Shots for Better Understanding of this Checking
Methods.
Step 1: Select Cone Option from Application Menu.
Step 2: Enter Input data of Cone Diameter and Cone Height in the input Fields and Press
Calculate Button.
Here Please keep in mind that while testing your results through cones calculator that if
you want to check for Full Cone then put Large End Diameter and Put Zero Value in Small
End Diameters. We had shown this by putting inputs as shown below.
92
In Such way that You can Check you Result by this Process or you can also check using
any methods you known. We are using this method we had already tested result of this app so
we testing our result using this application.
93
9. Truncated Cone Layout
Development
Truncated cone or Half Cone is also very common shape in fabrication industry as it is
most frequently used shape in fabrication so it is very necessary that every fabrication engineer
or professionals in fabrication field must have knowledge of Truncated Cone layout
Development if you have detailed knowledge of cone fabrication it is very useful to you while
working in fabrication daily activities. So, in this Chapter we are covering all the Points related
to Truncated Cone Fabrication Layout Development so that you can learn in depth and used
this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Truncated Cone
yourself and verify your answer by our tools and become expert in Truncated Cone Fabrication
Layout Development.
Geometrical Method for Truncated Cone Layout

Geometrical Method of Truncated Cone Fabrication Layout Development is also called
Graphical Method of Truncated Cone Layout Development, in this layouting Method layout
marking are developed using direct measuring of Geometrical shape of Truncated Cone. This
Method is Basic Method for fabrication Layout but it required much time to draw the
94
Now, we will move towards learning Truncated Cone Fabrication Layout Development
Step 1: Draw Elevation View & Plan View for Truncated Cone Shape.
Step 2: Divide Top View Circles of Cone in equal Parts
95
Step 3: Project Lines in elevation view to find cone intersection point or vertex of Cone.
Step 4: Measure Small and Large Slant Height of the Cone in elevation view.
96
Step 5: Draw Development Outer Circle with Radius as Large Slant Height and Inner
Circle with Radius as Small Slant Height.
97
Step 7: Mark the Development Circles with Dividing Distance (L) in to equal no of parts
in top view
Step 8: Trim the Remaining Extra part to get layout of the Full Cone.
In this way we can generate fabrication layout of Full Cone using Geometrical Method or
98
Numerical Method for Truncated Cone Layout
Numerical Method for Truncated Cone layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Truncated Cone
fabrication layout development in this Method We are Discussing Two Cases for Layout
Development.
Step 1: Define Generalised Diagram of Truncated Cone Layout Development
Step 2: Define Variables for Truncated Cone Layout
Let,
dD==Mean DiameterofofCone.
LargeDiameter
MeanSmall Cone.
H = Height of the Cone.

α = Cone Angle
R1 = Large Development Radius.
R2 = Small Development Radius
X1 Large Cord Length.
Θ ==Development Angle.
X2 = Small Cord Length.
99
Step 3: Calculate Development Radius R1 & R2
D—d
B = —
2
a = tan-"(#)
D/2
R1 ==%
Sin (0, )
d/2
Sin (0, )
D/2
e = **
R1
360
Step 4: Calculate Large Cord Length X1 & Small Cord Length X2
X1 = 2* R1 * sin (G/2)
X2 = 2* R2 * sin (O/2)
Step 5: Development of Truncated Cone Layout
x1
100
So, by using Numerical Formulae you can generate fabrication Layout Development of Full
Cone in very faster and efficient way.
In above Two Methods we learn How to Layout Full Cone Using


Method
Example: Generate Fabrication Layout Development Markings of Truncated Cone for
Following Sizes:
Solution:
Given Data:
D = 500
d = 250
H = 350.
Step 2: Calculate Development Radius R1 & R2.
B = ��−��
= ��−��
= 125
��
101
o, = tan—1*( B
- —1 125
- -
H ) = tanT"( 350 ) = 19.65
= P/* = */* =
Tsin (a) Tsin (1965) 743.44
= */* = **/* =
Tsin (2) Tsin (1965) 371.72
Step 3: Calculate Development Angle ()
e = **
R1
- 360 = 743.44.
** - 360 = 121.05
X1 = 2* R1 * sin (O/2)
X1 = 2* 743.44 * sin (121.05 / 2)
X1 = 1294.4
X2 = 2* R2 * sin (O/2)
X2 = 2* 371.72 * sin (121.05/2)
X2 = 647.21

1294.4
743.44
647.21
102
This is Final Fabrication Layout Markings of Truncated Cone for Given Example solved
by using Numerical Method. You have practice this method to become master in this type of
layouting and after practicing you will have confidence in your layouting and in latter part after
become expert you reduce your work by using method with the help of computerizes
numerical tools, for increase your accuracy and save time of calculations.
Example Solution Checking for Truncated Cone

Application Icon:
Truncated Cone Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
103
Step 1: Select Truncated Cone Option from Application Menu.
Step 2: Enter Input data of Cone Large End Diameter, Small End Diameter and Cone
Height in the input Fields and Press Calculate Button.
104
In Such way that You can Check your Result by this Process or you can also check using
105
10. Multilevel Cone Layout
Development
Multilevel Cone Layout Development is similar to Full Cone or Truncated Cone Layout
but Multilevel Cone Concept come in to picture when Full Cone or Truncated Cone is bigger
in size such way that we cannot make cone layout in Single part due limitation of sheet sizes
available with us in that situation multilevel cone concept is arise. In Multilevel Cone Just Full
Cone or truncated Cone is divide in to no of Parts Height Wise I called Multilevel Cone. So, in
this Chapter we are covering all the Points related to Multilevel Cone Fabrication Layout
Development so that you can learn in depth and used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Multilevel Cone
yourself and verify your answer by our tools and become expert in Multilevel Cone Fabrication
Layout Development.
Geometrical Method for Multilevel Cone Layout

Geometrical Method of Multilevel Cone Fabrication Layout Development is also called
Graphical Method of Multilevel Cone Layout Development, in this layouting Method layout
marking are developed using direct measuring of Geometrical shape of Multilevel Cone. This
Now, we will move towards learning Multilevel Cone Fabrication Layout Development
106
Step 1: Draw Elevation View & Plan View for Multilevel Cone Shape.
In this Process we had just taken four levels for Simplification you can use this method for
any no of level as per your requirements.
Step 2: Divide Top View Circles of Cone in equal Parts
107
Step 3: Measure R1, R2, R3, R4 and so on for next level of the Multilevel Cone in elevation
view.
Step 4: Draw Development Circles with Radius as R1, R2, R3, R4 and so on for Multi-level
Cone.
108
Step 6: Mark the Development Circles with Dividing Distance (L) in to equal no of
parts in top view.
109
Step 7: Trim the Remaining Extra part to get layout of the Full Cone.
If You want to make it in Radial Parts then Follow below steps.
Multilevel Cone Radial Parts Development
Step 8: Divide the Final layout with equal no of parts radially with equal angle.
In this way we can generate fabrication layout of Multilevel Cone using Geometrical
110
Numerical Method for Multilevel Cone Layout
Numerical Method for Multilevel Cone layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Multilevel Cone
fabrication layout development.
Step 1: Define Generalised Diagram of Multilevel Cone Layout Development.
Step 2: Define Variables for Multilevel Cone Layout
Let,
D1, D2, D3, D4 = Mean Diameter of Cone at level L1, L2, L3, L4.
T = Overall Height of Cone.
H = Level Height of the Cone.
α = Cone Angle
R1, R2, R3, R4 = Development Radius of Cone at Level L1, L2, L3, L4.
X1, X2, X3, X4 = Cord Length of the Cone at Level L1, L2, L3, L4.
111
Step 3: Calculate Development Radius R1, R2, R3, R4 etc.
& = tant"( wº )
D2 = 2 × (T – (1 × H)) × tan &
D3 = 2 × (T – (2 × H)) × tan &
D4 = 2 × (T- (3 × H)) × tan &
D1/2
R1 =
Sin (0, )
D2/2
Sin (0, )
D3/2
Sin (0, )
D4/2
T sin(x)
e = **
R1
360
112
Step 4: Calculate Large Cord Length X1, X2, X3, X4 etc.
X1 = 2* R1 * sin (O/2)
X2 = 2* R2+ sin (O/2)
X3 = 2* R3 * sin (O/2)
X4 = 2* R3 * sin (O/2)
Step 5: Development of Multilevel Cone Layout.
X1
Multilevel Cone in very faster and efficient way.
In above Two Methods we learn How to Layout Multilevel Cone

Using Geometrical and Numerical Methods, now we will see one Practical Example Solution
Using Numerical Method so that we can understand in better layouting by practicing it
Practically.
113
Multilevel Cone Radial Parts Development
Step 7: Calculate Development Angle () for Radial Parts.
Let, N = No of Radial Parts (S) = *#

D1/2
>k 360) / N
Step 8: Calculate Large Cord Length X1 & Small Cord Length X2.
X1 = 2* R1 * sin (O/2)
X2 = 2* R2 * sin (O/2)
X3 = 2* R3 * sin (O/2)
X4 = 2* R3 * sin (O/2)
Step 9: Development of Cone Layout with Radial Parts.
In this way we can layout Multilevel Cone by using Radial Parts Methods.
114
Method
Example: Generate Fabrication Layout Development Markings of Multilevel Cone for
Following Sizes:
Solution:
Given Data:
D = 500
N
H
T== 1000
4250
115
Step 2: Calculate Development Radius R1, R2, R3, R4
—1 (500/2)
-
OZ F ta (
La Il
*#) = tan-( 1000 ) = 14.04
D2 = 2 × (T – (1 × H)) × tan &

D2 = 2 × (1000 – (1 × 250)) x tan(14.04)
D2 = 375.10
D3 = 2 × (T – (2 × H)) × tan &

D3 = 2 × (1000 – (2 × 250)) x tan(14.04)
D3 = 250.06
D4 = 2 × (T – (3 × H)) × tan &

D4 = 2 × (1000 – (3 x 250)) x tan(14.04)
D4 = 125.03
R1 =
= P4/4
Sin (3) =
T sin999/4
(14.04) = 1030.50
_ D2/2 375.10/2 _
Tsin (, ) T sin (14.04) T 773.08
= D3/2 – 25006/2 –
T sin (, ) sin (14.04) 515.37
—
R4 = P4/2
sin = . 125,03/2
(a) Tsin (14.04) = 257.68
e = **
R1
360 = -º-
1030.50
360 = 87.33
116
X1 = 2* R1 * sin (O/2)
X1 = 2* 1030.5 + sin (87.33 / 2)
X2 = 1422.99
X2 = 2* R2+ sin (O/2)

X2 = 2* 773.08 + sin (87.33/2)
X3 = 1067.53
X3 = 2* R3 * sin (O/2)
X3 = 2* 515.37% sin (87.33/2)
X3 = 711.66
X4 = 2* R3 * sin (O/2)
X4 = 2* 257.68 + sin (87.33/2)
X4 = 355.82
In this way Multilevel Cone using by Numerical Methods
117
Steps for Radial Parts Layout
Step 5: Calculate Development Angle () for Radial Parts.
Let, N = 3 Nos
e = (# 360)/N
500/2
= (# 360)/3
N= 29.11
X1 = 2* R1 * sin (O/2)
X1 = 2* 1030.5 + sin (29.11/2)
X1 = 517.94
X2 = 2* R2 * sin (O/2)
X2 = 2* 773.08 + sin (29.11/2)
X2 = 388.56
X3 = 2* R3 * sin (G/2)
X3 = 2* 515.37% sin (29.11/2)
X3 = 259.03
X4 = 2* R3 * sin (O/2)
X4 = 2* 257.68 + sin (29.11/2)
X4 = 129.51
118
Step 7: Development of Cone Layout with Radial Parts.
This is Final Fabrication Layout Markings of Multilevel Cone for Given Example solved by
using Numerical Method. You have practice this method to become master in this type of
119
Example Solution Checking for Multilevel Cone
Application Icon:
Multilevel Cone Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
Step 1: Select Multilevel Cone Option from Application Menu.
120
Step 2: Enter Input data of Cone Large End Diameter, Small End Diameter, Cone Height
and No. of Levels in the input Fields and Press Calculate Button.
After Clicking on Calculate Button you will get Multilevel Page
121
122
11. Eccentric Cone Layout
Development
Eccentric Cone is also useful Shape in fabrication Field. Eccentric Cone is used in Process
Equipment Fabrication and Piping Industry. So, in this Chapter we are covering all the Points
related to Eccentric Cone Fabrication Layout Development so that you can learn in depth and
used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Eccentric Cone
yourself and verify your answer by our tools and become expert in Eccentric Cone Fabrication
Layout Development.
Geometrical Method for Eccentric Cone Layout
Geometrical Method of Eccentric Cone Fabrication Layout Development is also called

Graphical Method of Eccentric Cone Layout Development, in this layouting Method layout
marking are developed using direct measuring of Geometrical shape of Eccentric Cone. This
123
Now, we will move towards learning Eccentric Cone Fabrication Layout Development
Step 1: Draw Elevation View & Plan View for Multilevel Cone Shape.
Step 2: Project Lines to get cone vertex or intersection points.
If you want to layout full eccentric cone then follows further steps from here.
124
Step 3: Draw half Circle view of large side.
Step 4: Divide half circle view in equal No. of parts.
125
Step 5: Project vertical lines from divided point of the half circle.
Step 6: Mark the Development Circles with Dividing Distance (L) in to equal no of parts
in top view.
126
Step 7: Connect all points of the divided half circle to common point. and measure angle
for α further lay outing.
Lines Highlighted in red colour
Step 8: Measure length of lines L1, L2, L3, L4, L5, L6, L7 form vertex point or intersection
point o.
127
Step 9: Draw lines with equal angle α as measured in previous steps.
Step 10: Mark Points on equal angle lines by taking length as L1, L2, L3, L4, L5, L6, L7.
128
Step 11: Measure length of lines S1, S2, S3, S4, S5, S6, S7 form vertex point or intersection
point o.
Step 12: Mark Points on equal angle lines by taking length as S1, S2, S3, S4, S5, S6, S7.
129
Step 13: Connect all Marking Points with smooth curve to get half layout of eccentric cone.
Layout Profile Highlighted in Red Colour
Step 14: To get Full Section layout of the Eccentric Cone Repeat step 10 to get remaining
points of the Cone large Side.
130
Step 15: To get Full Section layout of the Eccentric Cone Repeat step 12 to get remaining
points of the Cone small Side.
Step 16: Connect all Marking Points with smooth curve to get Full layout of eccentric
cone.
Layout Profile Highlighted in Red Colour.
131
Step 17: Trim Extra Part of the Layout Get Final Layout of the Cone.
In this way we can generate fabrication layout of Eccentric Cone using Geometrical
Numerical Method for Eccentric Cone Layout

Numerical Method for Eccentric Cone layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Eccentric Cone
fabrication layout development.
Step 1: Define Generalised Diagram of Eccentric Cone Layout Development.
132
Step 2: Define Variables for Eccentric Cone Layout
Let,
M
|\
D = Mean Large Diameter \
d = Mean Small Diameter | \
T = Total Height of Cone. | a \
H = Height of the Cone. +- W
Q = Cone Angle. |
N = No. Of Parts. |
L1, L2, L3, L4, L5, L6, L7 = Large End Markings. _ •
S1, S2, S3, S4, S5, S6, S7 = Small End Markings.
C = Large End Marker.
Step 3: Calculate Total Height.
—
tan OZ = D-d
H
_ D
T tanº.
H1 = T — H
(S) = 360
N
- T XD
C = (+)
Step 4: Calculate Large End Markings
133
(0 xQ)
1 = Dx Sin (#) L1 = \/((T?) + (C12)
c = Dx sin &#22) L2=VTTÄTTC25

C, = Dx sin &#2) L3 = V(ÖT?) FCC32)
c = Dx sin &#22) L4=VTTÄTOCT)

C, = Dx sin &#2) L5 = V(ÖT?) FCC52)
C = Dx sin &#2) L6 = V(ÖT?) FCC62)
C = Dx sin &#22) L7 = V(T?) TCC72)
Step 4:Calculate Small End Markings
134
G = dx Sin (*.* ) s1 = \ſ(HTZ) T(GT2)
G. = dx Sin (++) S2= \ſ(OHTZ) T(G27)
G, = dx Sin (****) s3 = \ſ(OHTZ) TCC37)
G. = dx Sin (*.*) s4 = \ſ(OHTZ) TCG47)
G. = dx Sin (+*.) S5 = VC (H12) + (G52)
G. = dx Sin (*) S6 = \ſ( (H12) + (G62)
G = dx Sin (*.*) S7 = \ſ(OH12) + (G72)
to make layout in 36 Parts then then you have to take this formula up to 19-19". By using this
For Large End Marking,
((n-1) x0)
Cn = D x Sin ( 2
) Ln = y/((T2) + (C72)
For Small End Marking,
((n-1)xO)
Go = dx Sin ( 2
) Sn = \ſ(OHT2)T(G72)
no. of parts.
135
Step 5: Marking Layout Eccentric Cone Using Calculated Values.
Step 6: Final Layout Profile of Eccentric Cone.
Eccentric Cone in very faster and efficient way.
In above Two Methods we learn How to Layout Eccentric Cone

Practically.
136
Method
Example: Generate Fabrication Layout Development Markings of Eccentric Cone for

Following Sizes:
250
c
§
500
\
Solution: \
_|
T
i \\
Step 1: Note Down the Given Data of the Example. \
\
250
Given Data: H W
D = 500 |
d = 250 § a
H = 450
N = 12
500
Step 2: Calculate Total Height.
tang ======= 0.5555

=–P = * =
T tan, T 055 900
137
H1 = T – H = 909.09 – 450 = 450
—
(S) = 360
#= – 360
H = — 30 Degree
C = D x.Sin (*) = 500x sin (*) = 0

C = D x Sin (++-) = 500x sin (*) = 129.40
C3 = D x Sin (***) = 500 x Sin (***) = 250
(3 x0) (3 x 30)
C = D x Sin (==) = 500 x Sin (==) =353.55
C = D x Sin (+. *) = 500x sin (*) = 433.01

6 = D x Sin ( ***) = 500x sin (*)=482.96.
2
138
C7 = D x Sin (***) = 500 x Sin (***) = 500
L1 = V( (T2) + (c.12) = VC (9002) + (02) = 900
L2 = VC (T2) + (c22) = VC (9002) + (129.402) = 909.25
L3 = VC (T2) + (c.32) = VC (9002) + (2502) = 934.07
L4 = VC (T2) + (c42) = VC (9002) + (353.552) = 967.68
L5 = VC (T2) + (c.52) = VC (9002) + (433.012) = 998.74
L6 = VC (T2) + (có2) = VC (9002) + (482.962) = 1021.39
L7 = V( (T2) + (C72) = \ſ( (9002) + (5002) = 1029.56

Step 4: Calculate Small End Markings.
139
(0x0) (0 ×30)
G = dx Sin (==) = 250 x Sin (==) = 0
G. = dx Sin (+*) = 250x Sin (+*) = 64.70

G, = dx Sin (*) = 250 x Sin (**) = 125
2 2
(3 x0) (3 x30)
GA = dx Sin ( 2 ) = 250 x Sin ( 2 ) = 176.77
(4 x0) (4×30)
Gs = dx Sin ( 2
) = 250 x Sin ( 2 ) = 216.50
G. = dx Sin (*) = 250x Sin (*) = 241.48

(6 x0)
G = dx Sin ( 2 )=250x sin (*) = 250
S1 = y/((H12) + (G12) = V((4502) + (02) = 450
S2 = VC (H12) + (G22) = VC (4502) + (64.702) = 454.62
S3 = V( (H12) + (G32) = V((4502) + (1252) = 467.03
S4 = V((H12) + (G42) = V( (4502) + (176.772) = 483.47
S5 = VC (hí2) + (652) = VC (4502) + (216.502) = 499.37
S6 = W(CH12) + (G62) = V((450?) + (241.482) = 510.69
S7 = VC (hí2) + (G72) = VC (4502) + (2502) = 514.78
140
Step 4: Marking Layout Eccentric Cone Using Calculated Values.
L1 = 900. L2 = 909.25. L3 = 934.07. L4 = 967.68. L5 = 998.74. L6 = 1021.39 L7 =

1029.56
S1 = 450 S2 = 454.62 S3 = 464.03 S4 = 483.47 S5 = 499.37 S6 = 510.69 S7 = 514.78
C = 130.8
This is Final Fabrication Layout Markings of Eccentric Cone for Given Example solved by
141
Example Solution Checking for Eccentric Cone
Application Icon:
Eccentric Cone Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
Step 1: Select Eccentric Cone Option from Application Menu.
142
in the input Fields and Press Calculate Button.
values with alternate value such as S1, S3, S5, S7, S9, S11, S13 with your calculated values or
become master in fabrication layout development of Eccentric Cone.
143
12. Multilevel Eccentric Cone
Layout Development
Multilevel Eccentric Cone Layout Development is similar to normal Eccentric Cone but
Multilevel Eccentric Cone Concept come in to picture when Normal Eccentric Cone is bigger
in size such way that we cannot make cone layout in Single part due limitation of sheet sizes
available with us in that situation Multilevel Eccentric cone concept is arise. In Multilevel
Eccentric Cone Just Normal Eccentric Cone is divide in to no. of Parts Height Wise It is called
Multilevel Cone. So, in this Chapter we are covering all the Points related to Multilevel
Eccentric Cone Fabrication Layout Development so that you can learn in depth and used this
at the end of learning this Methods, we have taken one practical Example of Multilevel
Eccentric Cone Fabrication Layout Development to understand use of this method for layout
more examples yourself and verify your answer by our tools and become expert in Multilevel
Eccentric Cone Fabrication Layout Development.
Geometrical Method for Multilevel Eccentric

Cone Layout Development
Geometrical Method of Multilevel Eccentric Cone Fabrication Layout Development is also
called Graphical Method of Multilevel Eccentric Cone Layout Development, in this layouting
Method layout marking are developed using direct measuring of Geometrical shape of
Multilevel Eccentric Cone. This Method is Basic Method for fabrication Layout but it required
much time to draw the Geometry of actual size and it also has limitation for Bigger Sizes to
avoid this limitation you have to use computerized tool Such as Auto Cad Software and to
developed layout using this software also required skilled manpower to generate layout it cost
us more in terms of extra skilled manpower and extra time for drawing layout. If fabrication
layout shape is complex then it is not economical.
Now, we will move towards learning Multilevel Eccentric Cone Fabrication Layout
Development using Geometrical Method in Step by Step process.
144
Step 1: Draw Elevation View & Plan View for Multilevel Eccentric Cone Shape.
Step 2: Project Lines to get cone vertex or intersection points.
If you want to layout full eccentric cone then follows further steps from here.
Here
L1 = Level 1
L2 = Level 2
145
Step 3: Draw half Circle view of large side.
Step 4: Divide half circle view in equal No. of parts.
146
Step 5: Project vertical lines from divided point of the half circle.
Step 6: Connect lines from half circle projected points with vertex or intersection points of
the cone O.
147
Step 7: Connect all points of the divided half circle to common point. and measure angle
for α further lay outing.
Lines Highlighted in red colour.

Step 8: Measure length of lines L1, L2, L3, L4, L5, L6, L7 form vertex point or intersection
point o.

This is for Level 1 Large side Markings
148
Step 9: Draw lines with equal angle α as measured in previous steps.
Step 10: Mark Points on equal angle lines by taking length as L1, L2, L3, L4, L5, L6, L7.
149
Step 11: Measure length of lines M1, M2, M3, M4, M5, M6, M7 form vertex point or
intersection point o.

This is for Level 2 Large Side Markings or Level 1 Small Side Markings
Step 12: Mark Points on equal angle lines by taking length as M1, M2, M3, M4, M5, M6,
M7.
150
Step 13: Measure length of lines S1, S2, S3, S4, S5, S6, S7 form vertex point or intersection
point.

This is for Level 2 Small Side Marking
Step 14: Mark Points on equal angle lines by taking length as S1, S2, S3, S4, S5, S6, S7.
151
Step 15: Connect all Marking Points with smooth curve to get half layout of eccentric cone
Step 16: Repeat Steps 10, Step 12 and Step 14 process to get Full layout of Multilevel
eccentric cone.
152
Step 17: Trim Extra Part of the Layout Get Final Layout of the Cone.
In this way we can generate fabrication layout of Multilevel Eccentric Cone using
Geometrical Method or Graphical Method of Fabrication Layout Development.
Numerical Method for Multilevel Eccentric Cone

Layout
Numerical Method for Multilevel Eccentric Cone Layout Development is very faster and
time saving method for layouting, you can calculate the values of layout dimension by solving
Now we will move towards learning Numerical Method for Multilevel Eccentric
Cone fabrication layout development.
Step 1: Define Generalised Diagram of Multilevel Eccentric Cone Layout Development.
153
Step 2: Define Variables for Multilevel Eccentric Cone Layout
Let,
D1, D2, D3 = Mean Diameter at Level 1 & Level 2

LH = Level Height of the Cone
T = Total Height of Cone.
α = Cone Angle.
N = No. of Parts.
L1, L2, L3, L4, L5, L6, L7 = Large Side Markings at Level 1
M1, M2, M3, M4, M5, M6, M7 = Large Side Marking at Level 2
or Small Side Markings for Level 1.
S1, S2, S3, S4, S5, S6, S7 = Small End Markings at Level 2
C = Large End Marker.
154
Step 3: Calculate General Parameters.
tan & = **
0. H
D1
tan 0.
— 360
e ==
XD1
C = (+++)
Step 4: Layout Development for Level 1 & Level 2 Cone
H1 = T — LH
D2 = (T – LH) x tan &
Generalised Formulae for Multilevel Cone Intermediate Diameter

Calculation
D = (T – (MF x LH) x tan &
H1 = (T – (MF x LH)
MF = Multiplying factor = 1,2,3,4,5,6,7,8 so on for Levels 1,2,3,4,5,6,7,8 so

Ofn
N\
|\
\
\
+ o, \
L2 |
D2
}
s|| L1 ! :
D1
155
C = D1x sin (*) L1 = \ſ((T) T(CTF)
(1 x0)
C2 = D1 x Sin
=) L2 = \ſ((T) TCCZ)
C = D1x sin (**) L3 = \ſ(T3) TCC37)
C = D1x sin (**) L4 = V(KTZ) TCC475

(4 x0)
C5 = D1 x Sin 2 ) L5 = y/((T2) + (C52)
C = D1x sin (*) L6= \ſ(T3) TCC67)
C = D1x sin (**) L7 = MTZ) T(C7)
156
D2 x Sin (( ��×Θ
�� )); M1 = √((��)
+ ( ��)
G1 =
G2 M2=
G3 = D2x Sin (((��×Θ��));
��×Θ��)); M3 √((��)+(��)
= √((��)+(��)
D2x
= Sin (
G4 M4
D2x (��×Θ��)); = √((��)+(��)
= Sin (
G5 M5
G6 = D2x Sin ((��×Θ��)); M6 = √((��)+(��)
(��×Θ��)); = √((��)+(��)
D2x
= D2xSin
Sin ((��×Θ��
)
M7=
G7 ); √((��)+(��)
157
H1 = T- (2 x LH)
D2 = (T – (1x LH)) x tan &
D3 = (T – (2 x LH)) x tan &
F = D3x sin (**) S1 = y/((H12) + (F12)

1:
F = D3x sin (+) S2 = y/((H12) + (F22)
F = D3x sin (**) S3 = VC (H12) + (F32)
F = D3x sin (“”
2
S4 = V/((H12) + (F42)
F. = D3x sin (tº
:=) S5 = y/((H12) + (F52)
F. = D3x sin (→
2
S6 = y/((H12) + (F62)
F = D3x sin (*.
2
S7 = y/((H12) + (F72)
this layout in 12 Parts so that we had taken this formula up to L7, M7 & S7 markings lengths.
If you want to make layout in 24 Parts then you have to take this formula up to L13, M13 &
S13 or if you want to make layout in 36 Parts then then you have to take this formula up to
L19, M19 & S19. By using this formula, you can calculate layout marking for any no. of parts
but you to make changes in Cos Multiplying factor by increasing to next number than
previous. So then Generalised Formula for this will Become.
For Large End Marking,
C = DX sin (“tº Ln=JCCT*)T(C75

For Next End Marking,
G = dx sin (**) Mn = \ſ((HTZ) T(G77)

For Next End Marking,
F = D3x sin (“tºsh – WCCHT) TCF75

158
And so, on you can generate formulae for Next Levels, by using this generalised Formula,
you can calculate development marking lengths of any no. of parts.
Step 5: Mark All Points using Above Value and Connect with Smooth Curve to Get Final
Layout Shape.
Step 6: Final Layout Profile of Eccentric Cone
Multilevel Eccentric cone in very faster and efficient way.
In above Two Methods we learn How to Layout Multilevel Eccentric

Cone Using Geometrical and Numerical Methods, now we will see one Practical Example
Solution Using Numerical Method so that we can understand in better layouting by practicing
it Practically.
159
Method
Example: Generate Fabrication Layout Development Markings of Multilevel Eccentric
Cone for Following Sizes:
Solution:
D3
LH
H
N
Given 12
=Data:
D1==450
500
250
225
160
Step 2: Calculate General Parameters
tan O. = — = —Hi-- 0.5555
=# =# = 900
e = **=#=30 Degree
C = (+)=&#")=130.8
Step 3: Layout Development for Level 1 & Level 2 Cone.
Given, D1 = 500 LH = 225
H1 = T — LH = 900 – 225 = 675
D2 = (T – LH) x tan &
D2 = (900–225) x 0.5555
D2 = 375
161
(0x0) (0 ×30)
1 = D1 x Sin
2
) = 500x sin (==) =0
(1 x0) (1x30)
C2 = D1 x Sin
2
) = 500 x Sin ( 2
) = 129.40
C3 = D1 x Sin (***) = 500 x Sin (**) = 250
C = D1x sin (º) = 500x sin (*) =353.55

(4 x0) (4×30)
Cs = D1 x Sin ( 2
) = 500 x Sin ( 2 ) = 433.01
C = D1x sin (*) = 500x sin (*) =482.96

C = D1x sin (*) = 500x sin (*) = 500
162
L1 = VC (T2) + (c.12) = VC (9002) + (02) = 900
L2 = V( (T2) + (c22) = VC (9002) + (129.402) = 909.25
L3 = VC (T2) + (c.32) = VC (9002) + (2502) = 934.07
L4 = V((T2) + (C42) = \ſ( (9002) + (353.552) = 966.95
L5 = V( (T2) + (C52) = \ſ( (9002) + (433.012) = 998.74
L6 = W(CT2) + (C62) = \ſ( (9002) + (482.962) = 1021.39
L7 = V( (T2) + (C72) = \ſ( (9002) + (5002) = 1029.56
163
(0x0)
G = D2x sin (*) =375x sin (*) = 0
2 = D2 x Sin
**)=375x sin (+*) = 97.05
2
G. = D2x sin (*) =375x sin (*) = 187.5

G. = D2x sin (*) = 375x sin (*) = 265.16
G. = D2x sin (*) = 375x sin (*) = 324.76
G. = D2x sin (*) = 375x sin (*) =362.22
= D2x sin (*) =375x sin (*) = 375
164
M1 = y/((h12) + (G12) = VC (6752) + (02) = 675
M2 = y/((hí2) + (g22) = VC (6752) + (97.052) = 681.94
M3 = V((H12) + (G32) = \ſ( (6752) + (187.52) = 700.55
M4 = V((H12) + (G42) = V( (6752) + (265.162) = 725.21
M5 = V((H12) + (g52) = V( (6752) + (324,762) = 749.06
M6 = VC (H12) + (G62) = VC (6752) + (362.222) = 766.04
M7 = VC (H12) + (G72) = VC (6752) + (3752) = 772.17
165
E
L2
L1
I
|\
Given, LH = 225
H1 = T – (2 x LH) = 900 – (2 x 225) = 450
D2 = (T – (1x LH)) x tan &
D2 = (900 – (1 x 225) x 0.5555 = 375
D3 = (T – (2 x LH)) x tan &
D3 = (900 – (2 x 225) x 0.5555 = 250
166
F = D3x sin (*.*})=250x sin (*) = 0
1 x0)
F = D3x sin (+*) = 250x Sin ((1x30)) = 64.70
2 2
F = D3x sin (#.*) = 250x sin (*) = 125

F = D3x sin (*) = 250x sin (*) = 176.77
(4 x0) (4×30)
Fs = D3 x Sin 2
) = 250 x Sin ( 2
) = 216.50
O) (5 ×30)
F. = D3x sin (*) = 250x sin (*) = 241.48
F = D3x sin (*) = 250x sin (*) = 250
167
S1 = V( (H12) + (F12) = V((4502) + (02) = 450
S2= V( (H12) + (F22) = VC (4502) + (64.702) = 454.62
S3 = V( (H12) + (F32) = V((4502) + (1252) = 467.03
S4 = V((hí2) + (F42) = VC (4502) + (176.772) = 483.47
S5 = VC (hí2) + (F52) = VC (4502) + (216.502) = 499.37
S6 = W(CH12) + (F62) = V((4502) + (241.482) = 510.69
S7 = VC (H12) + (F72) = VC (4502) + (2502) = 514.78
168
Step 4: Collect all Markings Points to Mark Layout.
L1 = 900; L2 = 909.25; L3 = 934.07; L4 = 966.95; L5 = 998.74; L6 = 1021.39;

L7 = 1029.56
M1 = 675; M2 = 681.94; M3 = 700.55; M4 = 725.21; M5 = 749.06; M6 = 766.04;

M7 = 772.17
S1 = 450; S2 = 454.62; S3 = 467.03; S4 = 483.47; S5 = 499.37; S6 = 510.69; S7 = 514.78

C = 130.8
Step 5: Mark All Points using Above Value and Connect with Smooth Curve to Get Final
Layout Shape.
Step 7: Final Layout Profile of Multilevel Eccentric Cone.
169
This is Final Fabrication Layout Markings of Multilevel Eccentric Cone for Given Example
solved by using Numerical Method. You have practice this method to become master in this
type of layouting and after practicing you will have confidence in your layouting and in latter
part after become expert you reduce your work by using method with the help of computerizes
Example Solution Checking for Multilevel

Eccentric Cone
Application Icon:
Multilevel Eccentric Cone Layouts we had also added Screen Shots for Better Understanding
of this Checking Methods.
170
Step 1: Select Multilevel Eccentric Cone Option from Application Menu.
and No. of Levels in the input Fields and Press Calculate Button.
171
After Clicking Calculate Button Level Page Will be opened and select required level
values with alternate value such as S1, S3, S5, S7, S9, S11, S13 with your calculated values or
become master in fabrication layout development of Multilevel Eccentric Cone.
172
13. Tori Cone with Knuckle
Radius at Large End
Tori cone is used in fabrication where to reduce stress, it is generally used instead of direct
truncated cone. Tori cone is used due to use of Tori Cone Sharp Angle of Cone is avoided by
making knuckle radius in large end. So, it is very necessary that every fabrication engineer or
professionals in fabrication field must have knowledge of Tori Cone layout Development if
you have detailed knowledge of cone fabrication it is very useful to you while working in
fabrication daily activities. So, in this Chapter we are covering all the Points related to Tori
Cone Fabrication Layout Development so that you can learn in depth and used this method in
daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Tori Cone
yourself and verify your answer by our tools and become expert in Tori Cone Fabrication
Layout Development.
Geometrical Method for Tori Cone with

Knuckle Radius at Large End
Geometrical Method of Tori Cone Layout Development is also called Graphical Method of
Tori Cone Layout Development, in this layouting Method layout marking are developed using
direct measuring of Geometrical shape of Tori Cone. This Method is Basic Method for
fabrication Layout but it required much time to draw the Geometry of actual size and it also
has limitation for Bigger Sizes to avoid this limitation you have to use computerized tool Such
as Auto Cad Software and to developed layout using this software also required skilled
173
manpower to generate layout it cost us more in terms of extra skilled manpower and extra time
for drawing layout. If fabrication layout shape is complex then it is not economical.
Now, we will move towards learning Tori Cone with Knuckle Radius at Large End
Fabrication Layout Development using Geometrical Method in Step by Step process.
Step 1: Draw Elevation View for Tori Cone with Knuckle Radius at Large End Shape.
Step 2: Extends lines to get vertex point or intersection point as shown below
174
Step 3: Measure Total Length of Red Highlighted Parts.
Step 4: Mark Total length (L) Measured in Previous step on Projected Line.
175
Step 5: Make an Equivalent Truncated Cone by using Previous Step.
Step 6: Now, Layout This Equivalent Cone Using Truncated Cone Layout Graphical
Method Explain Chapter – 9.
176
Step 7: Final Layout Profile After Lay outing Using Truncated Cone Method.
In this way we can generate fabrication layout of Tori Cone with Knuckle Radius at Large
End using Geometrical Method or Graphical Method of Fabrication Layout Development.
Numerical Method for Tori Cone with knuckle

Radius at Large End
Numerical Method for Tori Cone layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Tori Cone fabrication
layout development in this Method.
Step 1: Define Generalised Diagram of Tori Cone with Knuckle at large ends Layout
Development
177
Step 2: Define Variables for Tori Cone with Knuckle Radius at Large End Layout
Let, d
D = Mean Large Diameter of Cone. |

d = Mean Small Diameter of Cone. &
H = Height of the Cone. |

Q = Cone Angle.
R = Large End Knuckle Radius. (ºr D1 2--"
S = Straight Face at Large End T-F------- - go
R1 = Large Development Radius. D

() = Development Angle.
X1 = Large Cord Length.
X2 = Small Cord Length
In above Step First figure is for Generalised Diagram of Tori Cone and Second Figure is
Equivalent Cone Diagram of Tori cone for Calculation.
Step 3: Calculate D1, SL, A, R1, R2 Parameters
D1 = D – (2 × (R – R x cos & ))
SL = (P1/*-*/*)
Sun 0.
A = R × (0 × +
-
180
Total Slant length = T = SL + A + S
_ , d/2
R2 = (#)
R1 = R2 + T
178
R1 × Sin &
(S) = ==x 360 = sing x 360
X1 = 2* R1 * sin (O/2)
X2 = 2* R2+ sin (G/2)
Step 6: Development of Cone Layout for
X1
Tori Cone in very faster and efficient way.
In above Two Methods we learn How to Layout Tori Cone Using

179
Method
Example: Generate Fabrication Layout Development Markings of Tori Cone with

Knuckle Radius at Large End for Following Sizes:
250
F-—
Solution:

Given Data:
D = 800
d = 250
R = 150
O = 31
S = 50
Step 2: Calculate D1, SL, A, R1, R2 Parameters
D1 = D – (2 × (R – R x cos & ))
D1 = 800 – (2 × (150 – 150 x cos 31 )
D1 = 757.15
SL = (p1/2- d/2)
Sun 0.
(757.15/2 — 250/2)
SL =
Sin 31
SL = 492.34
180
A= R -
+
× (ξ)
-
+
A = 150 x (31 xii;)
A = 81.15
Total Slant length = T = SL + A + S
T = 492.34 + 81.15 + 50
T = 623.49
R2 =
= , 44%. , =
(...) = (, #3"/#
Sin 31 ), =
= 242.70
R1 = R2 + T = 242.70 + 623.49 = 866.19
Step 3: Calculate Development Angle G)
R1 × sin &
(S) = –H–x 360 = Sin o. × 360 = Sin 31 × 360 = 185.41
X1 = 2* R1 * sin (O/2) = 2* 866.19% sin (185.41/2) = 1730.44
X2 = 2* R2 * sin (O/2) = 2* 242.70 * sin (185.41/2) = 484.85

Step 5: Mark Development Layout Using Above Calculated Values.
1730.44
866-19
| 484–85 |
181
This is Final Fabrication Layout Markings of Tori Cone for Given Example solved by
Example Solution Checking for Tori Cone

Application Icon:
Tori Cone Layouts we had also added Screen Shots for Better Understanding of this Checking
Methods.
182
Step 1: Select Tori Cone with Knuckle Radius at Large End Option from Application
Menu.
Step 2: Enter Input data of Cone Large End Diameter, Small End Diameter and Cone
Height in the input Fields and Press Calculate Button. Height Value is not available in Example
so it put as Zero as it is not Required.
183
184
14. Tori Cone with Knuckle
Radius at Both Ends
Tori cone with Knuckle radius at both ends is used in fabrication where to reduce stress at
both ends, it is generally used instead of direct truncated cone. Tori cone is used due to use of
Tori Cone Sharp Angle of Cone is avoided by making knuckle radius in large end. So, it is very
necessary that every fabrication engineer or professionals in fabrication field must have
knowledge of Tori Cone layout Development if you have detailed knowledge of cone
fabrication it is very useful to you while working in fabrication daily activities. So, in this
Chapter we are covering all the Points related to Tori Cone Fabrication Layout Development
so that you can learn in depth and used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Tori Cone
yourself and verify your answer by our tools and become expert in Tori Cone Fabrication
Layout Development.
Geometrical Method for Tori Cone with

Knuckle Radius at Both Ends
Geometrical Method of Tori Cone Layout Development is also called Graphical Method of
Tori Cone Layout Development, in this layouting Method layout marking are developed using
direct measuring of Geometrical shape of Tori Cone. This Method is Basic Method for
185
Now, we will move towards learning Tori Cone with Knuckle Radius at Both Ends
Step 1: Draw Elevation View for Tori Cone with Knuckle Radius at Both Ends Shape.
Step 2: Extends lines to get vertex point or intersection point as shown below
186
Step 3: Measure Total Length of Red Highlighted Parts.
Step 4: Mark Total length (L1, L2) Measured in Previous step on Projected Line.
187
Step 5: Make an Equivalent Truncated Cone by using Previous Step.
Step 6: Now, Layout This Equivalent Cone Using Truncated Cone Layout Graphical
Method Explain Chapter – 9.
188
Step 7: Final Layout Profile After Lay outing Using Truncated Cone Method.
In this way we can generate fabrication layout of Tori Cone using Geometrical Method or
Numerical Method for Tori Cone with knuckle

Radius at Both Ends
Numerical Method for Tori Cone layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Tori Cone fabrication
Step 1: Define Generalised Diagram of Tori Cone with Knuckle at Both ends Layout
Development
189
Step 2: Define Variables for Tori Cone Layout
Let,
D = Mean Large Diameter of Cone.

d = Mean Small Diameter of Cone.
α = Cone Angle.
R = Large End Knuckle Radius.
r = Small End Knuckle Radius.
S = Straight Face at Large End
S1 = Straight Face at Large End
S2 = Straight Face at Small End
R1 = Large Development Radius.
X1 = Large Cord Length.
X2 = Small Cord Length
In above Step First figure is for Generalised Diagram of Tori Cone and
Second Figure is Equivalent Cone Diagram of Tori cone for Calculation.
190
Step 3: Calculate D1, D2, SL, A1, A2, R1, R2 Parameters
D1 = D – (2 × (R – R x cos & ))
D2 = d -- (2 × (r – r x cos & ))
D2/2
y = | 2/
SlT1 0.
)
SL = (P1/*Sin= P2/*)
&
A1 = R × (4 × +
7. )
-
A2 = r × (4 × +
1. )
R1 = S1 + A1 + SL + Y
R2 = Y – (A2 + S2)
(S) = *x 360 = sing x 360
X1 = 2* R1 * sin (O/2)
X2 = 2* R2 * sin (O/2)
191
Step 6: Development of Cone Layout for
Tori Cone in very faster and efficient way.
In above Two Methods we learn How to Layout Tori Cone Using
192
Method
Example: Generate Fabrication Layout Development Markings of Tori Cone with
Knuckle Radius at Both Ends for Following Sizes:
Solution:
Given Data:
D = 800
d = 250
R = 150
r = 100
α = 34
S1 = 50
S2 = 50
193
Step 2: Calculate D1, D2, SL, A1, A2, R1, R2 Parameters.
D1 = D – (2 × (R – R x cos & ))
D1 = 800 – (2 × (150 – 150 x cos 34 ))
D1 = 748.71
D2 = d + (2 × (r–r x cos & ))

D2 = 250 + (2 × (100 – 100 × cos 34 ))
D2 = 284.19
Y = [PAE) = (#1%) = 254.10

Sun 0. Sin 34
SL = (P4/*Sin- P4/*)
&
= (7*71/*-***/*)
Sin 34
= 415.34
A1 = R × (0 × + \= + \ =
-
180 ) = 150 × (34 × 180 ) = 89.01
A2 = r × (4 × +
7. )\ = 100 × (34 × +
7. )\ = 59.34
R1 = S1 + A1 + SL + Y
R1 = 50 + 89.01 + 415.34 + 254.10 = 808.54
R2 = Y – (A2 + S2)
R2 = 254.10 – (59.34 + 50) = 144.76

R1 × sin &
X 360 = Sin & X 360 = Sin 34 × 360 = 201.30
e = ==
194
X1 = 2* R1 * ��(
Θ/2)
X1 = 2* 808.54 * ��(
201.30/2)
X1 = 1589.22
X2 = 2* R2 * ��(
Θ/2)
X2 = 2* 144.76* ��(
201.30/2)
X2 = 284.53
Step 5: Mark Development Layout Using Above Calculated Values.
This is Final Fabrication Layout Markings of Tori Cone with Knuckle Radius at Both Ends
for Given Example solved by using Numerical Method. You have practice this method to
calculations.
195
Example Solution Checking for Tori Cone with
Knuckle Radius at Both Ends
Application Icon:
Tori cone Layouts we had also added Screen Shots for Better Understanding of this Checking
Methods.
Step 1: Select Tori Cone with Knuckle Radius at Both Ends Option from Application
Menu.
196
Step 2: Enter Input data of Cone Large End Diameter, Small End Diameter and Knuckle
Radius at Large ends and Knuckle Radius at Small Ends and Straight Face at Both Ends in the
input Fields and Press Calculate Button. Height Value is not available in Example so it put as
Zero as it is not Required.
197
15. Square to Round or
Rectangular to Round
Layout
Square to Round or Rectangular to Round Geometrical Shape is also widely used shape in
Fabrication and Ducting Industry. This type of Layouts is also Called as Transition layouts. In
Square to Round or Rectangular layout Development Layout is made using Triangulation
Method. So, if you are working in fabrication Industry or Ducting Industry then learning of
this transition layout is boost your Knowledge in this Field. So, in this Chapter we are covering
all the Points related to Square to Round or Rectangular to Round Fabrication Layout
at the end of learning this Methods, we have taken one practical Example of Square to Round
or Rectangular to Round Fabrication Layout Development to understand use of this method
for layout Development, at the end of this Example Solution. We had also provided you
example solution checking method using our tool so that you can verify your calculation with
some tested tools and make you confident in fabrication layout. You can Practice this method
taking more examples yourself and verify your answer by our tools and become expert in
Square to Round or Rectangular to Round Fabrication Layout Development.
Geometrical Method for Square to Round or

Rectangular to Round
Geometrical Method of Square to Round or Rectangular to Round Layout Development is
also called Graphical Method of Square to Round or Rectangular to Round Layout
Development, in this layouting Method layout marking are developed using direct measuring
of Geometrical shape of Square to Round. This Method is Basic Method for fabrication
Layout but it required much time to draw the Geometry of actual size and it also has limitation
198
for Bigger Sizes to avoid this limitation you have to use computerized tool Such as Auto Cad
Now, we will move towards learning Square to Round or Rectangular to Round
Step 1: Draw Elevation and Top View of Rectangular to Round Transition.
Top View Elevation View
Step 2: Divide Circle in Top View to Equal No of Parts.
Highlighted in Red Colour
199
Step 3: Connect of Divided Points with Corner Point of Square or Rectangle.
Step 4: Measure Length L1, L2, L3, L4 from Top View of Divided Circle.
200
Step 5: Mark points on Horizontal line with distance L1, L2, L3, L4 measured in previous
step.
Step 6: Connect all marked points of previous step with common point O. as shown in
Figure and Measure S1, S2, S3, S4.
201
Step 7: Decide Seam / Weld Joint Location and Measure Arc Distance (A), Seam / Weld
Joint Length (J) Required for Layout
Seam / Weld Joint Highlighted in Red Colour.

Arc Distance highlighted in Blue Colour.
Step 8: Mark Final Layout Profile Using Measured Values from previous steps.
In this way we can generate fabrication layout of Square to Round or Rectangular to Round
202
Numerical Method for Square to Round or
Rectangular to Round Layout.
Numerical Method for Square to Round or Rectangular to Round layout Development is
Now we will move towards learning Numerical Method for Square to Round or
Rectangular to Round fabrication layout development in this Method.
Step 1: Define Rectangular to Round Generalised Diagram
Step 2: Define Variables for Tori Cone Layout
Let,
D = Mean Round Diameter

H = Height.
L = Length of Rectangle.
W = Width of Rectangle.
α = Parts Angle.
N = No. of Parts.
203
L1, L2, L3, L4, L5, L6, L7 = Marking Lengths in Top View.
S1, S2, S3, S4, S5, S6, S7 = Development Marking Length
J = Joint Length.
F = Joint Location.
A = Arc Distance for Marking.
Step 3: Calculate A, Q, J, F.
R= }
A = (+)
_ 360
& ===
J =JCW/2–R)*4 hº
F=;
204
Step 4: Calculate S1, S2, S3, S4.
si-Naz – R x sin(0 × 4))^+((W/2) – R x cos(0 × 2) )* + H2
sº-Ja/2) – R × sin(1 × 2) )* +((W/2) – R x cos(1x & )) * + H2
sº-Ja/2) – R x sin(2 × 2) )* +((W/2) – R x cos(2 × 2)) * + H2
sº-Ja/2) – R × sin(3 x , ) )* +((W/2) – R x cos(3 x , )) * + H2
this layout in 12 Parts so that we had taken this formula up to S4 markings lengths. If you want
to make layout in 24 Parts then you have to take this formula up to S6 or if you want to make
layout in 36 Parts then then you have to take this formula up to S9. By using this formula, you
can calculate layout marking for any no. of parts but you to make changes in Cos Multiplying
factor by increasing to next number than previous. So then Generalised Formula for this will
Become.
sn-J (L/2) – R x sin((n-1) x 2))^+((W/2) – R x cos((n-1) x 2))^+ H2
no. of parts.
205
Step 5: Mark Final Layout Profile Using Calculated Values from previous steps
Square to Round or Rectangular to Round in very faster and efficient way.
In above Two Methods we learn How to Layout Square to Round

Practically.

Method
Example: Generate Fabrication Layout Development Markings of Rectangular to Round
Cone for Following Sizes:
206
Solution:
Given Data:
D = 250
L = 500
W = 450
H = 350
N = 12
R = (#) = (#)=125
T XD TT ×250
A=( N )=( 12 ) = 65.44
360 360
& ======30
J= |(w/2–R): + H2
J= Jaso/2 – 125)* + (350)?

J = 364
— L – 500 —
F=; ==== 250
207
Step 3: Calculate S1, S2, S3, S4
si-Ja/2) – R x sin(0 × 2) )* +((W/2) – R x cos(0 × 2)) * + H2
si-Jogoo/2) – 125 x sin(0 × 30))^+((450/2) – 125 x cos(0 × 30) )* + 350°
S1 = V2502 + 1002 + 3502
S1 = 441.58
sº-Ja/2) – R x sin(1× 2) )*4-((W/2) – R x cos(1x & ) )* + H2
sº-Jagoo/2) – 125 x sin(1 x 30))^+((450/2) – 125 x cos(1x30))* + 350°
S2 = V187.52 + 116. 752 + 3502
S2 = 413.86
sº-Jaz. – R x sin(2 × 2) )*4-((W/2) – R x cos(2 × 2) )* + H2
ss=JCGoo/2) – 125 x sin(2 x 30))* +((450/2) – 125 x cos(2 x 30))” +350?
S3 = V141. 752 + 162. 52 + 350°
S3 = 411.09
sº-Ja/2) – R x sin(3 x 4))^+((W/2) – R x cos(3 x 4)) * + H2
sº-Jagoo/2) – 125 x sin(3 x 30))* +((450/2) – 125 x cos(3 x 30))” +350?
S4 = V1252 + 2252 + 3502
S4 = 434.45
208
Step 4: Mark Final Layout Profile Using Calculated Values from previous steps.
This is Final Fabrication Layout Markings of Square to Round or Rectangular to Round

Given Example solved by using Numerical Method. You have practice this method to become
master in this type of layouting and after practicing you will have confidence in your layouting
and in latter part after become expert you reduce your work by using method with the help of
209
Example Solution Checking for Square to
Round or Rectangular to Round Layout
Mobile Application Name: Transition Layouts
Application Icon:
Square to Round or Rectangular to Round Layouts we had also added Screen Shots for Better
Step 1: Select Rectangular to Round Option from Application Menu.
210
Step 2: Enter Input data of Rectangular Length, Width, Height and Round Diameter in
Input Fields and Select Check Box as 1 Part and 12 Lines option because we had solved above
example using Single parts and 12 lines option and Click on Calculate Button.
211
16. Round to Square or
Round to Rectangle Layout
Round to Square or Round Rectangular Geometrical Shape is Similar types of Shape as

Square to Round but in this shape Round Diameter is Larger than Square size so it is become
complicated shape for Layout But we had made it as simple as Square to Round Shape. It is
also widely used shape in Fabrication and Ducting Industry. This type of Layouts is also Called
as Transition layouts. In Round to Square or Round to Rectangular layout Development
Layout is made using Triangulation Method. So, if you are working in fabrication Industry or
Ducting Industry then learning of this transition layout is boost your Knowledge in this Field.
So, in this Chapter we are covering all the Points related to Round to Square or Round to
Rectangle Fabrication Layout Development so that you can learn in depth and used this
at the end of learning this Methods, we have taken one practical Example of Round to Square
or Round to Rectangular Shape Fabrication Layout Development to understand use of this
method for layout Development, at the end of this Example Solution. We had also provided
you example solution checking method using our tool so that you can verify your calculation
with some tested tools and make you confident in fabrication layout. You can Practice this
method taking more examples yourself and verify your answer by our tools and become expert
in Round to Square or Round to Rectangular Fabrication Layout Development.
Geometrical Method for Round to Square or

Round to Rectangle Layout.
Geometrical Method of Round to Rectangular or Round to Square Layout Development is
also called Graphical Method of Round to Square or Round to Rectangular Development, in
this layouting Method layout marking are developed using direct measuring of Geometrical
shape of Round to Square or Round to Rectangular. This Method is Basic Method for
212
Now, we will move towards learning Round to Square or Round to Rectangular
Step 1: Draw Elevation and Top View of Round to Square or Round to Rectangle
Transition
Step 2: Divide Circle in Top View to Equal No of Parts and marks each point.
213
Step 3: Connect of Divided Points with Corner Point of Square or Rectangle.

Step 4: Measure Length L1, L2, L3, L4 from Top View of Divided Circle.
214
Step 5: Mark points on Horizontal line with distance L1, L2, L3, L4 measured in previous
step
Step 6: Connect all marked points of previous step with common point O. as shown in
Figure and Measure S1, S2, S3, S4.
215
Step 7: Decide Seam / Weld Joint Location and Measure Arc Distance (A), Seam / Weld
Joint Length (J) & Joint Location (F) Required for Layout
Seam / Weld Joint Highlighted in Red Colour
Step 8: Mark Final Layout Profile Using Measured Values from previous steps.
In this way we can generate fabrication layout of Square to Round or Rectangular to Round
216
Numerical Method for Round to Square or
Round to Rectangular Layout.
Numerical Method for Round to Square or Round to Rectangular Development is very
faster and time saving method for layouting, you can calculate the values of layout dimension
by solving manually on scientific calculator or you can use any computerized tool for solving
such as MS excel or any other tool for Calculates Values in faster way.
Now we will move towards learning Numerical Method for Round to Square or
Round to Rectangular fabrication layout development in this Method.
Step 1: Define Round to Rectangle Generalised Diagram
Step 2: Define Variables for Round to Rectangular Layout
Let,
D = Mean Round Diameter

H = Height.
L = Length of Rectangle.
W = Width of Rectangle.
α = Parts Angle.
N = No. of Parts.
S1, S2, S3, S4, S5, S6, S7 = Development Marking Length
J = Joint Length.
F = Joint Location.
A = Arc Distance for Marking.
217
Seam Weld Joint
= d2
R = (#)
_ /T ×D
A=( N
360
3=+
J-Jºr-ºth.
F =
;
si-Jºn × sin(0 × 0. )) – (W/2))” + ((R × cos(0 × & )) – (L/2))* + H2
sº-Jon × sin(1 × 0. )) – (W/2))” + ((R × cos(1 x & )) – (L/2))” + H2
ss=Jon × sin(2 × 0. )) – (W/2))” + ((R × cos(2 x & )) – (L/2))” + H2
218
sº-Jon × sin(3 × & )) – (W/2))” + ( (R × cos(3 × 0 ).) – (L/2))* + H2
this layout in 12 Parts so that we had taken this formula up to S4 markings lengths. If you want
to make layout in 24 Parts then you have to take this formula up to S6 or if you want to make
layout in 36 Parts then then you have to take this formula up to S9. By using this formula, you
can calculate layout marking for any no. of parts but you to make changes in Cos Multiplying
factor by increasing to next number than previous. So then Generalised Formula for this will
Become.
sº-Jon × sin((n − 1) x & )) — (W/2) )* + ( (R × cos((n-1) × & ).) – (L/2))” + H2
no. of parts.
Round to Square or Round to Rectangular in very faster and efficient way.
In above Two Methods we learn How to Layout Round to Square

Practically.
219
Method
Example: Generate Fabrication Layout Development Markings of Round to Rectangular
Shape for Following Sizes:
350 x 250
a 1000
Ø 1000
Solution:
Given Data:
D = 1000
L = 350
W = 250
H = 500
N = 12
D 1000
R = (; ) = (==) = 500
TT XD T ×1000
A = (+) = (==) = 261.79
* = ** =# = 30
J-Jºr-º- + H2 = Goo-ºº-soo. = 625
L _ 350
F=; + = 175
220
st-Jº x sin(0 × 2) — (W/2))^+ ((R x cos(0 × 4)) – (L/2))^+ H2

S1 =JCGoo x sin(0 × 30) – (250/2))” + ((500 x cos(0 × 30)) – (350/2))” + 500?
S1 = \ſ(-125)? T(325)? T(500)?
S1 = 609.30
sº-Jºn x sin(1× 2) — (W/2))^+ ((R x cos(1x & )) – (L/2))^+ H2
sº-J Goo × sin(1× 30) – (250/2))* + ( (500 x cos(1x30)) – (350/2))” + 500?
S2 = \ſ(125)2 + (258)2 + (500)?

S2 = 576.35
ss=Jºn × sin(2 × 0.)) — (W/2))” + ((R × cos(2 × 0.)) — (L/2))” + H2
ss=JCGoo × sin(2 x 30) – (250/2))* + ( (500 x cos(2 x 30)) – (350/2))” + 500°
S3 = \ſ(308)2 + (75)2 + 5002

S3 = 592.02
sº-Jon × sin(3 x & )) — (W/2))” + ((R × cos(3 x & ).) — (L/2))” + H2
si-Jogo x sin(3 x 30) – (250/2))” + ((500 x cos(3 x 30)) — (350/2))” + 500?
S4 = \ſ(375)2 + (−175)2 + 5002

S4 = 649.03
221
This is Final Fabrication Layout Markings of Round to Rectangular Given Example solved
by using Numerical Method. You have to practice this method to become master in this type
of layouting and after practicing you will have confidence in your layouting and in latter part
after become expert you reduce your work by using method with the help of computerizes
222
Example Solution Checking for Round to
Square or Round to Rectangular Layouts.
Application Icon:
Round to Square or Round to Rectangular Layouts we had also added Screen Shots for Better
Step 1: Select Round to Rectangular Option from Application Menu.
223
Step 2: Enter Input data of Rectangular Length, Width, Height and Round Diameter in
Input Fields and Select Check Box as 1 Part and 12 Lines option because we had solved above
example using Single parts and 12 lines option and Click on Calculate Button.
224
17. Pyramid Layout
Development
Pyramid Type Shape is also used in Fabrication for Various types of Application such
making Hoppers and any other types of requirement in fabrication Industry. In this Chapter
we are learning Concentric Pyramid. Pyramid fabrication Majorly used in Feed Plants where
big type of Storage Bins having Discharge side made as Pyramid Type shape to free flow of
Materials from Bins. It is very useful if You have knowledge of fabrication layout of this types
of Shape. So, in this Chapter we are covering all the Points related to Pyramid fabrication
activity.
at the end of learning this Methods, we have taken one practical Example of Pyramid
yourself and verify your answer by our tools and become expert in Pyramid Fabrication Layout
Development.
Geometrical Method for Pyramid Layout

Geometrical Method of Pyramid Layout Development is also called Graphical Method of
Pyramid Layout Development, in this layouting Method layout marking are developed using
direct measuring of Geometrical shape of Pyramid. This Method is Basic Method for
225
Now, we will move towards learning Pyramid Fabrication Layout Development using
Step 1: Draw Elevation and Top View of Pyramid.
Step 2: Mark Corner points as A, B, C, D as Shown and Name Each Side as Plate-1, Plate
2, Plate-3 and Plate-4.
In this Pyramid, Side AB = Side DC; Side BC = Side AD

So, Plate 1 = Plate 3; Plate 2 = Plate 4
226
Step 3: To get Layout for Plate-1, Draw elevation View of Pyramid having Direction of
View is from Side AD, as shown in figure. And measure Length L.
Step 4: Draw the Layout for Plate-1 by using measure dimension from Previous Step
227
View is from Side AB, as shown in figure. And measure Length L.
Step 6: Draw the Layout for Plate-2 by using measure dimension from Previous Step.
228
Step 7: Layout All Four Plate to Get Complete Layout.
In this way we can generate fabrication layout of Pyramid using Geometrical Method or
Numerical Method for Pyramid Layout.

Numerical Method for Pyramid Development is very faster and time saving method for
layouting, you can calculate the values of layout dimension by solving manually on scientific
calculator or you can use any computerized tool for solving such as MS excel or any other tool
for Calculates Values in faster way.
Now we will move towards learning Numerical Method for Pyramid fabrication
Step 1: Define Round to Rectangle Generalised Diagram
229
Step 2: Define Variables for Pyramid Layouts
Let,
L = Base Length of Pyramid
W = Base Width of Pyramid.
H = Height of the Pyramid
S = Slant height of the Pyramid.
S1, S2, S3, S4 = Development Marking Length for Plate 1, Plate 2, Plate 3, Plate 4.
In this Case
Plate 1 = Plate 3
Plate 2 = Plate 4
230
Step 3: Calculate development Marking length S1 & S2.
s1 = |(})} + H2
S2 = |(}). + H2
S3 = S1
S4 = S2
Step 4: Mark Layout using Previous Calculated Value for Plate 1 and Plate 2.
O O
o (D
Plate -1 Plate -2
A W |B A L |B
Layout For Plate - 1 Layout For Plate - 2
Step 5: Layout All Four Plate to Get Complete Layout
Plate-2 Plate-4
Plate -1 Plate -3
Pyramid Layout Development in very faster and efficient way.
231
In above Two Methods we learn How to Layout Pyramid Using Geometrical and
Numerical Methods, now we will see one Practical Example Solution Using Numerical Method
so that we can understand in better layouting by practicing it Practically.

Method
Example: Generate Fabrication Layout Development Markings of Pyramid Shape for
Following Sizes:
400
-—
#
§
Solution:
Given Data:
L = 500.
W = 400.
H = 600.
In this Case
Plate 1 = Plate 3
Plate 2 = Plate 4
S1 = Jéº + H2 = Jºy + 6002 = 650

S2 = Jº Jº
+ H2 = + 6002 = 632.45
S3 = S1 = 650
S4 = S2 = 632.45
232
Step 3: Mark Layout using Previous Calculated Value for Plate 1 and Plate 2.
This is Final Fabrication Layout Markings of Pyramid Layout Given Example solved by
using Numerical Method. You have to practice this method to become master in this type of
233
Example Solution Checking for Pyramid
Layouts
Application Icon:
Pyramid Layouts we had also added Screen Shots for Better Understanding of this Checking
Methods.
234
Step 2: Enter Input data of Base Length, Width, Height of Pyramid in Input Fields and
Click on Calculate Button.
235
18. Truncated Pyramid
Layout Development
Truncated Pyramid Type Shape is also used in Fabrication for Various types of Application
such making Hoppers and any other types of requirement in fabrication Industry. In this
Chapter we are learning Truncated Pyramid. Truncated Pyramid fabrication Majorly used in
Feed Plants where big type of Storage Bins having Discharge side made as Truncated Pyramid
Type shape to free flow of Materials from Bins. It is very useful if You have knowledge of
fabrication layout of this types of Shape. So, in this Chapter we are covering all the Points
related to Truncated Pyramid fabrication Layout Development so that you can learn in depth
and used this method in daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Truncated
Pyramid Fabrication Layout Development to understand use of this method for layout
more examples yourself and verify your answer by our tools and become expert in Truncated
Pyramid Fabrication Layout Development.
Geometrical Method for Truncated Pyramid

Layout
Geometrical Method of Truncated Pyramid Layout Development is also called Graphical
Method of Truncated Pyramid Layout Development, in this layouting Method layout marking
are developed using direct measuring of Geometrical shape of Truncated Pyramid. This
236
Now, we will move towards learning Truncated Pyramid Fabrication Layout Development
Step 1: Draw Elevation and Top View of Truncated Pyramid.
Step 2: Mark Corner points as A, B, C, D & P, Q, R, S as Shown and Name Each Side as
Plate-1, Plate-2, Plate-3 and Plate-4.
In this
Plate
Side
So, AB
BC Side34AD
21 Pyramid,
==Plate DC
237
View is from Side AD, as shown in figure. And measure Length S1.
238
View is from Side AB, as shown in figure. And measure Length S2.
239
In this way we can generate fabrication layout of Truncated Pyramid using Geometrical
Numerical Method for Truncated Pyramid

Layout.
Numerical Method for Truncated Pyramid Development is very faster and time saving
Now we will move towards learning Numerical Method for Truncated Pyramid
fabrication layout development in this Method.
Step 1: Define Truncated Pyramid Generalised Diagram
240
Step 2: Define Variables for Truncated Pyramid Layouts.
Let,
L1 = Base Length of Pyramid.
W1 = Base Width of Pyramid.
L2 = Top Length of Pyramid.
W2 = Top Width of Pyramid.
S = Slant height of the Pyramid.
S1, S2, S3, S4 = Development Marking Length for Plate 1, Plate 2, Plate 3, Plate
4.
In this Case
Plate 1 = Plate 3
Plate 2 = Plate 4
241
S1 = √(��−��
)��+ ��
��
��
S2 = √(��−��)��+
S3 = S1
S4 = S2
Step 4: Mark Layout using Previous Calculated Value for Plate 1 and Plate 2
Truncated Pyramid Layout Development in very faster and efficient way.
In above Two Methods we learn How to Layout Truncated Pyramid
Practically.
242
Method
Example: Generate Fabrication Layout Development Markings of Truncated Pyramid
Shape for Following Sizes:
450
-—
250} O
O
c
3
LO
3
OW;
Solution:

450
Given Data:
Plate-1
L1 = 500 T] | 250} | U
W1 = 450 # O # 3
- O Lo
L2 = 200 * CN No
W2 = 250 Plate –3
H = 350.
In this Case
Plate 1 = Plate 3 -
Plate 2 = Plate 4
O
Lſo
co
S1 = Jºy + H2 = N (**): 13502 – 380.78

sº-Jº tº -Jeºisso. = 364
243
S3 = S1
S4 = S2
Step 3: Mark Layout using Previous Calculated Value for Plate 1 and Plate 2
This is Final Fabrication Layout Markings of Truncated Pyramid Layout Given Example
solved by using Numerical Method. You have to practice this method to become master in this
type of layouting and after practicing you will have confidence in your layouting and in latter
part after become expert you reduce your work by using method with the help of computerizes
244
Example Solution Checking for Truncated
Pyramid
Application Icon:
Truncated Pyramid Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
245
Step 2: Enter Input data of Base Length, Width, Height of Pyramid in Input Fields and
Click on Calculate Button.
246
19. Sphere Petal Layout
Development
Sphere Petal Layout Development is also very useful fabrication widely used in fabrication
Storage tank of Spherical Shape. It is nothing but Ball type of Shape and its Fabrication Layout
is Developed by using Petal type layouting procedure because it is simple way of fabrication of
Sphere. Sphere is normally used for Storage Purpose such as gaseous Storage, liquid Storage
because it has larger Volume capacity in less Space. So, if you are working in fabrication
Industry then learning of this transition layout is boost your Knowledge in this Field. So, in
this Chapter we are covering all the Points related to Sphere Petal type layout Fabrication
activity.
at the end of learning this Methods, we have taken one practical Example of Sphere
yourself and verify your answer by our tools and become expert in Sphere Petal Layout
Development.
Geometrical Method for Sphere Petal Layout

Geometrical Method of Sphere Petal Layout Development is also called Graphical Method
of Sphere Petal Layout Development, in this layouting Method layout marking are developed
using direct measuring of Geometrical shape of Sphere. This Method is Basic Method for
Now, we will move towards learning Sphere Petal Layout Development using Geometrical
Method in Step by Step process.
247
Step 1: Draw Elevation and Top View of Sphere.
Note: Sphere is looking same in Top and elevation View
Step 2: Divide Top View Circle in to equal no of parts.
248
Step 3: Consider Quarter parts of Circle and marks the points.
Step 4: Project Top view Circle Divided points on Elevation View Circle & Measure
Circular Arc Distance of Points 1-2, 2-3, 3-4 & A-B, B-C, C-D.
249
Step 5: Project Top Circle Divided Points on Horizontal line to get development circle as
shown in Figure.
Development Circle highlighted by Green Colour
Step 6: Measure Arc Distance A1, A2 as Shown in figure.
Arc distance Highlighted in blue Colour
250
Step 7: Draw Half Petal Layout Pattern by Using Previous Measured Distance 1-2, 2-3, 3-4
& A-B, B-C, C-D & Arc Distance A1, A2 etc.
Step 8: Repeat Same Process to Layout Full Pattern
251
Step 9: Final Petal Layout Pattern.
In this way we can generate fabrication layout of Sphere layout using Geometrical Method
or Graphical Method of Fabrication Layout Development.
Numerical Method for Sphere Petal Layout

Numerical Method for Sphere Petal Layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Sphere Petal fabrication
Step 1: Define Sphere Generalised Diagram.
252
Step 2: Define Variables for Sphere Petal Layout
Let,
D = Sphere Diameter.
R = Radius of Sphere.
N = No. Of Parts.
& = Part Angle.

A1, A2, A3, = Arc Distance in Top View.
L1, L2, L3 = Arc Distance in Elevation View.
Step 3: Calculate development Marking Arc lengths A1, A2, A3 & L1, L2, L3 etc
OZ
— 360
T N
D
R = -
2
T XD
L1 = L2 = L3 =
_ R × 2 × 11
A1 = 180
_ R ×cos (1× 2) × & × 11

A2
180
253
(2 × α) × α × ��
��×��
A3 =
��
this layout in 12 Parts so that we had taken this formula up to L3 & A3 markings lengths. If
you want to make layout in 24 Parts then you have to take this formula up to L5 & A5 or if
you want to make layout in 36 Parts then then you have to take this formula up to L8 & A8. By
using this formula, you can calculate layout marking for any no. of parts but you to make
changes in Cos Multiplying factor by increasing to next number than previous. So then
Generalised Formula for this will Become.
= ��×��((n-1)
��
× α) × α × ��
An
no. of parts.
Step 4: Mark Petal layout as shown in Figure using previous calculated Values
Sphere in very faster and efficient way.
In above Two Methods we learn How to Layout Sphere Using

254
Method
Example: Generate Fabrication Layout Development Markings of Sphere Petal Layout of
Following Sizes:
“goo
Solution:
Given Data:
D = 1000
N = 12
Step 2: Calculate development Marking Arc lengths A1, A2, A3 & L1, L2, L3 etc.
— 360 – 360 —
& ======30
D = 1000 —
R =# ====500
L1 = L2 = L3 = ** = ** =261.8
R × 0. × TT 500 ×30 x it
A1=======261.8
A2 = ****(**):
180
*** = ****(**):***
180
= 226.72
A3 = R ×cos(2 × 2) × 3 × 1 = 500 ×cos(2x30) ×30 × 11 = 130.89

180 180
255
Step 3: Mark Petal layout as shown in Figure using previous calculated Values.
This is Final Fabrication Layout Markings of Sphere Petal Layout Given Example solved
256
Example Solution Checking for Sphere Petal
Layout
Mobile Application Name: Petal Layouts
Application Icon:
Sphere Petal Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
Step 1: Select Sphere Option from Application Menu.
257
Step 2: Enter Input data of Sphere Diameter and Click on 12 Parts Button.
Only Change in this Result Page is nomenclature is Different so please verify your
L1, L2, L3 Values with H and A1, A2, A3 Values with L1, L2, L3 values of Application.
258
20. Dish Ends Petal Layout
Development
Dish Ends Petal Layout Development is also very useful and widely used in fabrication and
Insulation Industry. Dish Ends Petal type layout is majorly used in Insulation Industry and it
can be also used in fabrication for various application. So, if you are working in Insulation and
fabrication Industry then learning of this Dish ends Petals layout is boost your Knowledge in
this Field. So, in this Chapter we are covering all the Points related to Dish Ends Petal type
layout Fabrication Layout Development so that you can learn in depth and used this method in
daily fabrication activity.
at the end of learning this Methods, we have taken one practical Example of Dish Ends Petal
yourself and verify your answer by our tools and become expert in Dish Ends Petal Layout
Development.
Geometrical Method for Dish Ends Petal Layout

Geometrical Method of Dish Ends Petal Layout Development is also called Graphical
Method of Dish Ends Petal Layout Development, in this layouting Method layout marking are
developed using direct measuring of Geometrical shape of Dish Ends. This Method is Basic
Now, we will move towards learning Dish Ends Petal Layout Development using
259
Step 1: Draw Elevation and Top View of Hemi Dish End.
Step 2: Divide Top View Circle in to equal no of parts.
260
Step 3: Consider Quarter parts of Circle and marks the points.
Step 4: Project Top view Circle Divided points on Elevation View Circle & Measure
Circular Arc Distance of Points 1-2, 2-3, 3-4 & A-B, B-C, C-D & SF.
261
Step 5: Project Top Circle Divided Points on Horizontal line to get development circle as
shown in Figure.
Development Circle highlighted by Green Colour
Step 6: Measure Arc Distance A1, A2 as Shown in figure.
Arc distance Highlighted in blue Colour.
262
Step 7: Draw Half Petal Layout Pattern by Using Previous Measured Distance 1-2, 2-3, 3-4
& A-B, B-C, C-D & Arc Distance A1, A2 etc
Step 8: Repeat Same Process to Layout Full Pattern
263
Step 9: Final Petal Layout Pattern.
In this way we can generate fabrication layout of Dish Ends Petal layout using Geometrical
Numerical Method for Dish Ends Petal Layout

Numerical Method for Dish Ends Petal Layout Development is very faster and time saving
Now we will move towards learning Numerical Method for Dish Ends Petal
fabrication layout development in this Method.
Step 1: Define Dish Ends Generalised Diagram.
264
Step 2: Define Variables for Dish Ends Petal Layout
Let,
D = Sphere Diameter.
SF = Straight Face.
R = Radius of Sphere.
N = No. Of Parts.
& = Part Angle.

A1, A2, A3, = Arc Distance in Top View.
L1, L2, L3 = Arc Distance in Elevation View. |
|
D— O |
C -
B — 5
A A1
Li- | A1 |
UD
Step 3: Calculate development Marking Arc lengths A1, A2, A3 & L1, L2, L3 etc
360
z = −.
R = 22
L1 = L2 = L3 = ***
A1 = *****
180
265
��×��(1×
α) × α × ��
A2 =
��
A3 = ��×��(2��×α)
× α × ��
this layout in 12 Parts so that we had taken this formula up to L3 & A3 markings lengths. If
you want to make layout in 24 Parts then you have to take this formula up to L5 & A5 or if
you want to make layout in 36 Parts then then you have to take this formula up to L8 & A8. By
using this formula, you can calculate layout marking for any no. of parts but you to make
changes in Cos Multiplying factor by increasing to next number than previous. So then
Generalised Formula for this will Become.
= ��×��((n-1)
× α) × α × ��
An
��
no. of parts.
Step 4: Mark Petal layout as shown in Figure using previous calculated Values
Dish Ends Petal Layouts in very faster and efficient way.
In above Two Methods we learn How to Layout Dish Ends Petal
Layout Using Geometrical and Numerical Methods, now we will see one Practical Example
Solution Using Numerical Method so that we can understand in better layouting by practicing
it Practically.
266
Method
Example: Generate Fabrication Layout Development Markings of Dish Ends Petal
Layout of Following Sizes:
1000
3
Solution:
Given Data:
D = 1000
SF = 50
N = 12
Step 2: Calculate development Marking Arc lengths A1, A2, A3 & L1, L2, L3 etc.
360 360
o: = + = + = 30
N T 12
– D – 1000 —
R =# ====500
L1 = L2 = L3 = **
N
= ***
12
= 261.8
R × 0. × TT 500 × 30 × TT
A1 = 180 T 180 = 261.8
267
_R ×cos(1×
A2 = 3) × 2 × t
180 -
500 ×cos (1x30)
180
×30 x it = 226.72
A3 = R ×cos(2 × 2) × 2 × 11 – 500 xcos (2x30) ×30 × 11 = 130.89

180 180
Step 3: Mark Petal layout as shown in Figure using previous calculated Values.
D O
co
o
cºl
C– 131.8
co
o
cºn
B 226.7
co
to
col
A 261.8
261.8
c
Lo
This is Final Fabrication Layout Markings of Sphere Petal Layout Given Example solved
Note — For Petal Type Layout Development of other Types of Dish Ends Such as
Tori Spherical, Ellipsoidal Dish Ends You Need to use Geometrical Method of Petal
Layout. Above Discussed Numerical Method is only for Hemi Type Dish Ends. So,
For Other Type of Dish Ends other than Hemi head. its layout is Generated by Using
Geometrical Method as same as Hemi Head
268
Example Solution Checking for Dish Ends Petal
Layout
Mobile Application Name: Petal Layouts
Application Icon:
Dish Ends Petal Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
Step 1: Select Sphere Option from Application Menu.
269
Step 2: Enter Input data of Sphere Diameter and Click on 12 Parts Button.
Only Change in this Result Page is nomenclature is Different so please verify your
L1, L2, L3 Values with H and A1, A2, A3 Values with L1, L2, L3 values of Application.
270
21. Miter Bend Layout
Development
Miter Bend is also Called as Fabricated bend, Segment Bend, Cut bend. It is widely used in
fabrication Industry of Piping, Ducting and Process Equipment fabrication. So, if you are
working in fabrication of Piping, Ducting and Process Equipment Manufacturing Industry
then learning of this Miter Bend fabrication layout is boost your Knowledge in this Field. So, in
this Chapter we are covering all the Points related to Miter Bend Fabrication Layout
at the end of learning this Methods, we have taken one practical Example of Miter Bend
yourself and verify your answer by our tools and become expert in Miter Bend Fabrication
Layout Development.
Geometrical Method for Miter Bend Layouts

Geometrical Method of Miter Bend Layouts Development is also called Graphical Method
of Miter Bend Layouts Development, in this layouting Method layout marking are developed
using direct measuring of Geometrical shape of Miter Bend. This Method is Basic Method for
271
Now, we will move towards learning Miter Bend Fabrication Layout Development using
Step 1: Draw Elevation for Miter Bend
Step 2: Mark each part of Miter Bend.
272
Step 3: Consider First Part for Development Marking Layout.
Step 4: Draw half Circle for First Parts and Divide Circle in equal no of Parts as shown in
figure
Half Circle Highlighted in Green Colour

Divided Circle lines Highlighted in Red Colour
273
Step 5: Project half circle divided parts lines Vertically as shown in figure.
Projected lines highlighted in Red Colour.

Step 6: Marks the Projected lines on First Parts as Shown in Figure & Measure Length 1
1’, 2-2’, 3-3’, 4-4’, 5-5’, 6-6’, 7-7’.
274
Step 7: Mark layout of Part -1 & Part - 4 as shown in Figure using measured Value in
previous Step.
Layout of First & Last Parts is same.
Step 8: Mark layout of Part-2 & Part - 3 as shown in figure.
275
Step 9: Final Layout of all Parts.
In this way we can generate fabrication layout of Miter Bend, Fabricated Bend, Segment
Bend or Cut Bend using Geometrical Method or Graphical Method of Fabrication Layout
Development.
276
Numerical Method for Miter Bend Layouts
Numerical Method for Miter bend Fabrication Layouts Development is very faster and
Now we will move towards learning Numerical Method for Miter Bend fabrication
Step 1: Define Miter Bend Generalised Diagram.
Step 2: Define Variables for Miter Layout
Let,
d = Miter Bend Diameter.

R = Centre Radius of Bend
P = No. of Parts of Bend or No of Segment.
W = No. of Weld joint
N = No. of Parts to Divide Base Circle.
α = Miter Angle.
Θ = Angle of turn or Bend Overall Angle.
277
Part-4
Weld Joint
Part-1
L–H |--|--
Step 3: Calculate 0, 3 etc.

G) 4-f
OZ F Or OZ = — +.
2x (P-1) 2XW --~~
- 1 2 3 4 5 6 7
_ 360
g == Q
Step 4: Calculate development Marking lengths 1-1’, 2-2’, 3-3', 4–4, 5-5, 6–6, 7–7 etc
1-1’ = (R – (d/2)× cos(0 × 3)) x tan &
2-2' = (R – (d/2)× cos(1 × 3)) x tan &
3-3’ = (R – (d/2)× cos(2 × 3)) x tan &
4-4’ = (R – (d/2)× cos(3 × 3)) x tan &
5-5’ = (R – (d/2)× cos(4 × 3)) x tan &
6-6’ = (R – (d/2)× cos(5 × 3)) x tan &
7-7' = (R – (d/2)× cos(6 x 3)) x tan &
278
this layout in 12 Parts so that we had taken this formula up to 7-7’ markings lengths. If you
Ln = (��− (��)×⁄
��((��
− ��)× β)) × ��α
no. of parts.
Step 5: Mark layout of Part -1 & Part - 4 as shown in Figure using Calculated Value in
previous Step.
Step 5: Mark layout of Part-2 & Part - 3 as shown in figure given below.
279
Step 6: Final Layout of all Parts.
Miter Bend in very faster and efficient way.
In above Two Methods we learn How to Layout Miter Bend Using
280
Method
Example: Generate Fabrication Layout Development Markings of Miter Bend Shape for
Following Sizes:
Part-4
Part-3
Weld Joint
~, Part-2
3| | | w
*| || 2 | \ Part-1
| X* 2^
Z-Y-T \
300
Solution:
Given Data:
d = 300
R = 450
P = 4
W = 3
N = 12
(C) = 90
Step 2: Calculate 0, 3 etc.

G) 90
T 2. ET, T 2. (TT) T 15 Degree.
OR
G) 90
= 2XW
± = 2×3
± = 15 Degree
281
====
1-1’ = (R – (d/2)× cos(0 × 3)) x tan &
1-1’ = (450 – (300/2)× cos(0 × 30)) x tan 15
1–12 = 80.30
2-2' = (R – (d/2)× cos(1 × 3)) x tan &
2-2' = (450 – (300/2)× cos(1 × 30)) x tan 15
2-2' = 85.77
3-3’ = (R – (d/2)× cos(2 × 3)) x tan &
3-3’ = (450 – (300/2)× cos(2 × 30)) x tan 15
3–3’ = 100.48
4-4’ = (R – (d/2)× cos(3 × 3)) x tan &
4-4’ = (450 – (300/2)× cos(3 x 30)) x tan 15
4-4” = 120.57
5-5’ = (R – (d/2)× cos(4 × 3)) x tan &
5-5’ = (450 – (300/2)× cos(4 × 30)) x tan 15
5-5’ = 140.67
6-6’ = (R – (d/2)× cos(5 × 3)) x tan &
6-6’ = (450 – (300/2)× cos(5 x 30)) x tan 15
6–6’ = 155.38
282
7-7 = (R – (d/2)× cos(6 × 3)) x tan &
7-7°– (450 – (300/2)× cos(6 x 30)) x tan 15
7-7° = 160.76
Step 4: Mark layout of Part -1 & Part - 4 as shown in Figure using Calculated Value in
previous Step.
6 Z 6
: f:;:#: #
; ;;;;;; :
6' 7. o
This is Final Fabrication Layout Markings of Miter Bend Given Example solved by using
Numerical Method. You have to practice this method to become master in this type of
283
Example Solution Checking for Miter Bend
Layout
Mobile Application Name: Miter Bend Layouts
Application Icon:
Miter Bend Layouts we had also added Screen Shots for Better Understanding of this Checking
Methods.
Step 1: Enter Input data as Bend Diameter, Centre radius, No of Parts and Degree of turn
in Inputs Fields and Click 12 lines Check box option Click on Calculate Button.
284
Step 2: Match Result values of First and last Part Layout Development with your
Calculated values. if your calculated values Match with this Result Page Value then you are
correct if your values is not matching with result page values then recheck your calculation and
Find out Correct values for Accurate Result.
Step 3: Match Result Values of Middle Parts with your Calculated Values if your calculated
values Match with this Result Page Value then you are correct if your values is not matching
with result page values then recheck your calculation and Find out Correct values for Accurate
Result.
In Such way that You can Check you Result by this Process or you can also check using any
methods you known. We are using this method we had already tested result of this app so we
testing our result using this application.
285
22. Screw Flight Layout
Development
Screw Flight Layout development is most useful for those who are working in fabrication
Screw Conveyor Manufacturing Industry. It is also used in agitator, Mixers and Ribbon
Blenders for Various types of Blending Operation. Moving Part used in Screw Conveyor is
Called Screw Flight it made by using Forming methods. So, for Forming Process Required
Raw Blank Plate Size is calculated by using this Method. So, in this Chapter we are covering all
the Points related to Screw Flight Layout Development so that you can learn in depth and used
this method in daily fabrication activity.
We are going to explain this layout in Numerical Methods and at the end of learning
this Methods, we have taken one practical Example of Screw Flight Fabrication Layout
Development to understand use of this method for layout Development, at the end of this
Example Solution. We had also provided you example solution checking method using our
tool so that you can verify your calculation with some tested tools and make you confident in
fabrication layout. You can Practice this method taking more examples yourself and verify your
answer by our tools and become expert in Screw Flight Fabrication Layout Development.
Numerical Method for Screw Flight Layouts

Numerical Method for Screw Flight Fabrication Layouts Development is very faster and
Now we will move towards learning Numerical Method for Screw Flight fabrication
286
Step 1: Define Screw Flight Generalised Diagram.
Step 2: Define Variables for Screw Flights Layout.
Let,
D = Screw Outside Dimeter.
d = Inside Diameter or Pipe Diameter
P = Pitch of Screw Flight.
h = Width of Screw Flight.
R1 = Development Outside Radius
R2 = Development Inside Radius
α = Development Angle.
β = Radial Cut Angle.
X1 = Radial Outer Cord Length
X2 = Radial Inside Cord Length β
287
Step 3: Calculate Development Parameters R1, R2, X1, X2, X, 3 etc.
I
+
-—nº
ſ
L = VP2 + (11 × D)?
1 = y/P2 + (11 × d)?

_ LXh
R1
X1 = 2 × R1 × sing
X2 = 2 × R2 × sing
288
Step 4: Final Development layout Pattern.
So, by using this Numerical Formulae you can generate fabrication Layout Development of
Screw Flight layout in very faster and efficient way.
In above Method we learn How to Layout Screw Flight Layout Using

Numerical Method, now we will see one Practical Example Solution Using Numerical Method
so that we can understand in better layouting by practicing it Practically.
289
Method
Example: Generate Fabrication Layout Development Markings of Screw Flight for
Following Sizes:
300 -
Solution:

Given Data:
D = 350
d = 50
P = 300
h = 150
Step 2: Calculate Development Parameters R1, R2, 0, 3, X1, X2.
—
h = D-d – 350-50 –
:---- = 150
L = y/P2 + (11 × D)?
L = V3002 + (it x 350)?

L = 1139.74
290
1 = y/P2 + (trx d)?
1 = y/3002 TG X50)?
1 = 338.63
LX h 1139.74 ×150
R1 = = — = 213.4
L–l 1139.74 –338.63
R2 = R1 — h = 213.4 – 150 = 63.4
L T 1139.74 180
OZ R1
- — 180 =
— 213.4 X —
T E 306
3 = 360 – c. = 360 – 306 = 54
x1 = 2x R1 x sin (3/2) = 2 x 213.4 x sin(*) = 193.76

x2 = 2x R2 x sin (3/2) = 2 x 63.4 × sin(*) = 57.56
Step 3: Final Development layout Pattern.
345.28
54
213.4
This is Final Fabrication Layout Markings of Screw Flight Given Example solved by using
Numerical Method. You have to practice this method to become master in this type of
291
Example Solution Checking for Screw Flight
Layout
Mobile Application Name: Screw Flight
Application Icon:
Screw Flight Layouts we had also added Screen Shots for Better Understanding of this
Checking Methods.
Step 1: Enter Input data as Screw Diameter, Shaft Diameter, Screw Pitch, Blade Thickness
and select Material in Inputs Fields Click on Calculate Button.
292
Step 2: Match Result values with your Calculated values. if your calculated values Match
In this way we had learned most useful Methods for Fabrication layouting of Most
common Useful shapes in Fabrication Field. We hope that this knowledge is help you in build
your knowledge and skills in fabrication layout Development and you will become Master in
Fabrication layout Development.
293
Acknowledgement
I take this opportunity to thanks many people. When you write a book that is result of your
experience and your experience spans a couple of decades, there are countless people to
thanks! They include many people I have worked with, meets with that have contributed my
learning, building my experience in this fields. I thank to all organisations who given me chance
to build my career with them and help me to build my knowledge and experience in their
workshops and given chance to test my innovations, my research works with practical
experiments on their own equipment that help me to build my confidence in my work. I really
thank to all those organisation I work with them who help me finding out real practical
problems and difficulties comes in to fabrication field and that help me to research on that
problems and find solutions of these problems and this book is comes in to picture to helps all
those who are starting their career in fabrication.
I thank to my parents and my sweet wife who helps me to motivate

me every time and always be with my all decision and continuously supports me in every
situation.
I would like to thanks Mr. Paras Ram who guide me at starting of my

career in fabrication and continuously helps me to become expert in fabrication and share his
experience, skills, knowledge with me to build myself in this field of fabrication.
I would like to thanks Mr. Nitin Bagle who help me generating idea
to learn, guide and Digitize this fabrication techniques and that leads me to become an
entrepreneur and birth of this Let’sFab Education Services happened.
I would like to thanks Mr. Sunil Khalane who is always motivate and
cheers me to developed new products and always be with me from my childhood.
I would like to thanks Mr. Papalal Pinjari who is my Mentor and

Guide to influence my life to become successful, passionate, motivated, loyal and Credit of my
all Success goes to this person who build my life.
There is no way I can name all of them or hope to remember all the
people who helped me in my journey so far. But I know from my heart that I am grateful to
live in this wonderful time and be touched by all these magical people. It’s with Gratitude and
Joy that I share this book with all of You.
294
About the Author
Founder and CEO

Let’sFab Educational Services.
Learn, Guide and Digitize Fabrication Techniques.
Hello! I am Imran Sattar Pinjara. Nice to meeting you!
I am an Entrepreneur and Investor. I started Let’sFab in Sept 2016, led it as Founder and
CEO of Let’sFab Educational Services. I founded this company by finding Solutions to my
problems and difficulties arise during working in the field of fabrication. That helps me to
develop this idea of converting all fabrication techniques in to Digital Products. We have
converted many fabrication tools for increase efficiency, increase accuracy and save time of
fabrication we had developed eBooks, Mobile Applications, Excel utilities, E-Learnings, Video
Courses and Software etc. Our Aim is to convert all possible fabrication techniques in to digital
products.
I have 7+ Years of Professional Experience in Fabrication of All types

of Process Equipment, Conveying Equipment, Piping and other heavy fabrication. I had
worked in many fabrications Industries from Small Fabrication Workshop to MNC Company.
Whatever I learned and tools or products we had developed is practically tested and verified
during working in fabrication field.
I had Completed PGDM in Process Piping Design and Engineering as

Per ASME 31.3 from IPEBS Hyderabad. I had Experience of using many Software used in
fabrication such as Auto Cad, PV Elite, Plate and Sheet Professionals, Solid Works, CEASER
II, PDMS, CATIA, PRO-E.
I had Completed B.E in Mechanical Engineering Stream from Godavari College of

Engineering, Jalgaon. If you like our book then let all your friends know about the book.
Please Join us on our YouTube Channel to learn about fabrication and visit our website
www.letsfab.in to get update and know about our products. You Can follow us on Facebook,
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295
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296
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Website : www.letsfab.in Email: supports@letsfab.in.
299

Master in Fabrication Layout Development PDF

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1. Pipe or Shell Layout Development 06

Geometrical Method for Pipe or Shell Layout

Geometrical Method of Pipe or Shell Layout Development is also called Graphical

Step 2: Define variables for layout development.

T = Thickness of Pipe or Shell.

Plate Width W = It x (ID + T )

Plate Width W = It x (OD — T )

Plate Width (W)

Calculation on the Basis of Mean Diameter:

Plate Width W = It x (OD — T)

Plate Width W = It x (300 – 6) = 923.62 mm

Calculation on the Basis of Inside Diameter:

Plate Width W = It x (ID + T)

Plate Width W = It x (288 + 6) = 923.62 mm

Plate Size = 923.62 x 500 x 6. Thk

Plate Width (W) = 923.62

Download Website: www.letsfab.in/our-apps

Mobile Application Name: Branch Pipe Layouts

Geometrical Method for Truncated Pipe Layout

Numerical Method for Truncated Pipe Layout

1'-1” = L1 – ((R – R x cos(0 × 0)) x tan & )

& = tant"( aft ) = tant"( º ) = 21.8

1°-1” = L1 – ((R – R × cos(0 × 0)) × tan & )

2’-2” = L1 – ((R – R × cos(1 × 0)) × tan & )

3’-3” = L1 – ((R – R x cos(2 × 0)) x tan & )

42-4” = L1 – ((R – R × cos(3 × 0)) × tan & )

6'-6" = L1 – ((R – R × cos(5 × 0)) × tan & )

7°-7” = L1 – ((R – R x cos(6 × O)) x tan & )

Download Website: www.letsfab.in/our-apps

Mobile Application Name: Branch Pipe Layouts

Geometrical Method for Pipe to Pipe

Numerical Method for Pipe to Pipe Intersection

& = Part Angle.

Step 3: Calculate Q, P, R required in fabrication layout marking calculations.

1-1’ = C – (R × cos(0 × 0.) )

Ln = ��− (�� − ��)×

In above Two Methods we learn How to Layout Pipe to Pipe

Example: Generate Fabrication Layout Development Markings for Pipe to Pipe

Step 1: Note Down the Given Data of the Example.

& = Part Angle.

Step 2: Calculate Q, P, R required for layout marking length calculations.

1-1’ = C – (R × cos(0 × 0.) )

2-2' = C – (R × cos(1 × 0.) )

3-3’ = C – (R × cos(2 × 0.) )

4-4* = C – (R × cos(3 × 0.) )

5-5’ = 3-32 = 425

6–6’ = 2–2? = 370

7–72 = 1-12 = 350

Example Solution Checking for Pipe to Pipe

Mobile Application Name: Branch Pipe Layouts

Geometrical Method for Pipe to Pipe

Projected Lines are Highlighted using Green Colour.

Numerical Method for Pipe to Pipe Intersection

& = Part Angle.

Step 3: Calculate Q, P, R, r etc required in fabrication layout marking calculations.

1-1 = C – VR2 – (rx sin(0 × 2)?

In above Two Methods we learn How to Layout Pipe to Pipe

Step 1: Note Down the Given Data of the Example.

Step 2: Calculate Q, P, R, r etc. required for layout marking length calculations.

1-1 = C – VR2 – (rx sin(0 × 2))?

2-2' = C – VR4 – (rx sin(1 × 2))”