WORKSHOP

CALCULATION(UNIT 1)
INTRODUCTION AND INDUCTION TEST=10
EXAMPLES (1 HOUR)
UNITS OF LENGTH, WEIGHT, TEMPERATURE,
PRESSURE (0.5 HOUR)
AREA AND VOLUME ( 1 HOUR)
PYTHAGORAS THEOREM==DEMONSTRATION (0.5
HOUR)
TRIGONOMETRIC FUNCTIONS==
DEMONSTRATION (0.5 HOUR)
PRACTICE= 10 EXAMPLES ( 0.5 HOUR)
INTRODUCTION TO
UNITS(LENGTH)
1m = 100 cm 2.5 m= 2500 mm

1cm = 10 mm 50 in. = 127 cm

1m = 1000 mm 25300mm=25.3m

1 in. = 25.4 mm 1 ft. = 304.8 mm

INTRODUCTION TO UNITS ( PRESSURE)

PRESSURE UNIT = kg per OXYGEN PRESSURE ==

square cm OR pounds per 700 psi
square inch
700 psi = 47.58 kg/cm2
1 kg/cm2= 14.71 psi
INTRODUCTION TO UNITS ( TEMPERATURE)

TEMPERATURE UNIT == IF TEMP. IS 100F, THEN

DEGREE CENTIGRADE C=5/9( 100-32) SO,
OR DEGREE C=37.7
FEHRENHEIT
IF PREHEAT TEMP. IS
C = 5/9(F-32) 150C, THEN F=302
 AREA

DEFINATION: A SURFACE COVERED BY SPECIFIC

SHAPE IS CALLED AREA OF THAT SHAPE.
i.e. AREA OF SQUARE,CIRCLE ETC.

1. SQUARE: AREA OF SQUARE = L*L=L

L
WHERE L = LENGTH OF SIDE
L
SO IF L=5CM
THEN AREA = 5 * 5 = 25 CM
 AREA

2. RECTANGLE: AREA OF RECTANGLE = L* B

B
WHERE, L=LENGTH
B = WIDTH
IF L = 10 CM AND B = 6 CM L

THEN, AREA = 10 * 6 = 60 CM
3. CIRCLE :
AREA OF CIRCLE =
/4 * D D
WHERE D= DIAMETER OF THE CIRCLE

AREA OF HALF CIRCLE

= /8 *D
D

SAME WAY WE CAN FIND OUT AREA OF QUARTER OF CIRCLE

 AREA

3 . CIRCLE : HOLLOW BAR = * (D- d)

4 d

WHERE D = DIAMETRE OF GREATER CIRCLE

d = DIAMETRE OF SMALLER CIRCLE
D

SECTOR OF CIRCLE= * D *

4*360

D
 AREA

4. TRIANGLE: H

AREA OF TRIANGLE = B* H
WHERE B = BASE OF TRIANGLE
H = HEIGHT OF TRIANGLE B

5. CYLINDER:
D h
AREA OF CYLINDER
=*D*h
WHERE h = HEIGHT OF CYLINDER
D = DIAMETER OF CYLINDER
 AREA

EXAMPLES: 10
A1 20 A2 A3

40
TOTAL AREA OF ABOVE FIGURE
= A1+A2+A3 (A1=HALF CIRCLE,A2=RECTANGLE,A3=2NOS OF TRIANGLE)
NOW A1= D/8 (HERE D=20) NOW A2=L*B (L=40,B=20)
A1 = 3.14159 x 20 / 8 A2=40*20
= 157.079 = 800
AREA OF A3 =2(*B*H) (B=20/2=10,H=10 ) NOW AREA OF ABOVE FIGURE
A3=2(0.5 *10*10)=2(50) =A1+A2+A3 = 314.159+800+100
=100 =1214.159
 AREA

EXAMPLES : CALCULATE AREA OF GIVEN FIGURES

FIG.1
SOLUTION:
1.AREA OF CYLINDER =DH
3500MM
HERE D=3500 mm AND H=3000mm
SO A= *3500*3000 mm =32986722.86 mm
FIG.2

D1
2. AREA OF HOLLOW CYLINDER
= *( D1 - D2) HERE D1=3 m & D2=1.5 m D2
4
SO A = *(3-1.5) = 21.20 m
4 D1=3m
D2=1.5m
 VOLUME
DEFINATION: A SPACE COVERED BY ANY OBJECT IS CALLED
VOLUME OF THAT OBJECT.
SOME USEFUL FORMULAS TO FINDOUT VOLUME

1.SQUARE BLOCK : IN SQUARE BLOCK; LENGTH,

WI DTH AND HEIGHT ARE EQUAL, SO
L
VOLUME OF SQ.BLOCK =L*L*L=L L
L
2.RECTANGULAR BLOCK :
WHERE
VOLUME=L*B*H L=LENGTH
B= WIDTH H
H=HEIGHT B
L
 VOLUME

3. CYLINDER:
VOLUME OF CYLINDER
= CROSS SECTION AREA * LENGTH OF CYLINDER

D
VOLUME= D*H
H
WHERE;
D=DIAMETER OF THE CYLINDER
H=LENGTH OF CYLINDER
 VOLUME

H
4.PRISM OR TRIANGLE BLOCK :

VOLUME OF TRIANGULAR BLOCK L

B
= CROSS SECTION AREA OF TRIANGLE * LENGTH

(AREA OF RIGHT ANGLE TRIANLE= = B H )

WHERE
VOLUME = B H * L B= BASE OF R.A.TRIANGLE
H=HEIGHT OF R.A.TRIANGLE
L=LENGTH OF R.A.TRIANGLE
 TRIGONOMETRIC FUNCTIONS

TRIGONOMETRIC FUNCTIONS ARE USED X

TO SOLVE THE PROBLEMS OF DIFFERENT
TYPES OF TRIANGLE.
WE WILL SEE SOME SIMPLE FORMULAS TO SOLVE
RIGHT ANGLE TRIANGLE WHICH WE ARE USING IN
DAY TO DAY WORK. Y Z
LET US CONSIDERXYZ IS A RIGHT ANGLE TRIANGLE,
ANGLE XZY = , XY&YZ ARE SIDES OF TRIANGLE.
SO FOR THIS TRIANGLE.

SIN =FRONT SIDE /HYPOTENUSE = XY / XZ

 TRIGONOMETRIC FUNCTIONS

COS = ADJACENT SIDE / HYPOTENUSE X

= YZ / XZ

Y Z
TAN =FRONT SIDE /ADJACENT SIDE
= XY / YZ
 TRIGONOMETRIC FUNCTIONS

EXAMPLES:
FOR TRIANGLE ABC FIND OUT VALUE OF
AND . A

25 mm
WE WILL FIND VALUE OF BY TANGENT FORMULA
SO

TAN = FRONT SIDE / ADJACENT SIDE
B 25 mm C
= AB / BC = 25/25 =1
TAN = 1
= INV TAN(1) = 45
NOW, WE WILL FIND AC BY USING SINE FORMULA
SIN = FRONT SIDE /HYPOTENUSE
= AB / AC
AC = AB / SIN = 25 / SIN45 =25 / 0.7071 = 35.3556mm
 TRIGONOMETRIC FUNCTIONS

EXAMPLES:
WE WILL FIND VALUE OF BY COSINE FORMULA
A
SO
COS = ADJACENT SIDE / HYPOTENUSE

25 mm
= AB / AC = 25 / 35.3556
= 0.7071
= INV COS (0.7071) =45 B 25 mm C
 PYTHAGORAS PRINCIPLE APPLICATION

X
PYTHAGORAS PRINCIPLE:
IN ANY RIGHT ANGLE TRIANGLE A SUM OF
ADJACENT SIDE SQUARE IS
ALWAYS EQUAL TO IT HYPOTENUSE SQUARE.
Y Z

LET US SAY XYZ IS RIGHT ANGLE TRIANGLE .

XY AND YZ == ADJACENT SIDES AND XZ == HYPOTENUSE.
SO BASED ON PYTHAGORAS THEORY ,

XY + YZ = XZ
PYTHAGORAS PRINCIPLE APPLICATION

A
5
EXAMPLE : 3
PROOF OF THEORY
IN TRIANGLE ABC B 4 C
AB=3 , BC=4 AND AC=5
SO AC =AB + BC
=3 + 4 = 25
BY TAKING AC=5 SO AC = 25 IT MEANS THAT
LHS = RHS
 FAB UNIT -1 TEST PAPER

Q-1 . 5.5 M = ____________ inches = ____________mm.

Q-2. 3.4 kg/cm = ______________ psi.

Q-3 . 900 LBS = ________________kgs

Q-4. VOLUME

1200mm
20mm
2500 mm

VOLUME OF SHELL PLATE

= __________________
Q-5. AREA

100mm

100 mm
300 mm

AREAOF ABOVE SHAPE = ____________

Q-6 PYTHAGORAS
2000mm

x r
WHAT IS THE VALUE OF x ?
Q-7. PYTHAGORAS

4000 mm

5000 mm
10000 mm

WHAT IS THE VALUE OF X ?

Q-8. TRIGONOMETRIC FUNCTION

4200 mm
WHAT IS THE DISTANCE
60
BETWWEN TWO ROLLERS?

800
X
Q-9. TRIGONOMETRIC FUNCTION

X2

= 45

40

THK =60
2

18
=

X1 3

FIND OUT X1 AND X2 DISTANCE

 Q-10. TRIGONOMETRIC FUNCTION

4200 mm

800
2150 mm

FIND OUT ANGLE BETWEEN TWO ROLLER

Q-11 PYTHAGORAS

7800 mm
X

WHAT IS THE VALUE OF X ?

WORKSHOP CALCULATION
(UNIT 2)
WEIGHT CALCULATION AND WELD
DEPOSITION WEIGHT = WITH
DEMONSTRATION (2HOURS)
WEP CALCULATION, 1:3 AND 1:5
TAPER CALCULATION (1 HOUR)
PRACTICE EXAMPLES = 10 NOS. ( 1
HOUR)
 WEIGHT CALCULATION

EXAMPLES :
WEIGHT CALCULATION OF DIFFERENT ITEMS:

RECTANGULAR PLATE
CIRCULAR PLATE
CIRCULAR PLATE WITH CUTOUT
CIRCULAR SECTOR
SHELL COURCE

Specific gravity for (i) C.S.= 7.86 g/cm3 (ii) S.S.=8.00 g/cm3
 WEIGHT CALCULATION

EXAMPLES :
1. RECTANGULAR PLATE :

WEIGHT OF THIS PLATE 3.5 CM

= VOLUME * SP.GRAVITY 200 CM
=L*B*H*7.8gm/cc
HERE L=200 CM,B=WIDTH=100CM AND H=THK =3.5 CM
SO VOLUME = 200*100*3.5 cm
= 70000 cm
NOW WEIGHT OF PLATE = VOLUME * SP .GRAVITY
= 70000 *7.8 gm
= 546000gms
=546 kgs
 WEIGHT CALCULATION

EXAMPLES :

2. CIRCULAR PLATE :
300cm
WEIGHT= V *SP. GRAVITY
VOLUME V= CROSS SECTION AREA*THK
= D *4 cm THK=4 cm
= *300 *4 cm
= 282743.33 cm
SO W= V*SP.GRAVITY
= 282743.33*7.86 gms
=2222362.5738 gms
= 2222.362 kgs
 WEIGHT CALCULATION

EXAMPLES :
300cm
CIRCULAR PLATE WITH CUTOUT :

WEIGHT= V * SP.GRAVITY THK=40mm

NOW
VOLUME = CROSS SECTION AREA OF HOLLOW CIRCLE *THK OF PLATE
= (r1 - r2 ) *4 cm (WHERE r1= LARGER DIA , r2= SMALLER DIA
= (300 - 250 )*4 cm
= 345575.19 cm
NOW WEIGHT
W= V*SP.GRAVITY = 345575.19 * 7.86 gms
= 2716221 gms = 2716.221 kgs
 WEIGHT CALCULATION

EXAMPLES :
CIRCULAR SECTOR:
r1
r2
WEIGHT OF CIRCULAR PLATE SEGMENT :
W = VOLUME *SP.GRAVTY.
NOW VOLUME = CROSS SEC.AREA * THK
= * r1 - r2 * * 2 cm r1=400 cm
360 r2=350 cm
= * (400 - 350 ) * 120 * 2 THK= 2cm
360 =120
= 78539.81 cm
NOW WEIGHT = V* SP .GRAVITY
= 78539.81 *7.86 gms
=617322.95 gms
= 617.323 kgs
 WEIGHT CALCULATION

EXAMPLES :
SHELL COURCE :
W= V*SP.GRAVITY
V= *(OD - ID ) *LENGTH
HERE OD=400 + 10 =410cm
ID = 400 cm
LENGTH = 300 cm
SO V= *(410 - 400 ) *300 cm
=1908517.54 cm
NOW WEIGHT
W= V * SP. GRAVITY
=1908517.54 * 7.86 gms =15000947 gms
= 15000.947 kgs =@ 15 TON
 WEP CALCULATION

SINGLE 'V'
IN GIVEN FIGURE TO FIND OUT
A B
DIST AB WE WILL USE
= 60 98 TANGENT LAW
100 TAN q / 2 =AB / BC
C 2 HERE AB= ?, BC = 98 , q / 2 = 30
3 TAN 30 = AB / 98
AB = TAN30 98 = 0.577 98
= 56.54 mm
 WEP CALCULATION

DOUBLE 'V'
= 45 FOR DOUBLE V ALSO WE CAN CALCULATE

THK =60
40
DISTANCE BY SAME TRIGONOMETRY FORMULA
2 IN DOUBLE V THERE WILL BE TWO TYPES
18

1. EQUAL V
=
2. 2/3 rd &1/3 rd.
3
T JOINT
IN T JOINT ALSO BY TAN FORMULA
WE CAN FIND WEP DIMENSIONS:
40THK
= = AC=20 , = 5 , AB = ?
TAN = AB / AC
B
C
= 50
A AB = 20 C TAN 5
AB = 23.83
 WEP CALCULATION

COMPOUND 'V'

= 10
IN SUCH KIND OF COMPOUND V WE
56 ALWAYS DO MACHINING AND M/C IT

THK=70
SELF TAKE CARE OF ALL CALCULATION
= 45

12 AS SHOWN BY DOTTED LINE WE CAN

CALCULATE WEP DIMENSION BY SINE
R.F.= 2
OR TANGENENT LAW.

R.G.= 3
 WELD METAL WEIGHT CALCULATION

WELD METAL WEIGHT =

CROSS SECTION AREA OF PARTICULAR WEP X
LENGTH /HEIGHT /CIRCUMFERENCE OF THE SEAM X
DENSITY
BASICALLY WELD METAL WEIGHT CALCULATION IS
COMBINATION OF AREA,VOLUME TRIGONOMETRYAND
WEIGHT CALCULATION.
 WELD METAL WEIGHT CALCULATION

BASIC FUNDAMENTALS OF WELD METAL WEIGHT

CALCULATION
1.SINGLE V FOR LONG SEAM AND CIRCSEAM

FOR LONG SEAM WELD WEIGHT

= CROSS SECTION AREA C LENGTH OF SEAM C DENCITY
FOR CIRC SEAM
= CROSS SECTION AREA C MEAN CIRC.OF SEAM C DENCITY
 WELD METAL WEIGHT CALCULATION

3 1
=60 NOW A1= 2/3 C H C BEAD WIDTH
3 2 A1 = 2/3 C .3 C cm =1.2 cm
50
4

3
2
NOW A2 =A3
1.CROSSECTION AREA OF JOINT A2 = 1/2 *B*H = 0.5 * B *4.7 cm
A = A1 +A2 +A3 +A4 HERE B= 47 TAN30 =2.713CM
A2 = 0.5*2.713 * 4.7 cm
= 6.38 cm
A3 = 6.38 cm

NOW A =1.2 +6.38+6.38+ 0.94 cm

A= 14.9 cm A4 =0.2 * 4.7 cm
 WELD METAL WEIGHT CALCULATION

FOR LONG SEAM WELD WEIGHT

= CROSS SECTION AREA X LENGTH OF SEAM X DENCITY
= 14.9 cm *100 cm * 7.86 gm/cm
= 11711.4gms = 11.712 kgs for 1 MTR LONG LSEAM
FOR CIRC SEAM
= CROSS SECTION AREA X MEAN CIRC. X DENCITY
FOR CIRCSEAM HAVING OD =4000
WELD WEIGHT = 14.9 cm * P 405 * 7.86 gms
= 149009 gms = 149.009 KGS .
Taper Calculations
Whenever a Butt joint is to be made between two
plates of different thicknesses, a taper is generally
provided on thicker plate to avoid mainly stress
concentration.
x
1:3 Taper
60
40

Thickness Difference=60-40=20 mm.

X = 20 x 3 = 60 mm.
Instead 1:3 taper, if 1: 5 Taper is required, then,
X = 20 x 5 = 100 mm.
 WORKSHOP CALCULATION
(UNIT 3)
MEASURE TAPE ERROR CORRECTION AND
CIRCUMFERENCE CALCULATION= WITH
DEMONSTRATION (1 HOUR)
ORIENTATION MARKING( 0.5 HOUR )
OFFSET AND KINK, WEB AND FLANGE TILT, FLANGE
UNBALANCE CALCULATION (1 HOUR)
ARC LENGTH AND CHORD LENGTH CALCULATION
FOR WEB LAYOUT= WITH DEMONSTRATION ( 0.5
HOUR )
PRACTICE EXAMPLES= 10 NOS. (1 HOUR)
Use of calibration tape
How to refer calibration report?
Consider total error for calculation.
Standard error & relative error are for calibration
purpose only.
How to use calibration report?
Marking --Add the error.(Mad) rvaXo
Measuring --Substact the error (Mes) badbakI
During calculation, always put error value in brackets.
 Use of calibration tape
Example: Cut 1meter long bulbbar
Tape-01 Tape 02
Total error at 1m (+1) Total error at 1m (-1)
Marking of 1 m (add the error)
1000mm+(+1) mm 1000mm+(-1) mm
Marking at 1001 mm Marking at 999 mm
measure the length(substract the error)
Length found 1001 mm Length found 999 mm
1001-(+1) mm 999-(-1) mm
1000 mm actual length 1000 mm actual length
 Tape 01 (+1 mm error)

Bulb bar

Marking 1000+(+1) mm
Measuring 1001- (+1) mm error
Actual 1000 mm
 Tape 02 (-1 mm error)

Bulb bar

Marking 1000+(-1) mm
Measuring 999 - (-1) mm error
Actual 1000 mm
 Circumference calculation

Circumference = Pie * Diameter of job

If I/D is known and O/S circ. Is required then,
Circumference = Pie * (I/D+2*thick)
Here Pie value is very important.
Which is the correct value of pie?
22/7
3.14
3.1415926
Direct from calculator or computer.
 Circumference calculation

Example 1 : O/S dia of the job is 10000mm , calculate o/s

circumference.
1) 10000mm*22/7 = 31428.571 mm
2) 10000mm*3.14 = 31400.00 mm
3) 10000mm*3.1415926 = 31415.926 mm
 Circumference calculation

Example 2: Internal T-frame o/d -9998 mm

Shell thickness-34 mm ,Root gap -0.5 mm
Calculate shell o/s circumference.
Shell o/d=T-fr o/d 9998mm + root gap
(0.5mm*2) + thickness (34*2mm)
= 10067 mm
Circumference = Pie * 10067 mm
If pie = 3.1415926 then circ.= 31626.4 mm
If Pie = 22/7 then circ.= 31639.14 mm
If Pie = 3.14 then circ.= 31610.38 mm
 Offset calculation
Thickness difference measured from I/s or o/s on joining edges is called
offset.

Tolerance as per P-1402 offset

0.1T but<=2mm for web & <=3mm for flange Say T=34
mm than, Offset =0.1*34 mm=3.4mm
But max. 3mm allowed as mentioned above.
If by mistake 0.1% T considered than,
0.1*34/100 = 0.034 mm offset which is wrong.
Offset calculation

How to measure offset & kink ?

Here A=D
Offset=B-C
Kink =(A-B or C-D)
which ever is max.
Kink is nothing but D
pick-in/ pick-out
C
B

A
Offset calculation

How to measure offset& kink in case of thickness difference?

Here A=D
Offset=B-C
Kink =(A-B or C-D)
which ever is max.
D
Kink is nothing but
pick-in/ pick-out
C
B

A
 Orientation marking

Start orientation in following steps.

Measure circumference.
Check l/s orientation For reference.
Find out arc length for l/s from 0 degree.
Arc length = (circ./360)*orientation
Always take all digits of orientation given in drawing.
 Orientation marking

Example :O/s circ. = 25300 mm

L/s orientation = 75.162 degree
Find out arc length for 75.167
Arc length for l/s =(25300/360)*75.1= 5277.86mm
=(25300/360)*75.16=5282.07 mm
=(25300/360)*75.167=5282.56 mm
 Tolerances

Always read the drawing carefully to interpret tolerance correctly.

(1) Pre-tilt of web:
For 101 mm to 150 mm frame height --
0.025H but 3 mm
Example:
H=120 mm then, pre tilt = 0.025*120 = 3 mm
By mistake 0.025%H considered then,
Pre tilt = 0.025*120/100 = 0.03 mm which is wrong.
 Tolerances

How to check Pre tilt of web :[X-Y} = pre tilt

Y X
 Tolerances

(2) Flange pre tilt : <= 3 mm

[X-Y] = Pre tilt

Y
 Tolerances

(4) Out of circularity (OOC):

0.2 % R (R-theoretical radius of PRB)
Example: R = 4000 mm OOC = 0.2*4000/100
= 8 mm
(5) Flange position w.r.t web:
(Flange unbalance) :+/- 1mm
[X - Y] =2 mm

Y
Chord length

Example:Web segment size - 60 degree

Inside radius R - 4000 mm
Sine 30 =CB/4000 mm
1/2 chord length CB = 0.5*4000 mm
=2000 mm
Full chord length = 4000 mm

A C B
60 R
 CALCULATION PRACTICE

If you are marking 3500mm length with tape

1
error as (+2mm), what will be the actual

dimensions you will mark?

Add ERROR.
I.e. 3500mm +2
2 If

24mm 3200mm

What is plate length required ?

 00

3
550

44mm
6600mm

What is circumferential distance for

marking centre of nozzle ?
 32mm
4 55
I/S
54

24

60mm
21

What is kink & offset.

 S1

5 X1
S2
X2

3500mm 0 4000mm
60

Find out arc length & chord length.

 440mm
6
X1 X2

What is the maximum allowable

difference between X1 & X2
 330mm
7

Y1 600mm Y2

What is the maximum deviation allowed on Y1 & Y2

 200
8

94 90

16mm

Is the above stiffener acceptable

 27mm
9 Section 1
9mm

42mm
Section 2
18mm

Theoretical surface
8000mm ID

Outside Circumference of section 1 = 25240mm

out side Circumference of section 2 = 25295mm
 10 Out of circularity

7900mm
27mm 27mm

Maximum Out of circularity allowable= _______mm

WORKSHOP CALCULATION
(UNIT 4)
TANK ROTATOR LOCATION CALCULATION AND
SLING ANGLE FOR HANDLING A JOB CALCULATION (0.5
HOUR)
MACHINING ALLOWANCE CALCULATION FOR OVERLAY
AND MACHINING ALLOWANCE FOR BRACKET
CALCULATION (0.5 HOUR)
MARKING PCD AND HOLES FOR FLANGE CALCULATION=
WITH DEMONSTRATION ( 0.5 HOUR)
PRACTICE EXAMPLES= 5 NOS. (0.5HOUR)
TEST==> THEORY = 10 QUESTIONS
PRACTICAL= 4 QUESTIONS ( 2 HOURS )
 PYTHAGORAS PRINCIPLE APPLICATION

TRIMMING HEIGHT CALCULATION IN HEMISPHERICAL DEND

FOR MATCHING OD / ID OF DEND TO SHELL OD / ID WE HAVE TO DO ACTUAL
MARKING ON DEND FOR TRIMMING HEIGHT
WE CAN FIND OUT TRIMMING HEIGHT BY
PYTHAGORAS THEORY
AS SHOWN IN FIGURE WE CAN HAVE
FOLLOWING DIMENSION BEFORE
E D
MARKING TRIMMING A
AB= RADIUS OF DEND. BASED ON ACT B
CIRCUMFERENCE AT THAT END
AC = CD = DEND I/S RADIUS AS PER T.L
DRG.FROM T.L C
BC = STRAIGHT FACE OR HEIGHT FROM T.L TO DEND. EDGE
ED = DEND RADIUS CALCULATED FROM ITS MATCHING PARTS
CIRCUMFERENCE
BE = TRIMMING HEIGHT REQ TO MAINTAIN FOR REQ CIRCUMFERENCE OF
MATCHING PART CIRCUMFERENCE
 PYTHAGORAS PRINCIPLE APPLICATION

EXAMPLE :
AB= 1500 mm
AC = CD =1510 mm
BC =173.5 mm
ED = 1495 mm
E D
BE = ?
A
BASED ON PYTHAGORAS THEORY B
IN TRIANGLE CED CE + ED = CD
CE = CD - ED = 1510 -1495 T.L
CE = 212.3 mm C
NOW CE =CB + BE
BE = CE - CB = 212.3 - 173.5
= 38.8 mm
 TRIGONOMETRIC FUNCTIONS

TANK ROTATOR ROLLERS DIST. CALCULATION

AS SHOWN IN FIGURE WE CAN FIND OUT

TWO THINGS :
1. ANGLE BETWEEN TWO ROLLERS
2. DIST. BETWEEN TWO ROLLER FOR A
SPECIFIC DIAMETR OF SHELL .
WE WILL CHECK IT ONE BY ONE.
FOR SAFE WORKING, ANGLE
SHOULD BE 60- 90
D
C B
 TRIGONOMETRIC FUNCTIONS

TANK ROTATOR ROLLERS DIST CALCULATION

1.ANGLE BETWEENN 2 ROLLER: AS SHOWN IN FIGURE
A
BC = HALF OF THE DIST BETWEEN TWO ROLLERS
AD = SHELL O/S RADIUS
DC = ROLLER RADIUS
SO WE CAN GET ABOVE DIMENSIONS FROM DRG AND
ACTUAL DIST FROM TANK ROTATOR D
NOW AS PER SINE LAW SIN /2 = BC/ AC
AC = AD + DC (SHELL OD + ROLLER DIA )
C B
SIN /2 =BC / (AD +DC)
NOW IF WE TAKE BC=1500 mm ,AD = 2000mm AND DC = 400 mm
THEN SIN /2 = 1500 / (2000 +400 ) = 1500 / 2400 = 0.625
SIN /2 = 0.625 /2 =INV SIN 0.625 = 38.68
= 2 38.68 = 77.36
 TRIGONOMETRIC FUNCTIONS

TANK ROTATOR ROLLERS DIST CALCULATION

2.ROLLER DIST. BY DECIDING ANGLE A

BETWEEN TWO ROOLER
IF WE KEEP ROLLER ANGLE = 75
AD = SHELL O/S RADIUS =3000 mm
DC = ROLLER RADIUS = 400 mm
CE = DIST. BETWEEN TWO ROLLER D
= CB + BE = 2CB (CB = CE)
NOW BY SINE LAW C B E
SIN /2 = BC / AC BC = SIN/2 AC
BC = SIN37.5 3400 (= 75 /2=37.5 , AC = AD+DC =3000 + 400)
BC = 0.6087 3400 =2069.78 mm
DIST.BETWEEN ROLLER CE = 2 BC =2 2069.78
= 4139.56 mm
PCD & Hole Marking
Calculations
For Example, consider a flange 14-1500# with P.C.D.=600
mm & No. of Holes N= 12.
Mark P.C.D. = 600 mm.
Angular distance y = 360 / N = 360/12 = 30 degrees.
y P.C.D.
Chord length between holes
=2 x PCD x sin ( y/2 )
2
=2 x 600 x sin (30/2) N Holes
2
= 2 x 600 x 0.2588 = 155.28 mm.
2
Sling Angle Calculation.
Hook

4000
Sling Angle Calculation.

2000
CALCULATIONS

Sin = x/y
x = 2000 & y = 5000

= 23.5 0

2 = 23.5 * 2 = 470
M/Cing Allowances

Add 3 mm (min.) on all dimensions to provide for m/cing allowances.

Example of O/Lay on Gasket face of Flange:

2106 dia.(min.)
2100 dia.

8 (min.)
5

1894 dia.(max.)
1900 dia.
MACHINING ALLOWANCE CALCULATION

650

30 600 30

7 7
0 1
0 0

Machining Allowance
 FAB UNIT -1 TEST PAPER

Q-1 . 5.5 M = ____________ inches = ____________mm.

Q-2. 3.4 kg/cm = ______________ psi.

Q-3 . 900 LBS = ________________kgs

Q-4. VOLUME

1200mm
20mm
2500 mm

VOLUME OF SHELL PLATE

= __________________
Q-5. AREA

100mm

100 mm
300 mm

AREAOF ABOVE SHAPE = ____________

Q-6 PYTHAGORAS
2000mm

x r
WHAT IS THE VALUE OF x ?
Q-7. PYTHAGORAS

4000 mm

5000 mm
10000 mm

WHAT IS THE VALUE OF X ?

Q-8. TRIGONOMETRIC FUNCTION

4200 mm
WHAT IS THE DISTANCE
60
BETWWEN TWO ROLLERS?

800
X
Q-9. TRIGONOMETRIC FUNCTION

X2

= 45

40

THK =60
2

18
=

X1 3

FIND OUT X1 AND X2 DISTANCE

 Q-10. TRIGONOMETRIC FUNCTION

4200 mm

800
2150 mm

FIND OUT ANGLE BETWEEN TWO ROLLER

Q-11 PYTHAGORAS

7800 mm
X

WHAT IS THE VALUE OF X ?

PRACTICAL EXAMINATION
MARK WEB SEGMENT

INSIDE RADIUS = 3800 MM

OUTSIDE RADIUS = 4200 MM

SEGMENT ANGLE = 45
PRACTICAL EXAMINATION
ORIENTATION MARKING

MARKING ON SHELL

ORIENTATION = 237
PRACTICAL EXAMINATION
WEP MARKING

SHELL THICKNESS = 32 MM

WEP INCLUDED ANGLE = 50

ROOT FACE = 2 MM

ROOT GAP = 3 MM
PRACTICAL EXAMINATION
HOLES MARKING ON
FLANGE

PLATE OD = 800 MM
PLATE ID = 450 MM
P.C.D. = 600 MM
NO. OF HOLES = 16 NOS.
DIA. OF HOLES= 32 MM