WORKSHOP

CALCULATION
1
2
Introduction to Units ( Pressure)
PRESSURE CONVERSION
1 Kg / cm² = 14 . 223 psi ( Lb / In² )
1 Kg / cm² = 0 . 9807 Bar.
1 PSI = 0.07031 Kg / cm²

Introduction to Units (Length)

1m = 100 cm
1cm = 10 mm
1m = 1000 mm
1in. = 25.4 mm

3
 Introduction to Units ( Temperature)
Temperature unit = Degree Celsius
or
Degree Fahrenheit

C = 5/9(f-32)

If Temp. Is 100°f, Then C=5/9( 100-32)

So, C=37.7

If Preheat Temp. Is 150’c, Then F=302

4
 PYTHAGORAS PRINCIPLE APPLICATION
A
Pythagoras Principle :
In Any Right Angled Triangle a Sum of
Adjacent Side Square Is Always Equal to It
Hypotenuse Square.
B C
LET US SAY ΠABC is right angle triangle .
AB and BC = Adjacent sides and AC = Hypotenuse.
So based on pythagoras theory ,

AB² + BC² = AC²

5
PYTHAGORAS PRINCIPLE APPLICATION

Example :
A

5
3

B 4 C
Proof of theory in triangle ABC
AB = 3 , BC = 4 and AC = 5
SO AC² = AB² + BC²
= 3² + 4 ² = 25
By taking AC = 5 so AC² = 25 It means that
6
LHS = RHS
 TRIGONOMETRIC FUNCTIONS
A
Trigonometric functions are used to solve
the problems of different types of triangle.
θ
B C We will see some simple formulas to solve
right angle triangle which we are using in
day to day work.

Let us consider ΠABC is a right angled triangle,

Angle ∠ACB = θ , AB & BC are sides of triangle.
So for this triangle.

7
 TRIGONOMETRY
A

Hypoteneous SIN ø = Opposite Side = AB

Hypoteneous AC
Opposite
Side

TAN ø = Opposite Side = AB

ø Adjacent Side BC

B C
Adjacent Side

COS ø = Adjacent Side = BC

Hypoteneous AC

8
 TRIGONOMETRIC FUNCTIONS

Example : For triangle ABC find out value of θ and α.

A
α

25 mm
We Will Find Value Of θ By Tangent Formula So ,

Tan θ = Opposite Side / Adjacent Side

= AB / BC = 25/25 =1
θ
Tan θ = 1 B 25 mm C
∴ θ = Inv. Tan(1) = 45º

Now, We Will Find AC By Using Sine Formula

Sin θ = Opposite Side /Hypotenuse

= AB / AC
∴ Ac = AB / Sin θ = 25 / Sin45 =25 / 0.7071 = 35.3556mm 9
 TRIGONOMETRIC FUNCTIONS
Example: We Will Find Value Of α By Cosine Formula
A
α

25 mm

θ
B 25 mm C

Cos α = Adjacent Side / Hypotenuse

= AB / AC = 25 / 35.3556
= 0.7071
∴ α = Inv Cos (0.7071) = 45º 10
 TRIGONOMETRY
Example: FIND OUT ANGLE ‘ Ø ’ OF A TRIANGLE

A AB
SIN ø = OPPOSITE SIDE =
HYPOTENEOUS AC

= 30
OPPOSITE HYPOTENEOUS 50
SIDE
50
= 0.60
30
ø = InvSINE VALUE OF 0.60
ø ø = 36° - 52’
B C
ADJACENT SIDE

11
 AREA
Definition : 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 X L = L²

L
Where L = Length Of Side

L
So If L = 5cm
Then Area = 5 X 5 = 25cm²
12
 FIND OUT SIDE ‘ø ’ OF A TRIANGLE
Example:
A TAN ø = OPPOSITE SIDE = AB
ADJACENT SIDE BC

TAN 36° = 20
OPPOSITE HYPOTENEOUS
SIDE
BC
• 20
20 • • BC = TAN VALUE OF 36°
36° • 20
B C • • BC = 0.727
?
ADJACENT SIDE
•
• • BC = 27. 51 mm

13
 AREA
2. Rectangle: Area Of Rectangle = L X B
B
Where, L = Length
B = Width L
If L= 10 mm, And B = 6 mm
Then, Area = 10 X 6 = 60mm²

3. Circle :
Area Of Circle = π / 4 x D² D
Where D= Diameter Of The Circle

Area Of Half Circle = π/8 x D²

D

Same way we can find out area of quarter of circle 14

 AREA

4 . Circle : Hollow Circle = π x (D² - d²) d

4
WHERE D = Diameter of Greater Circle
d = Diameter of Smaller Circle D

Sector Of Circle= πxD²xØ

4 x 360 Ø

D
15
 AREA

4. Triangle : H

Area Of Triangle = ½ B x H
Where B = Base Of Triangle
B
H = Height Of Triangle

5. Cylinder :
D H
Surface area of Cylinder
=πxDxH
Where H = Height Of Cylinder
D = Diameter Of Cylinder
16
 VOLUME
Defination : A space covered by any object is called
volume of that object.

1. Square block : In square block; length,

width and height are equal, so L
Volume Of Sq. Block = L X L X L = L³ L
L
2. Rectangular Block :

Volume= L X B X H
Where H
B
L = Length
L
B = Width 17
H = Height
 VOLUME

H
[Link] or Triangle Block :
L
Volume of Triangular Block B
= Cross Section Area of Triangle x Length

( Area of Right Angle Triangle = ½ B H )

Volume = ½ B H X L Where
B = Base of [Link]
H = Height of [Link]
L = Length of Prism
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 VOLUME

4. Cylinder :

Volume of Cylinder = Cross Section Area x Length of

Cylinder

Volume= ¼πD² X H

D
Where : H

D = Diameter Of Cylinder
H = Length Of Cylinder

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 CG CALCULATION

CG
TAN LINE
m

DIA

CENTRE OF GRAVITY OF D’ENDS ( CG )

(1) HEMISPHERICAL ( m ) = 0.2878 r DIA

(2) 2:1 ELLIPSOIDALS ( m ) = 0.1439 r DIA
(3) TORI - SPHERICAL ( m ) = 0.1000 r DIA

20
 WEIGHT CALCULATION

Examples :

Weight calculation of different items:

• Rectangular plate
• Circular plate
• Circular plate with cutout
• Circular sector
• Shell coursce

Specific gravity for

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

Examples :
1. Rectangular plate :

CM
Weight of This Plate 3.5 CM

0
10
= Volume X [Link] 200 CM
= L X B X H X 7.86gm / CC
Here L = 200cm, B = Width = 100cm And H = Thk = 3.5 cm
So Volume = 200 X 100 X 3.5 cm³
= 70000 cm³
Now Weight Of Plate = Volume X Sp .Gravity
= 70000 X 7.86 gm/cc
= 550200 gms
22
= 550.2 kgs
 WEIGHT CALCULATION

Examples :

2. CIRCULAR PLATE :
300 cm
Weight= V X Sp. Gravity
Volume V= Cross Section Area X Thk
= ¼πD² X 4cm Thk = 4cm

= ¼π x 300² X 4cm
= 282743.33 cm³
So W = V X [Link]
= 282743.33 X 7.86 gms/cc
= 2222362.5738 gms
= 2222.362 kgs
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 WEIGHT CALCULATION
Examples :
Circular sector : R1

R2
Weight of Circular Plate Sector :
W = Volume X [Link]. ∅ = 120º
Now Volume = Cross [Link] X Thk
= π X ( R1² - R2²) X Ø X 2 cm R1 = 400 cm
360 R2 = 350 cm
= π X (400² - 350²) X 120 X 2 THK = 2cm
360 ∅ = 120º
= 78539.81 cm³
Now Weight = V X Sp .Gravity
= 78539.81 X 7.86 gms/cc
= 617322.95 gms
24
= 617.323 kgs
 WEIGHT CALCULATION
m
Examples : 300 c
Shell :
W = V X [Link]
V= ¼ π X ( OD² - ID² ) X Length 4 00 c m
Here OD = 400 + 10 = 410cm
ID = 400cm
Length = 300cm
5cm
So V = ¼π X ( 410² - 400² ) X 300cm
= 1908517.54cm³
Now Weight
W = V X Sp. Gravity
= 1908517.54 X 7.86 = 15000947gms
25
= 15000.947kgs = @ 15 Ton
 WEP CALCULATION
SINGLE 'V'
A B In given figure, to find out
Distance, we will use
θ =600
98 Trigonometric formula.

100 Tan θ / 2 = AB / BC
C 2 Here AB = ?, BC = 98, θ / 2 = 30º
3
∴ Tan 30 = AB / 98
∴ AB = Tan 30º X 98
= 56.54 mm
26
 WEP CALCULATION
Double ‘V’

For double v also we can calculate distance by

θ= 450

THK =60
40 same trigonometric formula. Double v are of
2 two types:
18 1. Equal v
θ= 600
3 2. 2/3 rd &1/3 rd.
T joint
• In t joint also by tan formula
we can find WEP dimensions:
40THK
= = AC = 20 , θ = 500 , AB = ?
B
θ = 500
Tan θ = AB / AC
C
AB = 20 x Tan 500
A
AB = 23.83
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 WEP CALCULATION
COMPOUND 'V'
P= 10

56

q= 45 THK=70

12

R.F.= 2

R.G.= 3

In such kind of compound “V”, we always do

machining to take care of all calculation.
As shown by dotted line, we can calculate WEP
dimensions by sine or tangent formula.
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 WELD METAL WEIGHT CALCULATION

Weld metal weight =

Cross section area of particular WEP x

length / circumference of seam x density

Basically weld metal weight calculation involves

Calculation of volume, trigonometry and

Weight calculation.

29
30
 WELD METAL WEIGHT CALCULATION

Basic fundamentals of weld metal weight Calculation

[Link] v for long seam and circseam

• Long seam weld weight

= Cross section area x length of seam x density
• Circ. seam weld weight
`= Cross section area x mean circ. of seam x density

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 WELD METAL WEIGHT CALCULATION

3 1 Now A1 = 2/3 x H x Bead Width

θ =60º ∴ A1 = 2/3 x 0.3 x 6 cm² = 1.2 cm²
3 2

50
4

Now A2 =A3
3
2
A2 = 1/2 x B x h = 0.5 x B x 4.7 cm²
Here B= 47 Tan30º =2.713cm
[Link] Area Of Joint ∴ A2 = 0.5 x 2.713 x 4.7 Cm²
A = A1 + A2 + A3 + A4 = 6.38 Cm²
A3 = 6.38 Cm²
Now A = 1.2 + 6.38 + 6.38 + 0.94 cm²
A = 14.9cm² A4 =0.2 * 4.7 cm²

32
 WELD METAL WEIGHT CALCULATION

For long seam weld weight

= Cross section area x Length of seam x density
= 14.9cm² x 100cm x 7.86gm/cm³
= 11711.4gms = 11.712kgs for 1 mtr long seam
For circ. seam
= Cross section area x Mean circ. x Density
For Circ. seam having OD = 4000 mm and Thk. = 50 mm
Weld Weight = 14.9cm² X 1240.9 cm X 7.86 gms/cc
= 145326gms = 145.326kgs.
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 TAPER CALCULATIONS
ÎWhenever a Butt joint is to be made between two
plates of different thickness, a taper is generally
provided on thicker plate to avoid mainly stress
concentration.

x
1:3 Taper

40 60

Thickness Difference = 60 - 40 = 20mm.

X = 20 x 3 = 60mm.
Instead of 1:3 taper, if 1: 5 Taper is required;
X = 20 x 5 = 100 mm. 34
MODULE : WORKSHOP CALCULATION
UNIT : 3

ÎMeasure tape error correction and circumference

calculation = with demonstration (1 hour)
ÎOrientation marking ( 0.5 hour )
ÎOffset and kink, web and flange tilt, flange
unbalance calculation (1 hour)
ÎArc length and chord length calculation for web
layout= with demonstration ( 0.5 hour )
ÎPractice examples = 10 nos. (1 hour)

35
 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)
Measuring - Subtract the error (Mes)
During calculation, always put error value in brackets.

36
 USE OF CALIBRATION TAPE.
Example: Cut 1meter long bulbar

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 1001mm Marking at 999mm
measure the length(subtract the error)
Length found 1001mm Length found 999mm
1001-(+1)mm 999-(-1)mm
1000mm actual length 1000mm actual length
37
Tape 01 (+1 mm error)

Bulb bar

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

38
Tape 02 (-1 mm error)

Bulb bar

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

39
 CIRCUMFERENCE CALCULATION
Circumference = Pie x Diameter of job
If I/D is known and O/S circ. Is required then,
Circumference = Pie x ( I/D + 2 x thick )
Here Pie value is very important.
Which is the correct value of pie?
22/7
3.14
3.1415926 (Direct from calculator/ computer)

40
 CIRCUMFERENCE CALCULATION
Example 1 : O/S Dia of the job is 10000mm, calculate O/S
circumference.
1) 10000mm x 22/7 = 31428.571mm
2) 10000mm x 3.14 = 31400.00mm
3) 10000mm x 3.1415926 = 31415.926mm

41
 CIRCUMFERENCE CALCULATION

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

Shell thickness - 34mm ,Root gap - 0.5mm
Calculate shell o/s circumference.
Shell o/d = T - fr o/d 9998mm + root gap
(0.5mm x 2) + thickness (34 x 2mm)
= 10067mm
Circumference = Pie x 10067mm
If pie = 3.1415926 then circ. = 31626.4mm
If Pie = 22/7 then circ. = 31639.14mm
If Pie = 3.14 then circ. = 31610.38mm
42
 OFFSET CALCULATION
Thickness difference measured from I/s or o/s on joining
edges is called offset. offset

Tolerance as per P-1402

0.1T but <= 2mm for web & <= 3mm for flange
Say T = 34 mm than, Offset = 0.1 x 34mm = 3.4mm
But max. 3mm allowed as mentioned above.
If by mistake 0.1% T considered than,
0.1 x 34/100 = 0.034 mm offset which is wrong.
43
 OFFSET CALCULATION

How to measure offset & kink ?

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

44
 OFFSET CALCULATION

How to measure offset& kink in case of thickness

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

45
 ORIENTATION MARKING

Start orientation in following steps.

• Measure circumference.

• Check long seam orientation from drawing.

• Find out arc length for long seam from 0 degree.

• Arc length = (circ./360 ) x Orientation.

Always take all digits of orientation given in drawing.

46
 ORIENTATION MARKING

Example : O/S circ. = 25300mm

L/S orientation = 75.162 degree
Find out arc length for 75.162
Arc length for L/S = ( 25300/360 ) x 75.1 = 5277.86mm
= ( 25300/360 ) x 75.16 = 5282.07mm
= ( 25300/360 ) x 75.162 = 5282.218mm

47
 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 ⊆ 3mm
Example:

H = 120mm then, pre tilt = 0.025 x 120 = 3mm

48
 TOLERANCES

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

Y X

49
 TOLERANCES

(2) Flange pre tilt : <= 3mm

[ X-Y ] = Pre tilt

50
 TOLERANCES
(4) Out of circularity (OOC) :
0.2 % R ( R-theoretical radius of PRB )
Example : R = 4000mm OOC = 0.2 x 4000/100
= 8mm
(5) Flange position w.r.t web :
(Flange unbalance) :+/- 1mm
[ X - Y ] = 2mm
X

Y
51
Example:
L = ARC LENGTH
L
a = AREA OF SEGMENT

h c = CHORD LENGTH
a q = ANGLE
C r = RADIUS
h = HEIGHT BETWEEN CHORD TO ARC

q r

(5) L= 0.0174533 rr r q
(1) c= 2 √ h (2r -h)
(6) q = 57. 29578 r L
r
( 2 ) a = 1/2 [ rL - c ( r - h ) ]
( 7 ) h = r [ 1 - COS ( q / 2 ) ]
(3) h = r - 1/2√ 4 r 2 - C2 ( 8 ) C = 2r ( Sin q / 2)
( 9 ) X = PCD ( Sin 180/ N)
(4)r = c2+4h2
8h X= Straight Distance between 2 holes &
N= No. of Holes 52
 CHORD LENGTH

A C B
60 R

Example :
Web segment size - 600
Inside radius R - 4000mm
Sine 30 = CB/4000mm
1/2 chord length CB = 0.5 x 4000mm
= 2000mm
53
Full chord length = 4000mm
 PYTHAGORAS PRINCIPLE APPLICATION
Trimming height calculation in hemispherical D’end
For matching OD / ID of D’end to shell OD / ID we have to do actual
Marking on D’end 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 D’end. Based on act B
Circumference at that end T.L
AC = CD = D’end I/S Radius as per
C
DRG. from T.L
BC = Straight face or height from T.L TO D’end. edge
ED = D’end radius calculated from its matching part’s
Circumference
BE = Trimming height req to maintain for req circumference of 54
Matching part circumference
 PYTHAGORAS PRINCIPLE APPLICATION

Example :
AB = 1500mm
AC = CD = 1510mm
BC = 173.5mm E D
ED = 1495mm A
BE = ? B
T.L
Based on Pythagoras theory C
In triangle ŒCED CE² + ED² = CD²
∴ CE² = CD² - ED² = 1510 ² - 1495²
∴ CE = 212.3mm
Now CE = CB + BE
∴ BE = CE - CB = 212.3 - 173.5
55
= 38.8mm
 TRIGONOMETRIC FUNCTIONS

Tank rotator rollers dist. Calculation

As shown in figure we can find out
Two things :
1. Angle θ between two rollers
2. Dist. Between two roller for A

specific diameter of shell . θ

We will check it one by one. α

For safe working, angle θ Should D

C B
be between 45- 60º

56
 TRIGONOMETRIC FUNCTIONS
Tank rotator rollers dist calculation
1. Angle θ between 2 roller: As shown in figure
BC = Half of the dist between two rollers A
AD = Shell o/s radius
DC = Roller radius
θ
So we can get above dimensions from DRG and
Actual dist from tank rotator D
Now as per sine formula Sin θ/2 = BC/ AC
AC = AD + DC ( Shell OD + Roller DIA ) C B
Sin θ/2 = BC / (AD +DC)
Now If We Take BC = 1500 mm, AD = 2000mm AND DC = 400 mm
Then Sin θ /2 = 1500 / (2000 + 400 ) = 1500 / 2400 = 0.625
Sin θ /2 = 0.625 ∴ θ /2 = INV Sin 0.625 = 38.68º
57
∴ θ = 2 X 38.68º = 77.36º
 TRIGONOMETRIC FUNCTIONS
Tank rotator rollers dist calculation : A
[Link] dist. By deciding angle
Between two roller
If We Keep Roller Angle = 75º θ
AD = Shell O/s Radius = 3000mm
DC = Roller Radius = 400mm D
CE = Dist. Between Two Roller
= CB + BE = 2 X CB (CB = BE)
Now By Sine Law C B E
Sin θ /2 = BC/AC ∴BC = Sin θ/2 X AC
∴ BC = Sin37.5º X 3400 (θ= 75º ∴ θ/2 = 37.5º, AC = AD + DC = 3000 + 400)
∴ BC = 0.6087 X 3400 = 2069.78 mm
∴ [Link] Roller CE = 2 X BC = 2 X 2069.78
58
= 4139.56mm
PCD & HOLE MARKING CALCULATIONS

Î For Example, consider a flange 14”-1500# with

P.C.D.=600 mm & No. of Holes N = 12.
Î Mark P.C.D. = 600 mm.
Î Angular distance y = 360 / N = 360/12 = 30 degrees.
Î Chord length between holes Y/2
P.C.D.
= 2 x PCD x Sin ( y/2 )
2
= 2 x 600 x Sin (30/2)
2 ‘N’ Holes
= 2 x 600 x 0.2588 = 155.28 mm.
59
2
SLING ANGLE CALCULATION.

Hook

00
50

60
4000
SLING ANGLE CALCULATION.

ø
00
50

61
2000
 CALCULATIONS

Sin Ø = x/y
x = 2000 & y = 5000

Ø = 23.5 0

2Ø = 23.5 X 2 = 470

62
 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.) 8 (min.)

1894 dia.(max.)
1900 dia.
63
64