OPCO TOOLKIT

Welding methods

Root + Hot pass

Fill + Cap pass

Pipe selection

Pipe size (NPS)

Schedule

Outside diameter (D)

508 mm

Wall thickness (T)

9.52 mm

Bevel parameters

Root opening (R) 2.4 mm

Root face (F) 1.0 mm

Bevel angle (α) 75°

Pipeline length 29,600 m

Repair allowance 2%

Bevel cross-section (pass-by-pass)

Pass breakdown

Per jointGMAW (root + hot) incl. waste + repair

0.38 kg

Per jointFCAW (fill + cap) incl. waste + repair

1.00 kg

Total Project (waste + repair)

Joints (12 m)2,797

GMAW1,170 kg

FCAW3,077 kg

Combined4,247 kg

Project totals (procurement, by method)

Total joints0

Combined consumables0 kg

NPS	SCH / WT	Length (m)	Root method	Fill method	Joints	Root mass	Fill mass

Each row uses its own welding method combination. Bevel parameters (root opening, root face, bevel angle, repair allowance) are taken from the Single pipe size sub-tab.

NPS (in)	OD (mm)	Wall thickness (mm)
NPS (in)	OD (mm)

Reference: ASME B36.10M (carbon & low-alloy steel pipe). Wall thickness shown in millimetres. Empty cells indicate the schedule is not standard for that pipe size.

Stamp	Name	Process	Position	OD range	Thickness range

Stamp	Name	Process	Position	Service

Stamp	Name	Processes	Position	OD range	Thickness range

Bolt selection

Bolt material

Bolt size

Lubricant

Required torque

Torque

—

N·m

Tightening method

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3-stage tightening (per procedure)

Stage 1 — 30%

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Stage 2 — 60%

—

Stage 3 — 100%

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Based on 70% bolt yield, outer-ring reinforced spiral wound gasket. For RTJ joints, repeat the 100% chase pass. For other gasket types, consult manufacturer.

Tightening sequence

Flange NPS

Flange class

Number of bolts

Bolt count auto-fills per ASME B16.5 when you change flange size or class. You can override manually if needed.

Tighten in three passes (30% → 60% → 100%) following this diametrically-opposed sequence at every stage. After the 100% pass, do a final clockwise chase pass at 100% torque until uniform. RTJ joints require a second 100% chase pass.

Full reference table

100% torque values in N·m. Updates automatically when you change the lubricant above.

Total WDI

—

Completed WDI

—

RT/UT tested

—

Project repair rate

—

Welder leaderboard — sorted by repair rate

low-sample welders shown last

Welder	Joints	Dia/inch	Tested	Repair	Repair %	Last weld

≤ 5% excellent 5–10% normal 10–20% watch > 20% review

Daily output — last 60 days

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Overall progress

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Completed—

Balance—

Total scope—

Progress by zone

—

Quick joint estimator

Pipe size (NPS)

Schedule

Joint volume

—

cm³

Joints / day

—

joints

Time per joint

—

hours

NPS (in)	OD (mm)	Seam (m)	Joints per day (avg)
NPS (in)	OD (mm)	Seam (m)

Each cell shows joints/day based on bevel cavity volume only (cap reinforcement excluded). Bevel parameters (root opening, root face, bevel angle) are taken from the Single pipe size tab. Joint volume = groove area × pipe circumference.

Quick joint estimator

Pipe size (NPS)

Schedule

Material

Location

Joint volume

—

cm³

Joints / day

—

joints

Time per joint

—

hours

NPS (in)	OD (mm)	Seam (m)	Joints per day (Shop / Field)
NPS (in)	OD (mm)	Seam (m)

Each cell shows joints/day for a Shop welder (top, blue) and a Field welder (bottom). Shop welders work in pre-fab areas with better access and lighting; field welders work in-situ with scaffold, position constraints (5G/6G), and tighter access. The model accounts for both welding time and fit-up overhead — fit-up is shorter in shop (controlled alignment) than in field. Joint time = welding time + fit-up time; productive shift is 360 min/day. Bevel parameters (root opening, root face, bevel angle) are taken from the Single pipe size sub-tab.

Welding parameters

Acceptance range

Travel speed unit

Pass-by-pass heat input

Process	Pass	Voltage (V)	Current (A)	Travel speed (mm/min)	HI gross (kJ/mm)	HI net (kJ/mm)	Status

Reverse calculation — find required travel speed

Process

Target HI net (kJ/mm)

Voltage (V)

Current (A)

Required TS

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Heat input formula: HI = (V × I × η × 60) / (TS × 1000), where η is the process arc efficiency per AWS D1.1 / EN 1011-1. HI gross uses η = 1.0 (raw arc energy); HI net applies the process-specific efficiency and is the value typically cited in WPS / PQR documents. Acceptance ranges are typical industry practice — always defer to the project specification.

Material grade preset Auto-fills typical mid-range composition

Joint & consumable parameters

Wall thickness (mm)

Diffusible H₂ (ml/100g)

Heat input (kJ/mm)

Preheat (°C)

Results

HAZ hardness (estimate)

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Estimate based on cooling rate (preheat, HI, thickness); actual value must be verified by PQR macro test. NACE limit 250 HV for sour

PWHT recommendation

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Based on thickness + alloy content

CE_IIW

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Carbon-equivalent (general carbon steel, AWS / IIW)

HAZ hardness sensitivity to preheat

Shows how HAZ hardness drops as preheat increases (heat input and thickness held at current values).

Chemical composition (% mass, from MTR)

C (carbon)

Mn (manganese)

Si (silicon)

Cr (chromium)

Mo (molybdenum)

V (vanadium)

Cu (copper)

Ni (nickel)

B (boron)

Formulae CE_IIW = C + Mn/6 + (Cr+Mo+V)/5 + (Cu+Ni)/15.
Preheat is calculated per EN 1011-2 Method B, using CET, wall thickness, diffusible hydrogen and heat input. HAZ hardness uses the Yurioka empirical correlation (CE-based). Always cross-check against the project specification — values are advisory.