LaOMRen & Toubro Limited- GGSRP Comp.

Works Bathinda
Welding Process wise Comparisons of Cost / ID
Date: 23.09.2020
SMAW FCAW
Sl. No. Elements of Cost GMAW ( Root) SMAW (Root) (Fill up & (Fill up & Remarks
Final) Final)
1 Average Cost of Welding Consumables / ID ( OMR.) 0.25 0.03 0.14 0.10

2 Average Cost of Welder / ID ( OMR.) 0.15 0.38 0.50 0.21

4 Average Cost of Grinding Wheel / ID ( OMR.) 0 0.041 0.041 0.015

5 Average Cost of Grinder / ID ( OMR.) 0 0.38 0.38 0.2 0.000

6 Average Cost of Welding Machine / ID ( OMR.) 0.15 0.02 0.02 0.25

7 Average Cost of Power for Electrodes Baking / ID ( OMR.) 0 0 0.04 0

8 Average Cost of Power for Welding / ID ( OMR.) 0.49 0.35 1.71 0.81

TOTAL COST / ID ( OMR.) 1.05 1.205 2.841 1.580 1032694

Note : All cost in Indian Rupees

79438
SMAW 4.045 OMR 4,177,521 ₹0 3177.52
SMAW + FCAW 2.785 OMR 2,876,186 ₹ 1,301,334 1059.173
GMAW + FCAW 2.6292031576 OMR 2,715,162 ₹ 1,462,359
Wave infra
Puratha
2669841
OMR 45,321 0.400685
6663193

000000Sensitivity: LNT Construction Internal Use

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 LaOMRen & Toubro Limited - GGSRP Comp. Works Bathinda
Welding Cost Working sheet for Welding Processes / ID
Date: 23.04.2010
(A) CONSUMABLE COST FOR VARIOUS WELDING PROCESSES
Welding Consumable Cost Welding Consumables Consumed Per inch dia Welding Consumables Cost Per inch dia (OMR.)

Argon +CO2 Filer Wire/ Filer Wire/

Sl. No. Process Filler Wire / Electrode/Fil Argon Gas Argon +CO2 Argon Gas Total Cost
Flux Mix Filler Wire/ Roll Electrode Flux Filler Wire/ Electrode Argon +CO2 Argon Gas
Roll ler Wire per (OMR/Kg) GAS (99.995%) (Kg) (Kg) Mix GAS (99.995%) Roll Flux Mix GAS (99.995%)
(OMR/Kg.) piece (OMR) (OMR/M3) (M3) (M3)
(OMR/M3) (Nos.)

2 FCAW (E71T8-K) 1.4 NA NA 0 NA 0.068 NA NA 0.041 NA 0.0952 NA NA 0 NA 0.10

3 GMAW Root (ER70S6) 1.8 NA 0 5.0833333333 NA 0.0256 0.0256 0 0.041 NA 0.04608 NA 0 0.208416667 NA 0.25
5 SMAW Root (E6010-2.5mm) NA 0.03276 NA NA NA NA 1 NA NA NA NA 0.03 NA NA NA 0.03
SMAW (E7018-2.5mm) NA 0.02856 NA NA NA NA 2 NA NA NA NA 0.05712 NA NA NA
6 0.14
SMAW (E7018-3.15mm) NA 0.02856 NA NA NA NA 3 NA NA NA NA 0.08568 NA NA NA
(B) Average cost of welder per inch dia.
SMAW FCAW
Sl No. Activity GMAW Root SMAW Root (Fill Up
Passes) (Semi auto Fill
up Passes)
1 Productivity per Shift ( ID) 132 60 40 95
2 Avg. Salary per Month (OMR) 525 600 525 525 0.68 23.8095238 0.02856 0.01828

3 Productivity per Month 3432 1560 1040 2470 500

(26 days)( ID)
Average cost of welder per inch dia.
4 0.15 0.38 0.50 0.21
(OMR)
(C) Grinder and Grinding wheel cost
FCAW
Sl No. Description GTAW Root SMAW Root SMAW 336
(Semi auto)
1 Grinder cost per inch dia. (OMR.) 0 0.38 0.38 0.2

2 Grinder wheel cost per inch dia. 0 0.05 0.05 0.015

(OMR.)
(D) Welding M/c Cost

Avg. Avg. cost of

Monthly Daily Hire Productivity Machine / ID
Sl. No. Description Qty Hire charge charge* per day Remarks
(OMR) (OMR)
(ID) (OMR)
1 RMD Machine GMAW (Root) 1 644 24.77 162 0.15 Productivity considered only for GMAW root welding
2 Welding generatoOMR (Root) 1 25 0.96 60 0.02 Productivity considered only for SMAW root welding
3 Welding generatoOMR 1 25 0.96 40 0.02 Full welding (SMAW)
4 FCAW MACHINE 1 644 24.77 100 0.25 Only fill up passes 5850
* Considering 26 working days in a month
(E) Powe** Since this machine is new purchased, hence cost is high.
Sl.NO
Average
Average Welding time Cost per Total
1 MACHINE DESCRIPTION CURRENT KW UNITS Productivity / Total Energy unit From Cost of Cost of Power
(KWH) 12 hr Shift Consumed (Unit) Oman Power per ID (OMR)
(ID) (OMR) (OMR)
(hr)
1 RMD Miller Machine (ROOT) 16 9.890 9.890 162 8 79.120 0.057 4.51 0.49
2 ADOR WELDING MACHINE (Root) 10.2 6.305 6.305 162 9 56.746 0.057 3.23 0.35
ADOR WELDING MACHINE (Fill up &
3 12.3 7.603 7.603 40 9 68.429 0.057 3.90 1.71
Final)
6 FCAW MACHINE 14.6 9.025 9.025 100 9 81.225 0.057 4.63 0.81
Baking OVEN(1.5 KW)** 4.8 1.104 2.967 1000 12 35.605 0.057 2.03 0.04
** Oven capacity (1500 nos of electrodes / 3 hr)
For 1" dia. and 10 mm thk. No of electrode consumed is 6 nos. ( 3.15 mm 3 nos. and 2.5 mm 3 nos.)
For 1500 nos we shall weld=1500/6=250" dia.

1438.461538
57.53846154
# 000000Sensitivity: LNT Construction Internal Use