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Assembly Manpower

The document provides details of the fabrication process for a boiler, including 26 steps and estimated man hours and costs for each. It lists fabrication tasks like positioning parts, welding panels and pipes, hydrotesting, and loading the completed boiler onto a truck. It also provides estimated man hours and costs for the roles of fabricator, welder, rigger, helper and QA/QC personnel for each step.

Uploaded by

Akil Prabhu
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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62 views6 pages

Assembly Manpower

The document provides details of the fabrication process for a boiler, including 26 steps and estimated man hours and costs for each. It lists fabrication tasks like positioning parts, welding panels and pipes, hydrotesting, and loading the completed boiler onto a truck. It also provides estimated man hours and costs for the roles of fabricator, welder, rigger, helper and QA/QC personnel for each step.

Uploaded by

Akil Prabhu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Fitter Fabricator

S.No Fabrication Process Linear weld 32 Per Hr 32


Qty Sar/Hr Qty

Positioning, aligning, leveling and fixing of


1 1 Day 2 64 2
temporary boiler mounting frame.
Positioning, aligning and fixing of steam
drum and water drum on the temporary
2 1 Day 2 64 2
boiler
mounting frame.

3 Fixing Temporary supports 1 Day 2 64 2

Positioning, Aligning, fixing of Bank Rear


4 10 Day 2 64 2
wall panel (17 Panels)
Gas tight Welding of Bank Rear wall panel
5 326.4 5 Day 2 64 2
(17 Panels)

6 Positioning, Aligning, fixing of Bank Tubes 5 Day 2 64 2

Positioning, Aligning, fixing of Shield Tubes


7 1 Day 2 64 2
panel

8 Gas tight welding of Shield Tubes panel 72.8 1 Day 2 64 2

9 Fixing Temporary supports 1 Day 2 64 2

Positioning, Aligning, fixing of Furnace


10 5 Day 3 96 2
Screen tube panel (17 Panels)
Gas tight Welding of Furnace Screen tube
11 262.0 4 Day 2 64 2
panel (17 Panels
Positioning, Aligning, fixing of Furnace Side
12 10 Day 2 64 2
wall tube panel (11 Panels)
Gas tight Welding of Furnace Side wall
13 262.0 10 Day 2 64 2
tube panel (11 Panels)
Positioning, Aligning, fixing of Front wall
14 1 Day 2 64 2
Panel
Welding of Furnace front wall to side and
15 25.0 3 Day 2 64 2
screen wall panels
Positioning, Aligning, fixing of rear wall
16 1 Day 2 64 2
Panel
Welding of Furnace rear wall to side wall
17 17.0 3 Day 2 64 2
panels
Positioning, Aligning, fixing of Superheater
18 2 Day 2 64 2
Element assembly
Welding of SH Headers with Superheater
19 70 Joints 3 Day 3 96 3
Element assembly
20 Welding of Riser Tubes 2 Day 2 64 0

21 Welding of Economisers 3 Day 2 64 0

Tubes Expanding into Drums (10


22 4105 Tubes 6 Day 12 384 1
Min/Tube)

23 Bottom frame assembling 3 Day 2 64 2

Tilting the Boiler to 90 deg vertical


24 1 Day 2 64
position

25 Hydrotest 2 Day 3 96 1

26 Loading to truck 1 Day 1 32 1


Fabricator Welder Rigger Helper QA/QC
35 35 22 55 Total Man power
manhrs cost
Sar/Hr Qty Sar/Hr Qty Sar/Hr Qty Sar/Hr Qty Sar/Hr

64 2 70 1 35 4 88 0.5 27.5 103.5 3485

64 2 70 2 70 4 88 0.5 27.5 112.5 3835

64 2 70 1 35 4 88 0.5 27.5 51.75 1742.5

64 1 35 1 35 4 88 0.5 27.5 945 31350

64 4 140 1 35 4 88 0.5 27.5 607.5 20925

64 1 35 1 35 6 132 0.5 27.5 562.5 17875

64 1 35 1 35 2 44 0.5 27.5 76.5 2695

64 1 35 1 35 2 44 0.5 27.5 76.5 2695

64 1 35 1 35 2 44 0.5 27.5 38.25 1347.5

64 1 35 1 35 3 66 0.5 27.5 472.5 16175

64 6 210 1 35 6 132 0.5 27.5 630 21300

64 2 70 1 35 2 44 0.5 27.5 855 30450

64 6 210 1 35 6 132 0.5 27.5 1575 53250

64 1 35 1 35 2 44 0.5 27.5 76.5 2695

64 5 175 1 35 5 110 0.5 27.5 418.5 14265

64 1 35 1 35 2 44 0.5 27.5 76.5 2695

64 5 175 1 35 5 110 0.5 27.5 418.5 14265

64 1 35 1 35 2 44 0.5 27.5 153 5390

96 3 105 1 35 3 66 0.5 27.5 364.5 12765


0 2 70 1 35 2 44 0.5 27.5 135 4810

0 2 70 1 35 2 44 0.5 27.5 202.5 7215

32 1 35 0 0 10 220 0.5 27.5 1323 41910

64 5 175 1 35 4 88 0.5 27.5 391.5 13605

0 2 70 2 70 2 44 0.5 27.5 76.5 2755

32 3 105 0 0 2 44 0.5 27.5 171 6090

32 2 70 2 70 1 22 0.5 27.5 67.5 2535

9981 338120
Manhr/pr
Total Manhrs
ocess

11.5 11.5

12.5 12.5

11.5 5.75

10.5 105

13.5 67.5

12.5 62.5

8.5 8.5

8.5 8.5

8.5 4.25

10.5 52.5

17.5 70

9.5 95

17.5 175

8.5 8.5

15.5 46.5

8.5 8.5

15.5 46.5

8.5 17

13.5 40.5
7.5 15

7.5 22.5

24.5 147

14.5 43.5

8.5 8.5

9.5 19

7.5 7.5

1109

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