WI-BLC-CG/A-01

WORK INSTRUCTION FOR BLC WAGON

OPERATION/STAGE: CENTER-SILL ASSBY (MIDDLE) A-CAR M/C NO./LOCATION : BAY NO. 9
DRAWING NO. : CONTR-9405-S/6 ALT 10 FIXTURE NO. : I-02

SL OPERATION REFRENCE DRAWING

1 VERIFY FIXTURE CALIBRATION DATE IS WITHIN

3 MONTHS. CHECK THE FIXTURE AND ENSURE
THAT ALL STOPPERS AND LEVEL PADS ARE
PRESENT AND ALL CLAMPS ARE WORKING AS
REQUIRED.

CENTRE GIRDER FIXTURES:

CENTRE GIRDER A-CAR LH&RH 1NO.
CENTRE GIRDER B-CAR LH&RH 1NO.
2 PRE-INSPECT PARTS TO DRAWING
DIMENSIONS AS SHOWN IN FIG. 1. PLACE
CENTRE SILL WEB (ITEM NO. 2.1) PLATE IN
POSITION ON FIXTURE.

ENSURE CONTACT WITH ALL STOPPERS &

48
LEVEL PADS BY SUITABLE

37
CLAMPING/WEDGING.

FIG. 1

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SL OPERATION REFRENCE DRAWING

3 PRE-INSPECT PARTS TO DRAWING

DIMENSIONS AS SHOWN IN FIG. 2. PLACE
CENTRE SILL BOTTOM PLATE (ITEM NO. 2.3) IN
POSITION ON FIXTURE.
ENSURE CONTACT WITH ALL STOPPERS &
LEVEL PADS BY SUITABLE
CLAMPING/WEDGING.
CHECK DIM 89mm & RIGHT ANGLE WITH
GAUGE AS SHOWN IN FIG. 2. ALSO CHECK DIM
78mm WITH GAUGE. FIG. 2 GAUGE
4 PRE-INSPECT PARTS TO DRAWING
DIMENSIONS AS SHOWN IN FIG. 3. PLACE
CENTRE SILL TOP PLATE (ITEM NO. 2.2) IN
POSITION ON FIXTURE.
CLAMP WITH HYDRAULICS AND ENSURE "0"
GAP AT BENDS AND MATING PARTS.
CHECK DIM 147mm & RIGHT ANGLE WITH
GAUGE AS SHOWN IN FIG. 3.

FIG. 3
GAUGE
5 TACK WELD THE WEB PLATE TO TOP AND
BOTTOM PLATE AS PER THE FOLLOWING:
A. TACK WELD SIZE TO BE LOWER THAN THE
ORIGINAL WELD SIZE, SO THAT IT IS
CONSUMED BY FINAL WELDING.
B. LENGTH OF TACK WELD SHOULD BE 3 TO 4
TIMES THE THICKNESS OF MATT.
C. TACK WELD SHOULD NOT BE DONE AT
ENDS.
FIG. 4
6 PUT CENTRE SILL ASSBY (MIDDLE) ON SAW
MANIPULATOR FIXTURE AND CLAMP SUITABLY.
WELD AS PER SPECIFICATIONS.
WELD TYPE - FILLET
WELD PROCESS - SAW
WIRE SIZE (mm) - 8
WIRE SPECIFICATION - W-4 IRS:M39-01
FLUX - F-4 IRS:M39-01
NO. OF PASS - 1
CURRENT (amp) - 500-550
VOLTAGE (volts) - 32-35
WELD POSITION - FLAT & H.V. SEQUENCE OF WELDING STARTING FROM THE CENTRE AND PROGRESS TOWARDS BOTH ENDS.
FIG. 5

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SL OPERATION REFRENCE DRAWING

7 TURN THE MANIPULATOR TO 45° ON EITHER

SIDE TO COMPLETE TOP & BOTTOM SUB-
MERGED ARC WELDING OF THE CENTRE SILL
ASSBY (MIDDLE). REPEAT THE SAME FOR THE
OTHER SIDE OF THE ASSBY.
FOLLOW THE WELDING SEQUENCE AS SHOWN
IN FIG. 5 TO PREVENT DISTORTION.
CARRY OUT GMAW FOR THE SLOPING
SECTIONS.
FIG. 6
8 LET THE ASSEMBLY COOL DOWN FOR 30MINS
BEFORE UN-CLAMPING.
FIT AND WELD STIFFENERS AS SHOWN IN FIG.
7 TO PREVENT DISTORTION.
R.H. = 16 NOS.
L.H. = 12 NOS.

WELD = 6mm FILLET

FIG. 7
9 LET THE ASSEMBLY COOL DOWN FOR 30MINS
BEFORE UN-CLAMPING.

FIT AND WELD STIFFENER FOR INSPECTION

WINDOW (ITEM NO. 2.4) AND STIFFENER FOR
PIPE (ITEM NO. 2.5) WITH THE CENTRE SILL
ASSBY. (MIDDLE).

FIG. 8
10 REPAT THE ABOVE STEPS FOR LEFT HAND
SIDE PART.

FIG. 9

PREPARED BY: SHINJAN BARDHAN

DATE: FEB, 2012
REFERENCE DRG.: CONTR-9405-S/6 ALT 10

DOC NO. - WI-BLC-CG/A-02

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