JINDAL RAIL

INFRASTRUCTURE LTD
DETAILED ANALYSIS ON WELDING CONSUMABLES
 Month wise consumption of Consumables
  Contact Tip Steel Liner Gas Nozzle Swan Neck Tip Adaptor Welding Torch

Month Esab Local Esab Local Esab Local Esab Local Esab Local Esab Local

Apr-21 1729 145 72     100   175 270 509 10  

May-21 410                 91    
Jun-21 500 500 60 50   170   111   750 20  
Jul-21 755   38     80   64        
Aug-21   500   50   100   75   300    
Sep-21   1000 25 140   150   150   650    
Oct-21 300 1350 50 160   200   144   650    
Nov-21   1000   70   30       350    
Dec-21   150   80   95   141   200 14  
Jan-22   1000   150   145   100   300 15  
Feb-22   650 25 175   100 5 41     15  
Mar-22   350   50   375   60   0    
Rate/Piece 182 103 1375 625  1092 430  2322 980 633 320 12500  

Total
3694 6645 270 925 0 1255 5 886 270 3040 74  
Consumption
 Summary of Welding Consumables comparison From Apr-
21 to Mar-22

Avg. consumable Avg. mig wire ER 308 L : ER Esab : Local Consumable

cost per month consumption per 90S-D2 ratio consumable ratio Cost/Wagon
month

 
1st Quarter 6.8 L 15380 74 :: 26 54 :: 46
11148
2nd Quarter 4.8 L 28042 14 :: 86 40 :: 60
6909
3rd Quarter 4.5 L 22642 00 :: 100 17 :: 83
6305
4th Quarter 3.5 L 26515 00 :: 100 02 :: 98
3889
 Consumables cost comparison – Esab vs Local
60

50

40

30

20

10

0
1st Quarter/Avg wagon per 2nd Quarter/Avg wagon per 3rd Quarter /Avg wagon per 4th Quarter /Avg wagon per
month:61 month:55 month:59 month:90

Average Consumable cost in Rs/KG mig wire Esab Consumable in %

Column2
 CONCLUSION
We have consumed average 60% more mig wire in 2nd,3rd
and 4th quarter w.r.t 1st quarter with 40 % lower
consumable cost using Local make consumables instead of
Esab make consumables.
 Cost comparison for Esab vs Local

Esab make Local Make

103.00
CONTACT TIP M 8, 1.2MM CUCRZR 182.00 CONTACT TIP CuCRZr,1.2 MM
430.00
GAS NOZZLE CONICAL 15 MM 1092.00 GAS NOZZLE
102.00
SPATTER PROTECTION 308.00 GAS DIFFUSER
320.00
TIP ADOPTOR M8 633.00 CONTACT TIP HOLDER
625.00
STEEL LINER 3 M 1.6MM 1375.00 STEEL LINER
980.00
SWAN NECK (BARE) 2322.00 SWAN NECK
NEW INNOVATION TO REDUCE
CONSUMABLE COST FURTHER

• We have taken 2 Torches with consumables, Make - Binzal from

Quality Engineering.

• The trial for the same is going on regarding performance of the

Torches & it’s consumables.
 Cost comparison for Esab vs Binzel

TORCH AND SPARES PRICE FOR ESAB PSF 505 TORCH AND SPARES PRICE FOR BINZEL make

  PSF 505 MIG TORCH 12500.00 015.0130. MIG TORCH 500 A YT501 9500.00
468502006 CONTACT TIP M 8, 1.2MM CUCRZR 182.00 140.0445 CONTACT TIP CuCRZr,1.2 MM 109.00

458465884 GAS NOZZLE CONICAL 15 MM 1092.00 145.0079 GAS NOZZLE 495.00

458471005 SPATTER PROTECTION 308.00 015.0021 GAS DIFFUSER 102.00

366395001 TIP ADOPTOR M8 633.00 142.0021 CONTACT TIP HOLDER 144.00

366549890 STEEL LINER 3 M 1.6MM 1375.00 124.0041 STEEL LINER 353.00

4651691893 SWAN NECK (BARE) 2322.00 015.0001 SWAN NECK 3865.00

458465884 HANDLE 2180.00 180.0037 HANDLE WITH MICRO SWITCH 1890.00

0700200151 CENTRAL CONNECTOR 1455.00 124.0041 CENTRAL CONNECTOR 1230.00

Efforts for further cost reduction

• Replace Esab make welding torch with Local make

torch
• Develop new local consumable vendor to compete
present vendor so as to get cheaper consumables
 Welding MIG wire
consumption For Wagons
Project for BFNV Wagons
• As per Drawing wise 345.60 kg welding to be used per wagon.
• As per BOM 360.00 Kg required which was considered practically and
actual welding parameters.
The theoretical calculation based on drawings comes out to be 345.6 Kgs. We
have taken 360 Kgs in BOM & the actual consumption of welding consumables is
found in line with the BOM. The deviation in theoretical calculation as per
drawings & the actual consumption/BOM is due to the following practical
reasons-

• The actual fillet size done in manual welding is equal to or slightly

higher than the fillet size shown in the drawings as lower size fillet is
not acceptable as per design.
• Due to camber in the wagons, there is always chances of slight
mismatch/extra root gap between the members & hence increases
the consumption of welding consumables.
• Sometimes, due to sudden gas fault, welding needs to be repaired.
• We are now doing all the tack welding work by MIG welding only
which is not considered in theoretical calculations.
• Some amount of unused welding wire is always left in the torch at the
end of the spool which is considered as waste.
• Since all the items fitted in the under frame are fabricated & there is
no CRF sections, consumption of welding consumables is more than
the wagons having CRF sections.
Calculation of all component’s welding
length as per drawing
Calculation of welding Consumable for BFNV Wagons Drawing wise
details
Sr.No Dwg No Item Sr.No Item Qty Length Total Length Details Size Kg/mtr Mtr. Total  

1 WD-20044-S-03 11 Side Angle 137.5 X 100 X 6 X 10034 2 10434 20868 10434 4 0.13 20.868 2.71284 20868

    22 Lifting Pad Assembly 4 2791 11164 2791 5 0.18 11.164 2.00952 11164

        4 2592 10368 2592 3 0.09 10.368 0.93312 10368

2 WD-20044-S-04 1 Sole Bar 2 36848 73696 36848 5 0.18 73.696 13.26528 73696

    2 Center Grider Assembly 2 25364 50728 25364 8 0.45 50.728 22.8276 50728

        1 10212 10212 10212 3 0.09 10.212 0.91908 10212

        2 2696 5392 2696 8 0.45 5.392 2.4264 5392

    3 Head Stock 4 2542.5 10170 2542.5 5 0.18 10.17 1.8306 10170

        4 2512 10048 2512 5 0.18 10.048 1.80864 10048

    4 Center Sill (End) 2 6468 12936 6468 5 0.18 12.936 2.32848 12936

        2 6076 12152 6076 8 0.45 12.152 5.4684 12152

        2 4045 8090 4045 8 0.45 8.09 3.6405 8090

    5 Cross Bar (Inner) 6 4384 26304 4384 4 0.13 26.304 3.41952 26304

        6 3246 19476 3246 4 0.13 19.476 2.53188 19476

    5.a Cross Bar (Outer) 4 4284 17136 4284 4 0.13 17.136 2.22768 17136

        4 3328 13312 3328 4 0.13 13.312 1.73056 13312

    6 Gusset Plate 2 2272 4544 2272 12 0.88 4.544 3.99872 4544

Calculation of welding Consumable for BFNV Wagons Drawing wise
details
Sr.No Dwg No Item Sr.No Item Qty Length Total Length Details Size Kg/mtr Mtr. Total  
3 WD-20044-S-05 1 Bolster Assembly 2 0 0 0 0   0 0 0
    1.a Bolster Top Plate 2 5650 11300 5650 4 0.13 11.3 1.469 11300
    1.b Bolster Bootom Gusset 2 10900 21800 10900 4 0.13 21.8 2.834 21800
    1.c Bolster Web Plate 4 6770 27080 6770 4 0.13 27.08 3.5204 27080
    1.d S.B.Support Plate 4 3168 12672 3168 4 0.13 12.672 1.64736 12672
    1.e S.B.Support Plate Small 4 2631 10524 2631 4 0.13 10.524 1.36812 10524
    1.f Bolster Inner Web 4 3656 14624 3656 4 0.13 14.624 1.90112 14624
    1.g Side Bearer Bracket 4 1960 7840 1960 6 0.24 7.84 1.8816 7840
    1.h Center Filler Bracket 2 4238 8476 4238 4 0.13 8.476 1.10188 8476
    2 Stringer End 4 6244 24976 6244 4 0.13 24.976 3.24688 24976
        4 2736 10944 2736 4 0.13 10.944 1.42272 10944
    3 Stringer Outer 4 5230 20920 5230 4 0.13 20.92 2.7196 20920
        4 2797 11188 2797 4 0.13 11.188 1.45444 11188
    4 Stringer Inner 4 3686 14744 3686 4 0.13 14.744 1.91672 14744
        4 2757 11028 2757 4 0.13 11.028 1.43364 11028
    5 Stringer Center 4 4730 18920 4730 4 0.13 18.92 2.4596 18920
        4 2632 10528 2632 4 0.13 10.528 1.36864 10528
    6 End Cross Bar 4 1100 4400 1100 4 0.13 4.4 0.572 4400
    7 Side Cross Bar 24 1020 24480 1020 4 0.13 24.48 3.1824 24480
    8 Bracket for Brake Cylinder 1 1674 1674 1674 3 0.09 1.674 0.15066 1674
    9 Bracket for Distributor Valve 1 1500 1500 1500 3 0.09 1.5 0.135 1500
    10 Angle for Reservoir Bkt. ISA 50X50X5 3 1760 5280 1760 3 0.09 5.28 0.4752 5280
    11 Center Cross Bar 5 1552 7760 1552 4 0.13 7.76 1.0088 7760
    12 Aux. Reservoir Support Bracket 3 2508 7524 2508 3 0.09 7.524 0.67716 7524
    13 Yoke Support Plate 2 945 1890 945 8 0.45 1.89 0.8505 1890
    14 Anchor Bracket for Bogie End Pull Rod 2 1200 2400 1200 8 0.45 2.4 1.08 2400
Calculation of welding Consumable for BFNV Wagons Drawing wise
details
Sr.No Dwg No Item Sr.No Item Qty Length Total Length Details Size Kg/mtr Mtr. Total  
4 WD-20044-S-06 1 Base Member Outer 6 10347 62082 10347 5 0.18 62.082 11.17476 62082
        6 7441 44646 7441 5 0.18 44.646 8.03628 44646
    2 Base Member Inner Large 6 10441 62646 10441 5 0.18 62.646 11.27628 62646
        6 8449 50694 8449 5 0.18 50.694 9.12492 50694
    3 Base Member Inner Small 6 10090 60540 10090 5 0.18 60.54 10.8972 60540
        6 7473 44838 7473 5 0.18 44.838 8.07084 44838
    4 Saddle Floor 12 4440 53280 4440 3 0.09 53.28 4.7952 53280
    5 Support Pressing Large 12 898 10776 898 3 0.09 10.776 0.96984 10776
    6 Support Pressing Small 12 898 10776 898 3 0.09 10.776 0.96984 10776
    7 Bottom Support Pressing Large 12 120 1440 120 3 0.09 1.44 0.1296 1440
    8 Bottom Support Pressing Small 12 120 1440 120 3 0.09 1.44 0.1296 1440
5 WD-20044-S-07 1 Base Member Outer 4 8335 33340 8335 5 0.18 33.34 6.0012 33340
    2 Base Member Inner 8 8335 66680 8335 5 0.18 66.68 12.0024 66680
    3 Saddle Floor (5 mm Thick.) 8 2389 19112 2389 3 0.09 19.112 1.72008 19112
    4 Support Pressing Large 8 840 6720 840 5 0.18 6.72 1.2096 6720
    5 Support Pressing Small 8 840 6720 840 5 0.18 6.72 1.2096 6720
    6 Bottom Support Pressing Large 8 120 960 120 5 0.18 0.96 0.1728 960
    7 Bottom Support Pressing Small 8 120 960 120 5 0.18 0.96 0.1728 960
6 WD-20044-S-08 1 End Wall Assembly 2 18388 36776 18388 3 0.09 36.776 3.30984 36776
    2 Locking Arrangement End Side 4 4291 17164 4291 5 0.18 17.164 3.08952 17164
    3 Locking Arrangement Inner Side 8 5008 40064 5008 5 0.18 40.064 7.21152 40064
    4a Guide Plate Large 6 3240 19440 3240 3 0.09 19.44 1.7496 19440
    4b Guide Plate Small 4 3130 12520 3130 3 0.09 12.52 1.1268 12520
    5a Rubber Liner for Large Saddle 12 0 0 0 0   0 0 0
    5b Rubber Liner for Small Saddle 8 0 0 0 0   0 0 0
    6a Rubber Base Plate Large 12 0 0 0 0   0 0 0
    6b Rubber Base Plate Short 8 0 0 0 0   0 0 0
    7 Saddle Outer Corner Cover Strip(5 X15X472) 4 1004 4016 1004 4 0.13 4.016 0.52208 4016
    8 Grating 25 mm Height 300 X 1230 5 3880 19400 3880 3 0.09 19.4 1.746 19400
    9 Tarpaulin cleat 40 120 4800 120 3 0.09 4.8 0.432 4800
    10 Grating 25 mm Height 150 X 470 10 1890 18900 1890 3 0.09 18.9 1.701 18900
    11 Grating 25 mm Height 150 X 300 10 1550 15500 1550 3 0.09 15.5 1.395 15500
Calculation of welding Consumable for BFNV Wagons Drawing wise
details
Sr.No Dwg No Item Sr.No Item Qty Length Total Length Details Size Kg/mtr Mtr. Total  
8 WD-20044-S-11 1 Horizontal Lever 2 80 160 80 5 0.18 0.16 0.0288 160
    2 Tie Rod 1 0 0 0 0   0 0 0
    3 Pull Rod Main 1 0 0 0 0   0 0 0
    4 Pull Rod Main Black Adjuster Side 1 0 0 0 0   0 0 0
    5 Horizontal Lever Support (Short) 1 200 200 200 5 0.18 0.2 0.036 200
    6 Horizontal Lever Support (Large) 1 1168 1168 1168 5 0.18 1.168 0.21024 1168
    7 Roller Bracket Assembly 1 0 0 0 0   0 0 0
    8 Brake Pull Rod Safety Loop 1 0 0 0 0   0 0 0
9 WD-20044-S-12 1 Hand Brake Pull Rod 1 0 0 0 0   0 0 0
    2 Hand Brake Shaft 1 0 0 0 0   0 0 0
    3 Hand Brake Screw 1 0 0 0 0   0 0 0

Hand Brake Screw Nut with M30 Washer & 5 Dia Split
    4 Pin 1 0 0 0 0   0 0 0
    5 Equalizing Lever Support Bracket 1 550 550 550 5 0.18 0.55 0.099 550
      Equalizing Lever Support Bracket 1 1072 1072 1072 3 0.09 1.072 0.09648 1072
    6 Brake Equalizing Lever 2 0 0 0 0   0 0 0
    7 Gear Box Hanger Bracket 1 2070 2070 2070 3 0.09 2.07 0.1863 2070
      Gear Box Hanger Bracket 1 1814 1814 1814 5 0.18 1.814 0.32652 1814
    8 End Support for Hand Brake Shaft 1 2372 2372 2372 5 0.18 2.372 0.42696 2372
      End Support for Hand Brake Shaft 1 840 840 840 3 0.09 0.84 0.0756 840
    9 Support Bkt. For Hand Brake Screw 1 850 850 850 5 0.18 0.85 0.153 850
      Support Bkt. For Hand Brake Screw 1 776 776 776 3 0.09 0.776 0.06984 776
    10 Middle Support for Hand Brake Shaft 2 20 40 20 5 0.18 0.04 0.0072 40
Calculation of welding Consumable for BFNV Wagons Drawing wise
details
Sr.No Dwg No Item Sr.No Item Qty Length Total Length Details Size Kg/mtr Mtr. Total  
10 WD-20044-S-15 1 Auxiliary Reservoir Suspension strap 3 0 0 0 0   0 0 0
    2 A.P.D for cut off Angle Cock 4 0 0 0 0   0 0 0
    3 Locking Bracket 4 960 3840 960 3 0.09 3.84 0.3456 3840
    4 Bracket Supporting Plate 2 1430 2860 1430 4 0.13 2.86 0.3718 2860
    5 Pipe Support Bracket -1 2 1050 2100 1050 3 0.09 2.1 0.189 2100
    6 Pipe Support Bracket -2 2 940 1880 940 3 0.09 1.88 0.1692 1880
    7 Pipe Support Bracket -3 2 1164 2328 1164 3 0.09 2.328 0.20952 2328
    8 Pipe Support Bracket -4 1 800 800 800 3 0.09 0.8 0.072 800
    9 Pipe Support Bracket -5 1 800 800 800 3 0.09 0.8 0.072 800
    10 Pipe Support Bracket -6 1 800 800 800 3 0.09 0.8 0.072 800
    11 Pipe Support Bracket -7 1 800 800 800 3 0.09 0.8 0.072 800
    12 Locking Bracket U pressing 2 0 0 0 0   0 0 0
11 WD-20044-S-16 1 Coupler Rod 2 0 0 0 0   0 0 0
    2 Hanger Bracket 2 2584 5168 2584 5 0.18 5.168 0.93024 5168
    3 Safety Strap for Bearing Piece 2 0 0 0 0   0 0 0
    4 Bearing Piece 2 0 0 0 0   0 0 0
    5 Washer 4 0 0 0 0   0 0 0
    6 Pin 25 Dia X 68 Long 2 0 0 0 0   0 0 0
    7 Stiffener for Uncoupling Bracket 4 0 0 0 0   0 0 0
    8 Coupling Rod Safety Bracket 2 1196 2392 1196 3 0.09 2.392 0.21528 2392
12 WD-20044-S-17 6 Retaining Ring 2 600 1200 600 10 0.66 1.2 0.792 1200
                        0
1374178   229.529 1374178

1374.178 Mtr
Calculation of welding Consumable for BFNV Wagons Drawing wise
details
Item Sr.No Item Qty Length Total Length Details   Kg/mtr Mtr. Total
1 Head Stock to Sole Bar 4 788 3152 788   0.75 3.152 2.364
2 Side Angle and Lifting Pad 2 22068 44136 22068   0.2 44.136 8.8272
3 Head Stock Top Flange to Centre Sill 4 611 2444 611   0.85 2.444 2.0774
4 Centre Sill 2 2960 5920 2960   0.48 5.92 2.8416
5 Head Stock 4 1800 7200 1800   0.33 7.2 2.376
6 Bracket for DV 1 200 200 200   0.34 0.2 0.068
7 Sole Bar To Bolster 16 100 1600 100   0.85 1.6 1.36
8 Bolster Bottom to Centre Sill 4 50 200 50   0.6 0.2 0.12
9 Bolster Bottom to Centre Girder 4 146 584 146   1.25 0.584 0.73
10 Stringer to Cross Bar/Bolster/Head Stock 32 125 4000 125   0.43 4 1.72
11 Cross Bar to Sole Bar/Centre Girder 40 125 5000 125   0.65 5 3.25
12 Centre cross Bar to Centre Girder 20 125 2500 125   0.65 2.5 1.625
13 Bolster to top plate/Sole Bar 4 3197 12788 3197   0.65 12.788 8.3122
14 Top welding to all Stringer 80 150 12000 150   0.45 12 5.4
15 Centre Sill Bottom to Bolster top Plate 2 440 880 440   0.65 0.88 0.572
16 Saddle To Saddle 72 1364 100216 614   0.52 100.216 52.11232
17 End Locking arrangment 4 1291 5164 1291   0.3 5.164 1.5492
18 Locking arrangment 8 1780 14240 1780   0.3 14.24 4.272
        222224       222.224 99.57692

Total 1596402 mm Total 329.106 Kg

1596.402 Mtr 5% Extra 16.4553 kg
345.6 kg
Current Project for BRNA Wagons
• As per BOM 223.0 Kg & 48.0 kg required which was considered
practically and actual welding parameters.
• As per Actual Drawing wise calculation is going on and report will be
ready soon.
• Calculate all components as per drawing and actual observed
dimensions.