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BEST OF Compendium 2009 to 2013 Global footprints of landmark solutions Global footprints of landmark solutions
BEST OF
Compendium 2009 to 2013
Global footprints of landmark solutionsGlobal footprints of landmark solutions
BEST OF
Compendium 2009 to 2013
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Equipped to Excel
In the year 1979, the late Mr. Vinayak Mehendale, a technocrat
with his long-standing experience in crane manufacturing, laid
the foundation of ElectroMech at Pune.
The aspiration was to manufacture a variety of high-quality
cranes, hoists and material handling equipment and provide
solutions at most reasonable prices. This, combined with
efficient before and after-sales service, completed the picture.
Aims and goals appear closer when skilled hands are willing to
work hard and minds are full of novel concepts and ideas. The
founder of ElectroMech never lacked both. As a result, the
company soon earned a firm footing and a veritable reputation
as one of the leading crane manufacturers in India. Its growing
customer base spanned across various industry verticals all over
India.
The year 2000 was a gloom-casting year for ElectroMech when
the founder passed away unexpectedly. On this backdrop, his
elder son, Tushar Mehendale took over the reins of ElectroMech.
Since then, he has been ably pursuing the illustrious founder's
ambition to make the ElectroMech equipment base span the
entire world.
At ElectroMech, we have been involved in the design,
manufacture, erection and commissioning of material handling
systems with a special emphasis on cranes and hoists since
1979. ElectroMech’s main manufacturing facilities are
at Pirangut, near Pune, India.
The Pirangut factory is considered to be the single largest
dedicated overhead crane manufacturing facility in India. This
facility is spread over 76,000sq.m of land and has more than
20,000sq.m of covered manufacturing area. This factory is
equipped with state-of-the-art machinery like CNC cutting
machines, semi-automated girder manufacturing fixtures,
a shot-blasting unit and a paint booth.
The infrastructure
3
in 2003 and won an Exporter Award in 2005. Recently,
ElectroMech has achieved the prestigious Welding Approval
Certificate from Germanischer Lloyd (GL) and the latest
ISO 9001:2008 certification from BVC.
The company has been consistently growing year-on-year at
a rate higher than the industry average. The vision of
ElectroMech is to achieve a leadership position in India in terms
of sales, number of cranes sold, sales network, service network
and manufacturing capacities.
The team at the helm of ElectroMech consists of qualified
technocrats with collective experience of more than one hundred
years in the industry. More than 500 motivated experts are
engaged in the manufacturing of more than 1000 cranes, hoists
and other similar lifting equipments every year.
The span of ElectroMech capabilities has ever been widening.
After achieving a position of market leadership in India,
ElectroMech is also spreading its wings to soar high in the global
markets. A substantial chunk of ElectroMech's revenues comes
from exports.
UAE, Qatar, Oman, Saudi Arabia and Iran. In
addition to the Middle East, ElectroMech also has its equipment
base across countries like Afghanistan, Bangladesh, Finland,
Kazakhstan, Kenya, Maldives, Mexico, Sri Lanka, Sudan and
Sweden. The list of countries keeps on growing with every
passing year.
The team
Global presence
Our subsidiary, ElectroMech FZE in Dubai is dedicated to
provide pre and post-sales service to our customers in the Middle
East and support hundreds of installations across different
countries like
Exploring technology
Far-reaching solutions
Latest technology - highest reliability
To maintain the highest product quality, newer concepts of
material handling are continuously explored by our R&D.
ElectroMech has always prided itself in being at the forefront
in adopting newer technological advances in cranes and is
considered as a pioneer in various fields by its peers. Constant
development is being undertaken with the sole intention of
maximising the value delivered to the customer in terms of lower
costs, higher reliability, higher safety and faster productivity.
As a result of our pursuance of world-class technology, our
equipment can be seen operating flawlessly at diverse locations.
ElectroMech supplies a variety of cranes and hoists
in capacities ranging from 80kg to more than 200MT across
different industry verticals like Automobile, Steel, Power,
Shipbuilding, Heavy Engineering, Fabrication and General
Engineering.
ElectroMech equipment is also conspicuously present in the
infrastructure segment. We are proud of the fact that a lot of
major infrastructure projects like roads, bridges, dams and
power plants have been made operational by using equipment
supplied by ElectroMech.
Variety, versatility, safety, affordability, convenience and peace of
mind are the standard features of any ElectroMech equipment. A
fact attested by several repeat orders received from all major
industrial groups not only in India, but also in the Middle East and
Africa as well.
ElectroMech which enjoys undisputed leadership in the segment
of Industrial Cranes in India, achieved the ISO 9001 certification
Company (CDC). CDC is one of the
leading Industrial groups in Qatar.
CDC’s trading arm will be responsible for
marketing and providing local service and
installation support to ElectroMech
projects.
These new tie-ups underline our
commitment and endeavor to serve our
customers in the Middle East and
Africa in the best possible manner. The
localization of our after-sales service
support and structural fabrication
activities in these territories will enable us
to provide turnkey solutions to the
customer at competitive prices.
ElectroMech FZE spreads its wings in Africa and QatarWe have recently forayed into the African
market with our association with Zenith
Steel Fabricators, Kenya. Zenith Steel
is one of the largest steel fabricators
operating in the East and Central African
regions with offices in more than seven
countries. They will be supplying cranes
using ElectroMech crane kits and their
expertise in steel fabrication.
The first lot of crane kits has been
dispatched to Kenya recently and we
expect to increase our business in this
region in the coming years.
Our presence in the Qatar market will be
further enhanced through a new channel
partner, Construction Development
Afghanistan
Bangladesh
Bhutan
Finland
Iran
Kazakhstan
KenyaMaldives
Mexico
Nigeria
Oman
Philippines
QatarSaudiArabia
Sri Lanka
Sudan
Sweden
YemenIndia
Dubai, UAE
ChinaIraq
Uzbekistan
Indonesia
ElectroMech FZE Corporate Office
ElectroMech IndiaCorporate Office and Plant
A world of satisfaction
July 2011
4
BEST OF
Compendium 2009 to 2013
Prestigious order from Impregilo S.p.A., Italy for tunnelling projects in Abu DhabiElectroMech FZE has won a prestigious order for 30MT Double
Girder Gantry cranes from Impregilo S.p.A., Italy. Impregilo is a
leading Italian engineering and general contracting group in
construction, marine, infrastructure and environmental sectors.
The state-of-the-art Gantry cranes with reach up to 90m deep
and with a hoisting speed of 30m/min, will be used in one of the
complex tunneling projects for Abu Dhabi Government. It will
involve simultaneous use of multiple earth pressure balance
tunnel boring machines to excavate and at the same time case
the tunnel with precast concrete sections. The supply and
execution will be in two phases.
ElectroMech has been active in the Middle East for several years
and has supplied number of cranes to a wide cross-section of
industry. The addition of an international construction major
such as Impregilo to our clients' list further demonstrates our
manufacturing and project execution capability on the global
platform.
Team ElectroMech is thankful to Impregilo management for their
trust and confidence and looks forward to a long-term
association and working on more challenging projects in the
future.
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July 2010
ElectroMech FZE receives a major order from Air Liquide Group of France
Our complete scope is for the manufacture, supply, erection,
commissioning, testing and certification of 29 EOT Cranes.
The cranes to be supplied are:
Ø 150MT DGEOT - 2 nos. Ø 20MT DGEOT - 11 nos.
Ø 10MT SGEOT - 14 nos. Ø 10MT DG Gantry Cranes - 2 nos.
These cranes will be installed in their plant in RAK Maritime City
which is the latest and most advanced maritime free zone to
open in the United Arab Emirates. The Air Liquide Group plant is
spread over 36 acres and the facility will be used for the
manufacturing of fabricated metal products, structures, tanks,
reservoirs and containers or in short cryogenic vessels.
This challenging project will be completed during FY 2013-14
successfully.
Air Liquide Group is a major player
in the oil & gas sector as well as
health & environment with
operations in over 80 countries. It is the world leader in
gases for industry, health and environment. The Group offers
innovative solutions based on continuously enhanced
technologies for cold box manufacturing which is used in Air
Separation Units / Cryogenic Air Separation Units (ASUs).
In a major breakthrough, our subsidiary, ElectroMech FZE, Dubai
bagged a major order worth approx. INR 200 million for
29 EOT Cranes from the French multinational, Air Liquide
Group. The order was received against tough competition from
several multinational companies.
September 2013
Prestigious installations in Abu Dhabi
July 2011
BEST OF
Compendium 2009 to 2013
Italian construction and civil engineering company,
Impregilo S.P.A. has landed a contract with Abu Dhabi
Sewerage Services Company (ADSSC) to build the first of the
three lots of the Strategic Tunnel Enhancement Program (STEP)
in Abu Dhabi. STEP involves construction of a 40km gravity
tunnel to collect waste water from the Abu Dhabi Island and
mainland, and convey it to the treatment plant in Al Wathba. The
new project involves construction of the first 15km of the tunnel,
with an excavated diameter of 6.3 meters, and six access shafts
to depths of between 40 and 50 meters. Impregilo has also been
awarded the third and final lot of the contract which includes
between 40 and 50 meters. Impregilo has also been awarded the
third and final lot of the contract which includes construction of
10km of 7m diameter water tunnel.
Impregilo selected ElectroMech FZE as its partner for
installation and commissioning of Gantry cranes required on this
project. ElectroMech FZE has successfully commissioned the first
lot of 30MT, 90m lift Double Girder Gantry Cranes. All the cranes
will be put in 24x7 operation working on one of the most
challenging projects in the region. These installations further
demonstrate ElectroMech’s capabilities in executing large scale
projects on a global platform.
6
Refurbishing of double girder trolleys at Diala State Company in Iraq
Handling challenges successfully in Iraq
Our global customers trust us for our solutions ability and
approach us to meet challenges in handling with our hoist
or crane solutions. This is true not only in case of
completely new projects, but ElectroMech is also their
trusted partner when it comes to refurbishment,
retrofitting or modernisation of existing cranes, where
they know for sure that ElectroMech can handle the job
swiftly and ably.
One such challenging requirement was successfully
handled by us for Diala State Company in Iraq. Diala is
engaged in the assembly and manufacturing of large
capacity distribution and power transformers and is one of
the largest transformer manufacturing companies in Iraq.
The project involved supply and retrofitting of completely
new hoisting units and refurbishing the old cranes with
new electrical systems. With our expertise in such
projects, we refurbished four units of Double Girder
trolleys of 100/30MT, 50/20MT, 15/10MT and 15/7MT
capacities.
This was a very challenging project considering the unrest
in Iraq and the critical time frame requirement of the
customer. However, our engineer, Santosh Tambe took on
the assignment, and with admirable courage and project
execution ability, completed the task in the given time
frame to the fullest satisfaction of the customer.
With the successful execution of this project, we now look forward to new
challenges in Iraq and the Middle East region.
7
December 2012
ElectroMech has already been an ISO 9001:2000 company. Now,
we are pleased to announce that ElectroMech is now
certified for ISO 9001:2008 standard with UKAS
accreditation. A stringent audit was conducted by Bureau
Veritas Certification at various locations such as ElectroMech
One more feather in our cap works, Sales and Service offices in Chennai and Delhi and at the
customer site in Coimbatore, in order to confirm the scope of
certification finalized as “DESIGN, MANUFACTURE, SUPPLY,
ERECTION, COMMISSIONING AND RELATED SERVICES FOR
CRANES, HOISTS, WINCHES AND CUSTOMIZED MATERIAL
HANDLING SOLUTIONS”.
More More More bays. cranes. smiles.
July 2010
In spite of the recent blow of recession, ElectroMech
expansion has been at its peak. We are about to finish with the
36m span x 200m long fabrication shop. The shop is being
equipped with advanced material handling equipments and
other facilities. While promising best product quality to our
valued customers, ElectroMech has invested in procuring
blasting equipments, paint booth systems, semi-automated
welding machines, etc. Execution of the same is in progress.
Starting with its own factory, ElectroMech has developed a
cost-effective solution for contact-less material handling
trolleys. Nine numbers of the same are being installed in the
factory. Looking at the increasing demand for ElectroMech
cranes, Chennai plant execution will commence shortly. This
plant will boast of the capacity to manufacture 200 cranes of
up to 250MT lifting capacity.
Enhanced infrastructure, capabilities and production will
certainly ensure more smiles.
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BEST OF
Compendium 2009 to 2013
GL approval for welding and ISO 9001:2008
July 2010
Implementation of ISO 9001:2008 has been the second
important step for ElectroMech after successful
implementation of SAP ECC 6.0 to improve overall
business processes, enhance customer satisfaction by
meeting requirements in more efficient manner and improving
the quality of products to have a better competitive edge. Now,
ElectroMech aims to be an ISO 18001 and ISO 14001 company to
have a systematic approach to put emphasis on safety,
occupational health and environment-related aspects.
Congratulations to the entire ElectroMech team for the
remarkable achievements.
Welding Quality
MacPILER, the first Hatch Cover Lifting equipment successfully
manufactured at ElectroMech was totally inspected and
approved right from the raw material stage to the final assembly
and testing by the leading classification society, Germanischer
Lloyd (GL), Hamburg, Germany.
However, as per the GL requirements, before production, it was
mandatory to get the Manufacturing Workshop approved to
attest the availability of the necessary infrastructure, calibrated
welding equipments, measuring instruments and competence of
manpower involved to produce the products of desired quality.
One of the key elements in this shop approval process was
Welding Procedure Specification (WPS) Approval and qualifying
the welders as per the GL rule book, based on DIN Standards.
After a rigorous shop audit, documentation review and all
essential tests, GL (Hamburg) issued ‘Approval for Welding’
certificate to ElectroMech.
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10
“Even though we started the XP Shop Crane installation
project late due to some major constraints, we ended up
with good speed. Your team, especially Mr. Dinesh More,
put in very good efforts to finish the same on time.”
Shankar Malge - Project In-charge
JCB Manufacturing Ltd., Pune
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“Thanks for the extensive support for the supply and
erection of the crane.”
T. S. Sampath Kumar - Manager-Purchase
Gamesa Wind Turbines Pvt. Ltd., Chennai
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“ I want to thank you all for your timely and continuous
support in resolving some of the issues related to crane
erection, maintenance and repair, which we were facing in
the last couple of days.
We extremely appreciate the efforts of both your teams,
Cranedge and ElectroMech, in sorting out all the issues in
the shortest span of time and with least follow up
(especially rigorous phone calls).
Once again thank you and looking forward to expecting the
same kind of Service & Support in the future as well.”
Mr. Raju Prasad of SIEMENS LTD. Energy Sector,
Power Transmission Divis ion, Gas Insulated
Switchgear(GIS), Aurangabad
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“I really appreciate your efforts in trying to help us to get
the module repaired. This type of cooperation and timely
help in overcoming our problems really raises our
confidence in you. We look forward to your cooperation in
the future as well.”
Vijay Arora - Plant Head
Mahindra Intertrade, Nasik
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“Just gone through EMPOWER newsletter Q2 2009-10. We
are very happy to note that you have launched a new
company in Jebel Ali, Dubai and has become a global
company in true sense, sooner than expected. Hearty
congratulations to you and your team for this well-
deserved success. Probably we noticed the spark in you in
early days and built relationship, which we are very proud
of.”
Sanjay Tikle, Plant Head
Mahindra Steel Service Centre Ltd., Maval
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“Your erection team has performed to more than our
satisfaction level. They understood the emergency of
cranes for our machine erection work and completed the
erection of three cranes in a very professional manner.”
Vaskar Mitra - Vice-President, Mechanical
Nahar Polyfilms, Bhopal
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Glad to serve. Pleased to hear.Customers appreciate our service efficiency
July 2010, December 2012
BEST OF
Compendium 2009 to 2013
11
Hoist magazine, published from UK, is a prestigious magazine
dedicated to the Hoist and Crane industry worldwide. In the
April 2012 issue of this magazine ElectroMech is featured as a
leading Asian player in this market. The photograph of our TBM
assembly crane supplied to SOMA for Mumbai water tunnel
project appears prominently on the cover of this magazine
highlighting its uniqueness and our solutions capability.
Hoist Magazine is published by World Market Intelligence - a
premium information and marketing solution company focused
on the provision of high-quality information and software
solutions to drive business success. This is the only international
magazine with news and information focused on overhead
cranes and industrial lifting equipments. The magazine reaches
almost 19,000 users and distributors of lifting equipments from
various countries across the globe.
The April 2012 issue of this magazine focuses on the emerging
South Asia market in which it has extensively covered Indian
crane industry from various perspectives.
The article mentions Mr. Tushar Mehendale's views on the
importance of tie-ups and how ElectroMech’s strategic
partnerships are a significant part of the ElectroMech growth
strategy.
Mr. Tushar Mehendale has highlighted the entry of ElectroMech
in the new market viz. the nuclear sector with the order for
cranes for critical handling applications at Kakrapara Atomic
Power Project set up by the Nuclear Power Corporation of India.
The cover of the April 2012 issue shows the ElectroMech crane
supplied to SOMA for Mumbai water tunnel project. This unique
project has also been described in detail in a separate article in
“We have always been a firm believer in tie-ups with
market leaders which allow both the partners to
effectively leverage each other's strengths and
derive synergies".
Mr. Tushar Mehendale, Managing Director, ElectroMech
HOIST is a prestigious international
magazine from UK. ElectroMech
is featured in it as a leading
Asian player. Our Tunnel Boring
Machine assembly crane appears
prominently on its cover.
the same issue. It highlights the uniqueness of crane solutions
supplied to these projects and the challenges fulfilled by them.
This news signifies our growing footprints in the global market.
With the encouragement and best wishes from our clients, we
look forward to several such news in the near future.
ElectroMech crane features on cover page of HOIST magazine, UK
December 2012
Award-winning solution for tunnelling operations
‘Manufacturing today’ award for ‘Excellence in Innovation’ in the SME category
Mr. AVR Murty, CEO, receiving the award on behalf of ElectroMech
ElectroMech is proud to have been awarded for our innovative
solution provided for the execution of the Mumbai water
supply project. ElectroMech, India's largest industrial crane
manufacturer and customised material handling
solutions provider was awarded the 'Excellence in
Innovation' award in the SME category for its
special ised Tunnel Mucking System at the
‘Manufacturing Today awards 2012’, conducted by
‘Manufacturing Today’, an ITP Publication group
magazine.
Commenting on the occasion, Mr. Tushar Mehendale,
Managing Director, ElectroMech said, "We are very
pleased to receive the award for our path-breaking
innovation. This award testifies that we continue to align
our innovation approach to meet our customer
expectations. This unique Tunnel Mucking System is a
boon for projects which require rapid removal of
overburden from tunnelling or shaft excavation and has
its own benefits as a special purpose crane. We will
remain committed to our customers and continue to
offer the best products."
ElectroMech's clients for its high-speed, high-lift Tunnel
Mucking Systems include several leading infrastructure
majors such as Gammon, HCC, Unity, Patel Engineering,
SOMA and IVRCL on sites in India and across the globe.
ElectroMech's unique Tunnel Mucking System has proved to be
an innovation in various critical projects for rapid removal of
overburden from tunnelling or shaft excavation. The recent
installations for the Mumbai water supply project
involved ElectroMech's tunnel mucking crane under the
government's Jawaharlal Nehru National Urban Renewal
Mission (JNNURM). The INR 2235 crore project was
divided into two parts. The construction work of this
prestigious project was awarded to two construction
majors namely, Soma Construction Company for Phase I
(Gundovali to Thane) and to a Joint Venture of Unity
Infraprojects Ltd. and IVRCL Ltd. for Phase II (Thane to
Bhandup). Interestingly, ElectroMech supplied tunnel
mucking cranes to both the companies, thus playing a
crucial role in BMC's ambitious 24x7 water supply project.
A high-lift, high-speed crane in operation at an HCC Hydroelectric Power Project in Punatsangchhu, Bhutan
12
September 2013IVRCL & ElectroMech teams
BEST OF
Compendium 2009 to 2013
Customer satisfaction is a top priority for ElectroMech. Every
action, effort and the organisational energy are directed towards
keeping our customers satisfied. It is of course important to keep
track of changing customer expectations and where we stand
while fulfilling them. To achieve this, we interact with our
customers on several platforms such as conferences, exhibitions
and customer visits by our sales team. This customer-centric
approach has helped us win the trust of thousands of crane users
in India and abroad. Satisfied with the ElectroMech experience,
our existing customers invariably approach us for their new
requirement of cranes. At the same time, new customers, some
of them users of other brands of cranes, who are looking for
better solutions, service and experience approach us as
well.
To further augment our efforts, a more systematic approach
in this direction was recently initiated by conducting a pan-
India survey among our customers through Nielsen, a
premier global market research organisation. The survey
findings are very encouraging and have provided insight
and clues for further improvements to excel in our field of
operations.
According to this survey, the attributes about ElectroMech
most appreciated by our customers were:
Ø The overall performance of our products
Ø Domain knowledge and skill set of team members
while understanding customer requirements
Ø Our ability to provide customised solutions which are
most relevant for a particular application
Ø Professional and ethical practices followed by the
company
Ø The technical competency of our team of engineers
Ø Our customer-oriented approach
Over the years, we have evolved as a leading and capable
'Solutions provider'. For this, we always ensure strong technical
and design support to our customers. To provide the most
pertinent solutions, our R&D team is constantly exploring ways
to improve our products and deliver a better customer
experience. Apart from this, we lay a great emphasis on adopting
most modern manufacturing practices which ensure high quality
and reliability of our cranes. This, in turn, translates into a
greater benefit for our customers. According to them, the
following are the important benefits with our crane systems.
Ø Safety features of equipment
Ø Smoothness and low noise levels of equipment
Ø Necessary safety and statutory regulations followed by our
installation team
Apart from the above, customers have appreciated our systems
during and after the tendering process. According to them,
Ø Accuracy, completeness and timely submission of technical
documentation are highly satisfactory
Ø Interaction, courtesy and politeness of the sales team are
appreciable
Ø Majority of our customers also admired our ability
to provide 24x7 service support
Ø ElectroMech deploys a well-trained and skilled team
of engineers and technicians on the field to provide numerous
trusted services
A very encouraging comment received in response to the
question, “How likely are you to recommend ElectroMech and
Cranedge Service to a business associate?” For calculating
the Net Promoter score on a scale of 0 to 10 - ElectroMech was
rated 9.
Also, when the customer was asked for a 'top-of-the-mind' recall
we were happy to know in terms of awareness ElectroMech is
the leading brand name for EOT cranes in India.
At ElectroMech, we have taken cognisance of all the feedback
from our clients and are implementing certain changes to
increase customer satisfaction. For example, Radio Remote
Controls have been made standard across our range of cranes
based on customer feedback during this survey.
We thank all our customers for participating in this survey
and provide us with their valuable time and feedback.
*Source: Nielsen Survey February 2013 (sponsored by ElectroMech)
Our customers reaffirm our positioning.*A recent customer satisfaction survey by Nielsen reveals the fact .
Ø ElectroMech is mainly known for providing customised solutions, technical competency, excellent product performance and customer-centric approach.
9 out of 10 customers will definitely recommend our cranes and services to other businesses.
ElectroMech has the highest recall amongst all the crane brands in India.
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Survey highlights
13
September 2013
An interesting challenge in this order from BMM will be the supply
of Cranes with Rotating Trolleys.
This is achieved in two ways :
n Via slewing wheels
n Via slew bearing for the 12.5t cranes
This trolley consists of two parts viz. the upper trolley
frame and the lower trolley frame. The main hoisting machinery
is mounted on the upper trolley frame which has slewing wheels
that run on a circular rail track fitted on the lower trolley frame.
This will be used to rotate a spreader beam with magnets
attachment through 270 degrees with a slewing speed of 2 rpm.
The magnets are capable of handling hot billet bundles at 0600 C and are designed for 60% duty cycle (having class H
insulation with temperature rise limited to class B). These
magnets are equipped with a battery back up system for
15 minutes. This crane will normally be used for stacking of
billets, loading/unloading of billets/bars.
This trolley consists of two parts viz. the upper trolley
frame and the lower trolley frame. The slewing bearing is
fitted in between these two frames. The main hoisting machinery
is mounted on the upper trolley frame. This will facilitate the
spreader beam (having magnets attachment) to rotate through
270 degrees with a slew speed of 2 rpm.
This is the single largest order for ElectroMech from a steel plant.
The entire project is expected to be completed by the end of
2013. We sincerely thank the entire BMM team for their trust in
our solutions capability and look forward to a successful
completion of the project.
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Rotating Trolley on slewing wheels
Rotating Trolley on slewing bearing
BMM is a Rs.2000 crore company with a focus on market
orientation and optimal usage of technology to achieve process
efficiency and value addition. BMM has always believed in its core
value - 'potential in tonnes' and hence continues to transfer the
benefit derived from sustained growth to all its stakeholders. The
unique value proposition that defines the very fabric of the BMM
culture is the firm's belief in unleashing this 'potential in tonnes'
in terms of its human capital, continuous growth and consistent
transfer of benefits to its stakeholders.
n BMM Ispat Limited - Located at Danapur, Hospet, Karnataka
n BMM Cements Limited - Located at Gudipadu, Yadiki
Mandalam, Anantapur District, Andhra Pradhesh
n Beneficiation plant - 2.60 million tonnes per annum
n Pellet plant - 2.40 million tonnes per annum
n Sponge iron plant - 0.73 million tonnes per annum
n Induction furnace - 0.10 million tonnes per annum
n Rolling mill - 0.09 million tonnes per annum
n Power plant - 165 MW
BMM Ispat Ltd. has embarked upon an expansion project to set
up an Integrated Steel Plant of 2.00 million tonnes per annum in
two phases and a Power Plant of 70 MW.
During the summer of 2012, senior executives from BMM visited
the ElectroMech factory in Pune for capacity evaluation. They
were very impressed with our plant facilities, systems, design
facilities and our ability to achieve on time performance. After
thorough evaluation, they have placed an order on ElectroMech
for 15 cranes for their Steel Melting Shop and Rolling Mill which
will be a part of the new 1.25 mtpa Steel Plant.
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The BMM Group has two manufacturing facilities -
Current capacities at BMM ISPAT Limited are
ElectroMech receives a single largest order from a steel plant - BMM Ispat Ltd.
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December 2012
BEST OF
Compendium 2009 to 2013
Prestigious order from Mazgaon Dock LimitedIntelligent design for overcoming space constraint to handle heavy loads
Mazagon Dock Limited, Mumbai, an ISO 9001:2008 company is
one of the leading shipbuilding and offshore fabrication yards in
India. The yard was established in the 18th century, and over 200
plus eventful years, has earned a reputation for quality work and
established a tradition of skilled and resourceful service to the
shipping world in general and the Indian Navy, Coast Guards &
ONGC in particular.
After 1960, Mazagon Dock grew rapidly to become a premier
warship building yard in India, producing sophisticated warships
for the Navy and offshore structures
for the ONGC. It has grown from a
single unit, small ship repair
company, into a multi-unit and
multi-product company, with a
significant rise in production,
use of modern technology and
sophistication of products. The
company’s current portfolio of
designs spans a wide range of
products for both domestic and
overseas clients.
Mazagon Dock is in the process
of expanding its facility to
manufacture submarines for the Indian Navy. This is a very
prestigious, challenging and critical project for the Indian
Ministry of Defence. Handling requirements in this plant vary
from a few tonnes to as high as 300 tonnes. Needless to say, safe
handling of these critical components is of utmost importance.
The frequency of utilisation and the operating speeds are very
high. Further complicating these challenges is the fact that space
availability is a great constraint in this plant.
The challenge
Keeping this in mind, extensive engineering has been done to
optimise the crane dimensions, to ensure maximum and
effective space utilisation.
After a thorough assessment of various crane manufacturers in
India, Mazagon Dock Limited selected ElectroMech to design,
manufacture and commission the cranes for this new submarine
manufacturing unit.
ElectroMech has designed 3-tier
cranes to suit the client
requirement. This type of design
will ensure compact construction
of the cranes to fit into the
limited space available. We will
be supplying 7 heavy-duty
cranes. The client being a
Defence organisation, the
manufactured cranes will be
undergoing close monitoring and
quality checks from the officials
of the Defence Ministry.
The order will be executed during
the year 2014 and we are
confident of meeting the
expectations of the client.
Ø 150/30MT Semi-Goliath Cranes, Span 16m, HOL 22m-2 nos.
Ø 60/20MT Semi-Goliath Cranes, Span 23m, HOL 22m-1 no.
Ø 30/10MT DG EOT Cranes, Span 41.5m, HOL 32m-2 nos.
Ø 30/10MT DG EOT Cranes, Span 41.5m, HOL 27m-2 nos.
l
l
ElectroMech solution
Details of the order
15
September 2013
Roads, highways and bridges form a network that unites the
nation, brings people together and expedites communication.
Bridge construction has undergone revolutionary changes over
the years. Advanced, gigantic construction equipment and the
use of precast and pre-fabricated components have reduced
much of the cumbersome manual labour and has increased the
speed of construction significantly. ElectroMech, with its proven
expertise in material handling, is also a part of this construction
revolution.
Soma Enterprises Ltd., the infrastructure construction
company is an esteemed user of different types of ElectroMech
gantry cranes on a number of major projects for varied
applications. ElectroMech has always stood up to Soma's unique
requirements and expectations. As a result,
Soma puts its complete trust in the capabilities
of ElectroMech, thrusting newer challenges
our way, which we have always lived up to.
This recent, new challenge was not an
exception. ElectroMech was to supply bridge
building girders 60 meters in length. The
girders were required at the site of a bridge
construction at Cochin in Kerala. The task, apparently simple,
demanded great precision and manufacturing using special jigs
and fixtures. Transportation, material costs, operational
simplicity and actual joining of pieces posed several challenges
for ElectroMech, which braced against them successfully and
provided the client with the best solution.
The solution was devised in the form of separate pieces of
girders, precisely manufactured, each of 15 meters in length.
Accurate positioning of pieces of girders was ensured using
special fixtures at ElectroMech plant. Arrangement of nuts and
bolts for joining them eliminated the need of any welding on the
site. Such girders can conveniently be used and reused for
constructing bridges quickly, using advanced technique.
The bridge building girders supplied by
ElectroMech offer great operational simplicity,
re-usabi l i ty, accuracy and ease of
transportation. All this results into
considerable reduction in the turnaround time
of the project, hard work, material costs and
risks.
Bridge Building Girders
Connecting places - Connecting lives
16
July 2011
BEST OF
Compendium 2009 to 2013
Mumbai - the business capital of India - the city of dreams
for millions - has been growing exponentially. This growth is
taking place in a narrow, long stretch of the costal land.
The existing 21 million and growing population naturally
needs adequate supply of water for today and tomorrow.
The Tansa Dam situated around 75km from
Mumbai is the major source of water supply to
Mumbai since it was built in 1892. The existing
pipeline which carries this water to Mumbai
was laid down in the British era. Over decades,
the pipeline has rusted and eroded due to
which bursting and leakages are quite
frequent. Naturally, it interrupts the water
supply, creating shortage.
To avoid this, MCGM (Municipal Corporation of
Greater Mumbai) has undertaken a very
ambitious water supply project by building a
new underground leak-proof tunnel which is
8.3km long. The tunnel is being constructed at
the most critical part of the supply system over
a stretch of 15km from Gundovali village
(near Bhiwandi) to Bhandup. The construction
work of this prestigious project has been
awarded to two construction majors namely,
Soma Construction Company for Phase I
(Gundovali to Thane) and to a Joint Venture of
Unity Infraprojects Ltd. and IVRCL Ltd. for
Phase II (Thane to Bhandup).
ElectroMech has supplied special tunnel mucking cranes for both
the phases where shafts of 140 meters are to be excavated at
4 different locations. ElectroMech has also provided cranes of
105MT for lowering the Tunnel Boring Machine up to 100meters
below the ground level. Additionally, a special type of crane,
which will be installed 100 meters below the ground level is
provided to assemble the Tunnel
Boring Machine. This crane has
four winches operating in tandem
for precision work, which is
required for the Tunnel Boring
Machine assembly.
32MT Gol iath cranes are
deployed at the entry and exit
points of the shafts, where high-
speed hoisting equipment,
incorporating 3.4 meter long rope
drums rotating almost non stop
lift the muck at 40 meters /min.
The criticality of the cranes
operating on these projects
lies in 'Continuous operation
without any down time' and
ElectroMech’s proven track
record on several infrastructure
projects makes it an ideal choice
to ensure that uninterrupted
work.
MCGM has undertaken a very
ambitious water supply project
by building a new underground
leak-proof tunnel which is 8.3km
long. This prestigious project
has been awarded to Soma
Construction Company (Phase I) and
to a Joint Venture of Unity
Infraprojects Ltd. and IVRCL Ltd.
(Phase II). ElectroMech has supplied
special tunnel mucking cranes for
both the phases where shafts of
140 meters are to be excavated at
4 different locations. A special type of
crane is provided to assemble the
Tunnel Boring Machine. This crane will
be installed 100 meters below the
ground level.
Clients : Ø Soma Construction Company Ø Unity-IVRCL Ltd. (A joint venture company)
ElectroMech supplies tunnel mucking cranes and special hoisting equipment for lowering and assembling of Tunnel Boring Machine.
Pivotal role in Mumbai's unique water supply project
17
July 2011
Installation at Amtek Auto Ltd.
A challenge for our problem-solving ability
About Amtek Auto Ltd.
The challenge
Amtek Auto Ltd. is headquartered in New Delhi and is one of the
largest integrated automotive component manufacturers in
India with a strong global presence. The company has world-
class manufacturing facilities in India, Europe and North
America. Amtek Auto has significant expertise in forging, gray
and ductile iron casting, gravity and high-pressure aluminum die
casting and machining and sub-assembly. The company also
manufactures components for non-auto sectors such as
railways, specialty vehicles, aerospace, agricultural and heavy
earth moving equipment.
This article talks about an interesting event which is not related
to any special requirement of cranes, but a very unusual logistic
challenge. We recently supplied Double Girder EOT cranes (6
nos.) to the Dharuhera, Rajasthan plant of Alliance Integrated
Metaliks which is a part of the Amtek Group.
The site had a restriction in the form of a very sharp turn within
the factory premises that would not allow a trailer longer than
60ft to turn around that bend and enter the site. This posed a
problem to most of the suppliers, including ElectroMech, whose
equipment needed to be transported over long distances on 80 ft
trailers. At one point, it looked like the only option was to
AMTEK
Client : Amtek Auto Ltd.
No. of cranes: 6 nos.
Location of crane installation: Dharuhera (Rajasthan)
engineer the girders so that they could be transported in two
pieces and then attached using a bolted flange joint at site. Of
course, other equipment couldn’t be broken down like this.
While anticipating and realizing the challenge posed by the site
conditions, our installation team, backed by our experience of
having transported cranes to the most treacherous locations in
the Himalayas was ready with a simple, but ingenious solution.
They simply transferred the girders to a specially arranged trailer
just outside the site entrance, allowing the girders’ easy entry.
Although this may sound simple, surprisingly, this solved their
major problem of bringing in the other machinery as well. The
Amtek team, impressed with our job, asked us to repeat the
entire procedure, capturing a video of this procedure to be
displayed to their other vendors who supply bigger machinery to
them. After witnessing the entire process, the client was
confident that it will solve their major problem and will surely
help other vendors in easily bringing their machinery inside the
plant.
Several such challenges on site help ElectroMech to hone its skills
and develop problem-solving ability to be truly called a Solutions
Company.
The solution
18
March 2012
BEST OF
Compendium 2009 to 2013
When productivity takes a new turnThe rotating crab at Valmont makes
tasks easier; enhances productivity.
The company
The challenge
Valmont is a world-renowned company manufacturing street
lighting poles, traffic signal poles, utility poles, communication
poles and poles to light up large sports complexes and stadiums.
In India, Valmont has a large manufacturing plant at Indapur
(Maharashtra). The plant is designed in such a way that the
entire production process follows a linear path right from the raw
material arrival to the dispatch bay. The plant employs state-of-
the-art manufacturing facilities.
Valmont uses 11 ElectroMech cranes throughout their
manufacturing plant. They are being used at various stages in
manufacturing, right from the unloading of steel coils from
trailers and placing them on the conveyor. The requirement from
an EOT crane at the last stage of manufacturing was most
challenging. Here, the poles, completely ready for despatch, are
carried by the conveyor. At this point, they are to be lifted and
placed on the trailers. But, the direction of the trailer is
perpendicular to the conveyor. This necessitates lifting and then
rotating of poles by 90º. Conventional cranes pose limitations in
rotating the poles automatically and also placing them precisely
on the trailers.
The solution
The result
The engineering team at ElectroMech perfectly understood this
problem. Using the conventional solution was ruled out because
of its limitation of automatically turning the pole to change its
orientation. It would have been very cumbersome, involving lot
of labour to do the job if a conventional crane was used.
Considering this aspect, our design engineers designed a special
crane with a rotating crab. Such a design allows extreme
flexibility. It can rotate the object by 360º clockwise or anti-
clockwise. This special design consists of two hoists of 10Ton
capacity each mounted on a rotating crab of a double girder
crane. The span of the crane is 17.6m and the height of lift is
7.6m. It can lift a load up to 120Ton. When ready-to-despatch
poles come out of the shed along the conveyor system, they are
lifted using this crane, turned by 90º to bring them in line with
the trailer and then carefully placed on the trailer.
This ingeniously designed system resulted in a tremendous
amount of saving in labour, time and enhanced productivity of
the despatch area. Team ElectroMech thanks Valmont for
involving us in this challenging project and proving the real
solutions ability of ElectroMech.
19
December 2012
A challenge 100m beneath the ground
ElectroMech has
designed a unique
crane with
triple girder design
and four 25MT crabs.
With the use of the
4-crab arrangement,
it becomes extremely
easy to assemble
the longer parts
of the TBM.
The project
Carrying components for a 1km long
TBM (Tunnel Boring Machine) through
a shaft and assembling it in a tunnel
100 meter beneath the ground was the
challenge posed to ElectroMech by the
construction giant, Soma Enterprises Ltd.
As usual, we handled it swiftly while
demonstrating a well-orchestrated
performance along with Soma’s
engineering team.
It all began when Soma was awarded
the challenging contract to excavate
an underground water tunnel for
Brihanmumbai Municipal Corporation
(BMC) - the city’s civic body.
Mumbai is the fourth most populous
city in the world with a population of
20.5 million people. Providing water
uninterruptedly to such a large
population and industries around the city
has always been a challenge for BMC. To
effectively meet this challenge of today
and future, the Government of
Maharashtra sought help from the
Government of India under its
Jawaharlal Nehru National Urban
Renewal Mission (JNNURM). This entire
project would replace the outdated
pipelines which have been providing
water to Mumbai from the Tansa
reservoir.
The INR 2235 crore project is divided
into two parts, one being awarded to
Unity-IVRCL joint venture and the other
to Soma Enterprises Ltd. Interestingly,
ElectroMech has also supplied tunnel
mucking cranes to Unity and IVRCL.
20
BEST OF
Compendium 2009 to 2013
digging and concreting of the 100m deep
shaft and excavated a 1km long tunnel
at this depth using the conventional
method. For further work, Soma decided
to use a modern TBM and chose
Herrenknecht, Germany to hire the TBM.
A TBM is a mammoth machine, 1km in
length, 100MT in weight and consisting
of thousands of components, each of
which had to be lowered into the tunnel
through the shaft individually. Some of
these components are close to 100MT
and assembling this machine on site is
a herculean task. Once assembled, it
appears like a train with the only
difference of the cutter head at the front
instead of an engine. It excavates the
tunnel just like an earthworm.
The solution
For handling this challenge successfully,
ElectroMech was involved at two critical
stages. The first stage involves lowering
hundreds of components into the tunnel
through the 100m deep shaft. Second
was to assemble the complete TBM
inside the tunnel itself. Soma selected
ElectroMech as its trusted partner to
meet these handling requirements based
on their previous experience with
ElectroMech’s competency in the field.
ElectroMech modified a previously
supplied 120MT Gantry crane at the
opening of the shaft. This crane served
two purposes. Firstly, it acted as a shaft
The challenge
As per Soma’s project plan, the first
phase involves completing the tunnel
from Kalher to Kapurbavdi. Accordingly,
work started at Kalher, where a shaft of
100m depth and 10m diameter was dug.
The entire tunnel will be approximately
100m beneath the ground. For
excavating the tunnel, Soma had two
options. The first was conventional rock
drilling and blasting, and the other was to
use a modern Tunnel Boring Machine. By
November, 2011, Soma completed the
mucking crane for removal of overburden
while digging the shaft of 100m depth
and secondly, it helped in lowering
hundreds of components of the TBM into
the tunnel.
Another interesting feature is the multi-
layer rope drum with a guiding
mechanism, necessitated by the 100m
height of lift and total wire rope of almost
2.5km. The same crane was also used for
routine up-down movement of workforce
for which a 15MT auxiliary hoist was
provided.
The second challenge was the actual
assembly of the TBM. To handle this
demanding application, ElectroMech
designed a special crane with unique
triple girder design and 4 crabs of 25MT
each. With the use of the 4-crab
arrangement, it became easy to
manoeuver and assemble the longer
parts of the TBM. The crane movement
also needed precision as the alignment
and matching of the TBM parts is very
crucial.
By meeting both these challenges
successfully, ElectroMech is indirectly
playing a crucial role in BMC’s ambitious
24x7 water supply project.
The most challenging task
was lowering an 11m
long, 95MT component
through the 10m diameter
shaft which required an
ingenious solution.
To tackle this requirement,
we designed a special
attachment beam on which
two 30MT chain pulley
blocks and two wire rope
slings were fitted. Using
this arrangement, the
c o m p o n e n t c o u l d b e
precisely tilted to a pre-
determined angle and then
lowered through the tunnel.
21
March 2012
Prime Electric installation -
Successful handling of a new challenge
At PEL, ElectroMech cranes
will integrate the handling of
transformers through various
processes and assembly
stations from incoming raw
material to the dispatch bay.
ElectroMech has supplied
14 cranes ranging from 5MT,
8.5m span to 150/30MT,
30m span.
ElectroMech has achieved another
milestone by adding Prime Electric Group -
a leading manufacturer of Transformers to
its client list. The plant has recently been
commissioned and all ElectroMech cranes
are operational, helping them achieve the
required handling task.
Introduction
Prime Electric Limited (PEL) is one of
India’s largest transformer manufacturers,
catering to the requirements of Indian and
international markets for power utilities,
EPC companies, substations, power
generation, transmission and distribution
companies and large industries from
various sectors (steel, cement, petroleum,
petrochemicals, etc.) using bulk power.
PEL is one of the most significant activities
of the Prime Group. The rich experience
of the Prime Group in addressing the
most exacting needs of the power sector
and through its range of eco-friendly
(low noise), aesthetically designed, extra
high voltage power transformers up to
1000MVA/500kV. PEL's production
capacity, projected to 35000MVA,
makes it one of the largest manufacturers
from India, producing world-class extra
high voltage power transformers for users
across the globe. PEL’s 100 acres
manufacturing location is at Nayudupet
Special Economic Zone in Nellore district
of Andhra Pradesh.
150/30MT Double Girder Crane
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BEST OF
Compendium 2009 to 2013
A challenge for ElectroMech
The task assigned at Prime Electric is
challenging in several aspects. ElectroMech
cranes are expected to integrate the handling
of transformers through various processes and
assembly stations from incoming raw material
to the dispatch bay. As the transformers pass
through the assembly, their weight gradually
increases, the heaviest transformers weighing
as much as 300MT. Two 150MT cranes are used
in tandem with a specially designed lifting
beam to lift these large transformers.
ElectroMech cranes cover the entire length and
width of the shop-floor, providing maximum
coverage by reaching every nook and corner.
The most critical part of the process is filling of
oil in assembled transformers. For this, the
transformer is to be lowered into a vacuum
chamber where it is completely dried to make it
moisture-free. Here, precision positioning
using the cranes is very important. After this,
the transformer is filled with oil and to be
moved without any spillage due to jerks.
Hence, the cranes should be able to handle the
load ensuring absolutely jerk-free movement.
ElectroMech solution
ElectroMech has supplied 14 cranes
ranging from 5MT, 8.5m span
to150/30MT, 30m span. ElectroMech
cranes ensure complete integration of
handling on the shop-floor while
covering every process station and
reaching every corner. These cranes
cover the handling requirements
existing at various places on the
shop-floor including handling of raw
material such as steel coils and copper
plates, various assembly stations,
core winding stations, vacuum
chamber, oil filling station, testing
room and finally, the dispatch bay.
ElectroMech is proud to be associated
with Prime Electric Ltd. for one of their
largest transformer manufacturing
facilities in India.
Application
Ø
Ø T
Ø T
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
ElectroMech cranes are used in
handling and lifting of transformers
and their parts in the assembly line.
The complete scope of supply includes:
150/30MT, 30m span, 16m lift x 3 nos
50/10M , 30m span, 17m lift
30/10M , 30m span, 17m lift
30/10MT, 15m span, 11m lift
15MT, 15m span, 11.4m lift
15MT, 10m span, 11.4m lift
10/2MT, 20m span, 11.4m lift x 2 nos
10/2MT, 10m span, 11.4m lift
5MT, 30m span, 22.7m lift
5MT, 30m span, 11.7m lift
5MT, 10m span, 11.7m lift
30/10MT EOT crane in huge transformer core winding handling bay
23
March 2012
ElectroMech has proved to be
a reliable partner to several
EPC companies. Hardly any
large scale infrastructure
project is complete without
ElectroMech. In keeping with
this tradition, we have supplied
several cranes for the Chennai
Metro Rail project, handled by
Gammon India and Soma
Constructions, reasserting our
successful track record.
Metro rails are the new lifelines of
modern India. With the ever-growing
population of Indian cities, rapid mass
transportation systems are the need of
the hour. A metro rail is best suited for
this purpose with an added advantage of
economy in commuting. After their
successful implementation in Kolkata,
Delhi & Bangalore, several other cities
such as Chennai, Mumbai, Pune are
following suit.
ElectroMech continues to play a pivotal
role in several metro rail projects by
installing cranes for precast segment
yards and in flyover construction activity.
A railway track is an essential
requirement for a metro rail and the
congested nature of most Indian cities
necessitates an elevated structure over
existing roads.
Hence, most of the routes of the metro
rail track consist of flyovers. These
flyovers are necessarily built using
modern construction techniques
consisting of pillars and precast
segments, which allow quick, precise and
reliable construction.
For using this method of construction,
precast segments are manufactured in
a central precast segments yard which is
usually located far away from the
construction site. These precast
segments are then carried to the project
location. They are then lifted and
precisely placed to form the track length.
ElectroMech's experience at metro
rail projects
ElectroMech is looked upon as a reliable
partner by several EPC companies for
their metro rail projects. ElectroMech has
supplied a 60 Ton launching girder hoist
to Gammon India for the Delhi metro rail
project. We have also been a part of
Bangalore metro rail project by supplying
two 120 Ton gantry cranes to Navayuga.
ElectroMech cranes are conspicuously
present at several flyover projects,
precast segments yards, highway
construction and other infrastructure
projects in India.
The current project
Recently, ElectroMech supplied several
cranes for the Chennai Metro Rail
project. This is being jointly executed by
Gammon India Ltd. and Soma
Constructions Ltd., both of whom are
ElectroMech clients.
Cranes for casting yards
Gammon India and Soma both have
large casting yards on the outskirts of
Chennai where precast segments are
manufactured and then transported to
project sites. ElectroMech Gantry Cranes
are used in these casting yards for
24
BEST OF
Compendium 2009 to 2013
Being on the right track
ElectroMech clients
Photo courtesy : Infrawindow.com
ElectroMech marks its presence at the Chennai Metro Rail project
efficient and safe handling of precast
segments. These gantry cranes
practically cover the entire length and
breadth of the yards, reaching every
corner. They are used to handle precast
segments through various stages of
manufacturing and then for moving them
to the stocking area. ElectroMech gantry
cranes are also used for loading of
precast segments onto trucks.
These cranes are reliably performing
round-the-clock for continuous handling.
Cranes on flyovers
ElectroMech is synonymous with
handling solutions. Obviously, for any
challenging requirement, industries look
at us with great expectations and trust.
One such challenging requirement at the
Chennai metro rail project was to
construct a parapet wall using precast
cemented blocks. ElectroMech was quick
to respond to this unusual requirement.
The solution came in the form of a
7MT gantry crane running on top of the
flyover, with overhangs on both sides.
With this arrangement, it was very easy
to lift precast segments and position
them precisely to form the parapet wall.
The same crane was used to build
platforms on the elevated track of the
metro rail.
By meeting the requirements of
Gammon India and Soma successfully
at the Chennai Metro Rail project,
ElectroMech has reasserted its
successful track record once again.
25
December 2012
The company
The challenge
CMI Fpe is a global leader in designing, manufacturing, erection
and commissioning of Cold Rolling Mill plants. In India, they have
large plants at Taloja and Silvassa, where they manufacture
various equipments required in Cold Rolling Mills. These two
units are equipped with high precision, ultra-modern machinery,
and all the assembly activities conform to high quality standards.
In the entire plant, emphasis is laid on automation where
handling of various components and parts during the assembly
impacts the productivity of the plant.
CMI Fpe’s Taloja plant consists of several manufacturing
bays. With the growing demand for their equipment and
machinery, the company has also constructed another plant
beside the existing one. With this new addition, the
manufacturing activity is carried out in one plant and the
assembly in the other plant. For handling requirements
in a particular bay, the company uses EOT cranes. However,
the inter-plant handling of high tonnage machinery from one
bay to another and intra-plant movement of components
and semi-assembled machines weighing up to 150Ton posed a
great challenge.
The solution
The result
The ElectroMech solution for intra-bay and intra-plant transfer
and handling of loads came in the form of a transfer trolley. This
is a specially designed trolley operating on ground rails. It
consists of a platform of size 9m x 3.5m with 8 wheels, capable of
handling 225Ton shock load. It traverses on a 112 m long set of
rails which efficiently integrates various bays and also two plants
in the premises. Handling is made extremely easy with a pendant
control, and a load of 150Ton at a time can be transported at a
speed of 40m/min. Power supply to this transfer trolley is
through a spring operated cable reeling drum. To ensure safety,
power cables run through a cable tray which is 6 inches below
the ground.
This highly efficient and safe system has made handling
extremely efficient. Previously, for the same job the company
was using a trailer, which has now become redundant. All the
bays and two plants are conveniently connected to operate
without requiring any special skill. The transfer trolley system
from ElectroMech is a new development ideally suitable for intra-
bay and intra-plant handling of heavy loads. This is a completely
in-house development introduced in the market after
successfully using it in our own plant for more than 3 years. The
system is also proving its worth at Prime Group, Reniguntta plant
and Enpro Industries, Pune.
26
December 2012
BEST OF
Compendium 2009 to 2013
Transfer trolleyAdding flexibility to handling
CMI Fpe benefits from our new transfer trolley system for intra-bay and intra-plant handling of loads
CMI FPE trusts our solutions capability
CMI FPE Limited - formerly
Flat Products Equipments
India Ltd. was incorporated in
1986. The company, over the
last 22 years, has acquired a global
leadership posit ion in the design,
manufacture, erection and commissioning of cold rolling mill
complexes and auxiliary equipments for the cold rolling industry
and the metal processing industry. The Belgian Group CMI
(Cockerill Maintenance & Ingénierie) completed the acquisition
of Flat Products Equipments India Limited in 2008 and has now
been renamed CMI FPE Limited. The principal activities of the
company comprise manufacturing and installation of cold rolling
mills complexes, processing lines, chemical processes, thermal
processes and automation equipments for ferrous and non-
ferrous industries worldwide. As of today, CMI FPE Limited has a
global footprint across Asia, Africa, Middle East, Europe, North
America, South America and Russia.
CMI FPE is currently working on a steel mill project for JSW Steel
Ltd. at Tarapur, Thane. While working on this project, a big
challenge was posed by the handling requirement at the
galvanising plant. The company was looking for a Pot handling
crane of suitable design to be fitted exactly above the zinc pot.
The challenge
What is a Pot crane? Working and uses
ElectroMech solution
These types of cranes are placed above the pots in galvanising
plants. It is primarily a maintenance crane, used to maintain and
replace the galvanising equipment such as rolls and slits when
required. The space constraint is high, and precise hook
positioning is required as the hook needs to be positioned exactly
above the zinc pot.
Having experienced our solutions capability previously, CMI FPE
approached us to design a unique solution for their current
challenge. The end client, JSW steel further attested this
decision.
After carefully studying the process and the requirements, our
design team developed a solution which was a perfect fit for their
requirement. The design is very different from a conventional
DG EOT crane.
The crane has 2 hoists of 7.5MT capacity each, mounted on
cantilever beams hanging on the crab. The hoists were modified
to suit this particular handling requirement. This design has been
made for the specific application, considering the critical end
approach requirements. The crane offers a span of 8m and lifting
height of 18m. The overall system, in spite of the customised
design, proved to be an economical solution for the client. This
crane was under commissioning at the time of going to print.
ElectroMech develops Pot handling crane with unique design by using 2 hoists on a single beam
27
September 2013
Nuclear Power Corporation of India Limited (NPCIL) is a Public
Sector Enterprise under the administrative control of the
Department of Atomic Energy (DAE), Government of India. It
was established in 1987 with the objective of operating atomic
power stations and implementing atomic power projects for
generation of electricity. It is responsible for design,
construction, commissioning and operation of nuclear power
reactors in India.
For the 3rd and 4th units of its Kakrapar Atomic Power Project
near Surat in Gujarat, NPCIL sought a competent and
experienced crane manufacturer with the capability to design,
manufacture and commission 29 EOT cranes according to the
critical requirements of the project while being able to adhere to
stringent quality norms. The cranes are to be installed at crucial
locations in the reactor building, reactor auxiliary workshop and
mechanical workshop of the nuclear plant. The scope of the work
also includes the designing of three critical Single Failure Proof
Cranes (SFPs).
The order was received after a thorough technical and
commercial evaluation of the bid, which was followed by a
factory visit by a cross-functional team from NPCIL to evaluate
our infrastructure and capabilities to execute the order. Satisfied
with the capability and competency of ElectroMech, NPCIL
placed the package order on ElectroMech in the month of August
2011. The total scope of the work includes design, manufacture,
inspection, assembly, shop testing, packing & forwarding, safe
delivery to site, unloading, storing, handling at site, erection,
final testing commissioning and handing over of cranes as per
NPCIL specifications.
This order includes:
Ø Single Failure Proof Cranes - 3 nos.
Ø Double Girder EOT Cranes - 6 nos.
Ø Single Girder Underslung Cranes - 6 nos.
ElectroMech - Selected as a most reliable project partner
Ø
Ø Manually Operated Cranes - 6 nos.
Ø Chain Hoists - 4 nos.
Among these, one of the most challenging requirements was
that of the 60MT Single Failure Proof Crane to be installed in the
reactor building.
Ø Crane SWL: 60MT Ø Span: 21m Ø HOL: 38m
Ø Class of duty: M7 Ø Operation: Cabin, Radio Remote Control
& Pendant Ø Crane weight: 80MT Ø Crab weight: 30MT
Ø Hook: 60MT Ramshorn Type Single Failure Proof Hook
Gantry Cranes - 4 nos.
Technical specifications of the 60MT Single Failure Proof
Crane
28
BEST OF
Compendium 2009 to 2013
Story of unfailing commitment to deliver first Single Failure Proof EOT Crane to NPCIL
In a major international bid, ElectroMech won an order to supply 29 EOT
cranes to Nuclear Power Corporation of India (NPCIL) for their Kakrapar
Atomic Power Project (KAPP) near Surat in Gujarat. This order includes
3 Single Failure Proof (SFP) Cranes.
What is a Single Failure Proof Crane?
A Single Failure Proof Crane has redundant systems &
mechanisms built into it, so that should one system or
mechanism fail, the backup system ensures that the work cycle
is completed. In the case of these cranes, it means that if a load
carrying system or mechanism suffers a failure, the full load is
taken by the backup or redundant mechanism. This, in turn,
prevents any major catastrophe in case of failure of any load
carrying component in the system.
Application
The first crane supplied is mainly to be used for handling Primary
Coolant Pump Motors, which are located exactly above the
reactor. The secondary application is for erection, maintenance
related activities of all the equipments within the reactor
building.
September 2013
29
Design
One of the biggest challenges for the designers was that this
Single Failure Proof Crane for the 700MWe reactor was to be
made with the same dimensional constraints as a regular EOT
crane. Moreover, the span of the crane for the 700MWe reactor is
21m as compared to 10m for a crane in the 500MWe reactors.
This made the design and arrangement of the crane components
a daunting task while meeting the dimensional requirement.
Finally, after months of painstaking efforts, dozens of proposals
and several brainstorming sessions, our design team along with
the NPCIL design team narrowed down to a double-decked
arrangement of the trolley mechanism. The design of this trolley
having a height of approximately 6.5m and sitting on top of the
reactor building was successfully undertaken by our design
team. This new concept was endorsed by the NPCIL team, so
much so that the same concept will be adopted in unit 7 of their
Rajasthan Atomic Power Plant as well.
Design to ensure structural integrity during a seismic event was
called for. The crane structural needed to be designed for Safe
Shutdown Earthquake (SSE) and Operating Base Earthquake
(OBE) standards as per the furnished Floor Response Spectra.
For the design and qualification of the plant the Safe Shutdown
Earthquake (SSE) standard is adopted. In simple language, this
means, in the eventuality of an earthquake it must be possible to
Seismic Design
Why is this required?
How is this achieved?
This crane will operate at the top of the Reactor Building dome,
directly above the reactor which is the heart of a nuclear power
plant. The location of the crane thereby demands a very high
level of safety, necessitating the need for a Single Failure Proof
Crane.
The required redundancy is achieved by using two independent
load paths through two rope drums. Both the rope drums are
driven by separate gearboxes and motors, synchronised to
ensure equal displacement of wire rope in each load path. Each
load path is designed to hold the rated load. Both the wire ropes
reevings are taken on alternate pulleys to maintain equilibrium of
load in case of failure of one rope system. The hooks used are of
dual design with dual attaching points thereby if one attachment
fails, the other load path continues to support the load without
excessive drop or swing.
Project challenges
30
BEST OF
Compendium 2009 to 2013
Single Failure Proof EOT Crane for NPCIL
shut down the plant and equipment safely. Similarly, the intensity
of the Operating Base Earthquake (OBE) is related to the
production period of the Nuclear Power Plant. After an OBE, it
should be possible to shut down the plant safely and further
operation of the plant and equipment should be possible after
checking and a certain amount of repair work.
The Floor Response Spectra is tabulated data that gives the
acceleration forces that may act on the crane in the event of an
earthquake. These acceleration values are a function of
equipment frequency and the elevation (i.e. crane location)
amongst many other factors. By using this data given by NPCIL
for the particular site location, the structurals of the crane were
qualified accordingly.
The ElectroMech design was reviewed by the NPCIL design team
and handed over to a third party for analysis using software to
simulate more virtual conditions. Finally, after 12 months of
detailed engineering and analysis, the structural design was
approved.
The special design called for use of special / non-standard
materials. For example, MS plates of grade E350 instead of
Procurement, Quality and Production
conventional grade E250 were used for girder fabrication, square
tubes were used for trolley fabrication and caliper brakes were
used, to mention a few. WPS PQR were re-established to meet
the customer requirement as per ASME. Above all, a stringent
quality plan was followed whereby material at each stage of its
production cycle - from raw material to finished component, was
tested to meet the highest quality standards. Obviously, this
couldn’t be achieved without a very efficient procurement,
quality and production team.
Ø First Single Failure Proof EOT Crane supply by ElectroMech
Ø First supply to a nuclear power plant by ElectroMech
The first Single Failure Proof (SFP) Crane was manufactured and
despatched in March 2013. This was tested for full load and
overload in our factory before despatch in the presence of a
specialist team across NPCIL, QS Pune and NPCIL Mumbai.
Several tests were conducted by simulating even the rare
possibilities and our cranes satisfactorily passed all of them. The
remaining 2 Single Failure Proof Cranes will be supplied during
this financial year.
Setting new records at ElectroMech
September 2013
31
hermax Ltd., headquartered in Pune, has been providing
engineering solutions for decades to the energy and
environment sectors. One of its biggest divisions
supplies boilers to the power sector. The company recently
entered into a joint venture with Babcock & Wilcox (USA), a
global leader in the power generation industry, to manufacture
super critical boilers for the power sector. The Thermax Babcock
& Wilcox (TBW) plant is spread over 100 acres of land at Shirwal
near Pune. The manufacturing facilities are split into 3 units; a
25,000 sq.m Section shop, a 16,000 Panel shop and a
18,000 Header shop.
ElectroMech has been supplying cranes to all of Thermax
factories as well as their projects. The Thermax factory in
Chinchwad, Pune has several cranes from ElectroMech and these
are used for various applications like loading, unloading,
handling, assembly work, etc. Satisfied with their past
experience of using ElectroMech cranes, TBW approached
ElectroMech at the planning stage itself to discuss the crane
requirements for this new plant.
At the new TBW plant, 34 ElectroMech cranes with capacities
ranging from 10MT to 50MT integrate the entire handling
operations on three shop-floors. This covers handling right from
raw material storage to the final despatch, including several
fabrication and assembly stations.
The interesting part of this entire project was the involvement of
ElectroMech right from the project conception and designing
stage of the plant building. Consideration of overhead cranes in
the plant is crucial in determining the overall specifications of the
building. This is because overhead cranes run on gantry girders
that are supported by the building structure. In addition to the
sq.m
sq.m
building structure and roof itself, the entire load of the crane as
well as the job being handled is borne by the factory columns.
Involving us at the factory planning stage is beneficial to a client
as the structural engineer can optimise the factory building
based on the wheel loads and crane dimensions provided by us.
This also allows us to provide inputs on the workflow, so as to
optimise the choice of cranes to keep costs low while achieving
maximum resource utilisation.
The work of the TBW factory building started almost two years
ago and following a consultative approach, ElectroMech
designed a solution that was economical, had advanced
features, matched speed, technical specifications and other
parameters of the crane such as the geometries, wheel loads,
etc.
An apt example of the benefit of involving us during the planning
stage is seen in the plant’s section shop. The highest capacity
crane is 50MT, which would logically require the entire factory
building to be designed for the loads exerted by this crane.
However, during detailed analysis of the client’s work flow, it was
apparent that the 50MT job would never traverse the entire
length of the shop floor. This allowed the structure to be
optimised so that only the necessary portion has been built to
take the load from the 50MT crane. Safety limit switches ensure
that the 50MT crane does not travel with its full load to other
parts of the shop. This solution gave TBW substantial saving in
their structural cost for this shop.
ElectroMech advised TBW to opt for a power supply system,
especially for the outdoor duty gantry cranes, that is more
Saving on project costs
Reduced maintenance
Ene rgy So lu t i ons
T
How project costs can be saved by involving ElectroMech at plant designing stage A testimony at Thermax Babcock & Wilcox Ltd., Pune
32
BEST OF
Compendium 2009 to 2013
Photo courtesy: Vogel Business Media India Pvt. Ltd.
reliable and has zero maintenance compared to what is used
traditionally. Typically, for a gantry crane, one uses cable reeling
drums. The cable reeling drum mechanism itself can prove to be
problematic in some cases as it increases maintenance. Again,
because we were involved with the customer from the
beginning, we were able to factor in, at the time of construction
itself, a way to use regular shrouded bus bar for supplying power
to the outdoor gantry cranes. By this, we have eliminated a lot of
hassles which might have arisen in the future had we resorted to
the cable reeling drum concept. This approach has also led to
further reductions in the project cost.
Thermax has always used conventional cranes of the older
generation of technology, based on the older Russian designs in
their older plants. Cranes from ElectroMech used at the super
critical boiler plant are more compact, efficient and lighter in
weight. These cranes are reliable with practically no breakdowns
and minimal requirement in regular maintenance. These cranes
are also inverter-driven. Hence, there is better control on various
parameters like smoothness of operation, precise control on
speeds. Energy efficiency is further enhanced as cranes take only
as much power as is required. If one were to combine the total
power consumption of all the cranes used throughout the TBW
factory, it would be observed that there is a reduction of at least
15-20 percent over conventional cranes.
ElectroMech has also supplied TBW with unique solutions like
wall travelling cranes. On a shop-floor, with respect to the
principles of lean manufacturing, waiting time is one of the prime
sources of waste. Wall travelling cranes allow workers to service
workstations individually without using cranes on the top.
Waiting time for the crane is thus eliminated and productivity of
the individual workstation is enhanced.
This is a much better solution than a semi-gantry crane, in which
one end carriage runs on the gantry girder, while on the other
side a leg runs on the floor. Having an end carriage running on
the factory floor, creates a safety hazard due to the possibilities
of collisions with men, machines and material. Rail tracks or
supports would also be needed on the ground, increasing the
civil cost. Wall travelling cranes have no legs and travel in the air
independently on their own supporting structure integrated with
the factory building, thus enabling efficient and safe layout of the
workstation. Integrating wall travelling cranes into the layout
was only possible because ElectroMech was involved in the
project from the factory planning stage.
Though material handling forms a critical part of any workshop,
Power saving
Faster handling. Higher profits. Higher safety
Customer satisfaction
lean manufacturing philosophy dictates its reduction. By taking
cognisance of what needs to be done on a shop-floor, arranging
processes accordingly and by optimising speeds and geometries
of cranes, material handling time can be drastically reduced. This
needs to be planned in the early stages of the project to derive
maximum advantage.
Adding further value is the ElectroMech factory, which uses
almost every type of crane that we manufacture, acts as a
showcase. This allows customers to experience a new solution
that we may recommend to them, building their faith in the
usefulness of the product.
We are indeed very thankful to the TBW team for reposing their
trust in our solutions approach and capability and for involving
us at the project planning and building designing stage.
How project costs can be saved by involving ElectroMech at plant designing stage A testimony at Thermax Babcock & Wilcox Ltd., Pune
Thermax Babcock & Wilcox (TBW) wanted a material
handling system that was technically proven, matched
their applications and was cost-efficient.
Wall travelling cranes were suggested by ElectroMech
to TBW for carrying out their operations effectively;
various zone protection systems were introduced
which helped them save their structural cost. Inverter
drives were used to save on power consumption.
Challenges
Solution and Results
Divisional Manager-Manufacturing, Thermax
Babcock & Wilcox Energy Solutions Pvt. Ltd.,
Mr. Rajeev Sondur seconds the fact that including
ElectroMech from the start provided numerous
benefits. He said, “The company was able to fine
tune our plant layout to ensure maximum space
utilisation and save on our asset costs.”
33September 2013
At ElectroMech, customer service Hence, undertaking proactive
has always been the topmost preventive maintenance activities
priority. In fact, the ethos at on cranes becomes a topmost
ElectroMech is that, first and priority.
foremost we are a service-oriented For addressing all the above company. Be it pre-sales service or pressing issues, it becomes services provided to our customer extremely important to have a during the execution of the order or partner that has a rich experience in post-sales service. the crane industry and which has a
Post-sales service for cranes is an pan-India network to cater to
area where we find several lacunae different installations all across the
in the Indian industry. Although country.
ElectroMech has always had the Therein lies the case for Cranedge. reputation of addressing the customer's issues on priority, we At ElectroMech, we have spun off a set of service offerings under found that owners of cranes from other brands have not been so the brand name of Cranedge to address all the above-mentioned lucky in getting their problems addressed. pain areas. We aim to leverage our rich experience of more than
Furthermore, as the customer's scope of work changes, the three decades in this industry and our existing national service
hoisting requirements also change. Hence, it becomes network to provide an enhanced range of services to our clients.
imperative for customers to find an able partner who can help Under the umbrella of Cranedge, we will be undertaking Annual
them in modernizing or retrofitting their existing equipment to Maintenance Contracts for cranes of any make in any corner of
suit their new requirements. Some factory owners in India have the country. We will also attend to breakdown calls from our
equipment which is quite ancient and finding spares and customers in the shortest possible time. In addition to this, we
expertise to keep such equipment running in optimum condition aim to provide to our customers spares support for different
becomes a harrowing task. crane brands. Our engineers will also be able to evaluate
requirements for modernizations and retrofitting of existing In today’s scenario of lean manufacturing systems, where cranes at the customer end in order to increase their life and productivity levels are being continuously monitored and enable our customers in deriving maximum value of their downtime on the shop-floor can translate into huge losses, it is investment. Please visit for further extremely important to ensure that all the machinery involved in details about our service offerings or write to various processes runs perfectly. Cranes are an essential part of
for more information.several processes on the shop-floor.
www.cranedge.com
New service brand from ElectroMech for reliable maintenance of cranes of all makes
Launch of CRANEDGE
Ø Inspections
Ø Spare Parts
Ø Emergency Breakdown Repairs
Ø Formal Proactive PredictiveMaintenance Program
Ø Modernizations
Get your edge.Get Cranedge.
34
June 2009
BEST OF
Compendium 2009 to 2013
ElectroMech - Cranedge Fighting nature’s wrath
A damaged crane was
reconditioned after reverse
engineering, design,
manufacture and supply of
damaged parts, assembly
and load testing.
The task was completed
in a record time.
In June 2009, an 80/20MT EOT crane that
Nilanchal Ispat Nigam Ltd. (NINL) had
purchased from another OEM fell victim to
nature’s wrath, when the cyclone
packing winds of over 180km/hr blew the
crane away.
The crane was amongst others that were
erected at their site in Kalinganagar
Complex, Duburi, near Cuttack-Jajpur
road and the project was nearing
commissioning. The crane which weighed
almost 150MT, fell from a height of 22
meters and was severely damaged under
the impact of its own weight.
The crane required extensive rework to
bring it back to operational level, however,
the OEM was unwilling to take up the job
and
ElectroMech, with the support of its
service subsidiary, Cranedge India Pvt.
Ltd. (a company specializing in crane
services and refurbishment) took up the
challenge.
Aila
who could be better than ElectroMech
to execute it!
A special team was formed, led by
Mr. Omkar Majumale to complete this
daunting task.
The crane was badly damaged and to add
to the woes, the crane was not stored
properly which led to rusting and
accumulation of dust. Undeterred, our
team took it as an opportunity to explore
new horizons. Throughout the project, the
team remained focused, complemented
each other and completed the work
within the given time frame without
compromising on the quality and safety
norms.
The scope of work consisted of
complete dismantling of
the damaged crane at NINL
Dubur i , t ransport ing i t
to ElectroMech Pirangut,
completely reconditioning
the crane which included
reverse engineering, design,
manufacture , repa i r o r
replacement of damaged
parts, assembly, load testing
and transporting it back to
NINL Duburi .
35
March 2012
The crane after repairsThe damaged crane
Repaired crane being load-tested
Caterpillar India Ltd.
On a pleasant October morning last year in Pune, Cranedge Help
Desk was flooded as usual with calls. A few minutes later there
was a moment’s quiet. Just as the person at the desk reached out
to pick up her coffee mug, the phone rang. Glancing at the Caller
ID, she noticed the Chennai STD code. The
caller politely introduced himself and
asked to be connected to a decision
maker at Cranedge. He was quickly
put through to Mr. Raj Shrivastav,
our CEO. Pleasantries were quickly
exchanged and the conversation
was short and crisp.
An immediate conference call
ensued between our Technical
Services Team at Pune and our
Chennai Office. Anxious to know
why they were summoned at such
short notice, our Pune and Chennai
team came on line, expecting the
worst. In fact, what they heard set
their adrenalin rushing. The purpose
was explained to them very simply:
"Ensure zero down time of the cranes
installed at CAT, Chennai works for the next 3
months – starting within the next day". This was a
huge business opportunity and actually a litmus test for
Cranedge since the world’s largest construction equipment
manufacturer CAT had turned to us for critical help! Only a few
hours were available at hand for preparation. Quickly, a mission-
specific core group was formed. Tasks were listed out and
deadlines set. Everyone was made aware and mentally prepared
for a long-haul operation which would stretch for the next couple
of months.
The scorching sun and dusty locale did not deter team Cranedge.
The march began towards Melnallathur, in Tiruvallur district of
Tamil Nadu, about 45km from Chennai. At 14:30 sharp, the
Cranedge team was in front of a large gate of the massive factory
whose facia read, 'Caterpillar India Ltd.' The team was already
briefed on the new task - Ensuring zero down
time of their cranes installed in the
assembly shop of heavy construction
equipment till, at least, the end of
December 2009. Caterpillar was heavily booked with orders and
only uninterrupted production round the clock could help meet
their target. Elaborate discussions were held with the CAT
production team and Cranedge maintenance team to ascertain
and reconfirm their production cycle and the crane usage
cycle - all of which was highly demanding. This ruled
out the possibility of any major repairs. Cranedge
team quickly carried out the Health Assessment
of cranes. The crane history sheets were
analysed with clear identification of
the associated working risks. A
resource p lan and da i l y
maintenance and preventive plan
were worked out in consultation
with CAT team to ensure 100%
up time. This also called for
arranging spares immediately.
Minimum essential quantities of
parts were organized and our
engineers were deployed on two-shift
basis at the works. A core team
consisting of CAT and Cranedge engineers
was formed to focus on these cranes. The first
target was achieving at least 120 shifts without any
breakdown! We started an exercise in routine and preventive
maintenance. With a constant vigil and monitoring of the crane
operations, the core group worked round the clock at times, to
ensure that not a single hour of production time was lost.
January 01, 2010. The Cranedge team proudly submitted a blank
paper to CAT management. It was titled 'Downtime record of
cranes on assembly shop II'. Indeed, by the end of December 09,
Cranedge could successfully achieve its target, but more
importantly, CAT production team could accomplish their
commitment to the management of meeting the targeted
production, ensuring zero down time for the last three months on
the shop-floor and being well within their cost target for usage of
spares.
However, the real appreciation for the Cranedge team came in
the form of an extended service contract further till the end of
March 2010. Once again, the highly motivated and professional
Cranedge team was entrusted with a new challenge!
1
Cranedge passes the litmus test with two giants
CATERPILLAR & its logo are the trademarks of Caterpillar
36
July 2010
BEST OF
Compendium 2009 to 2013
Pipavav Shipyard Ltd.
Pipavav Shipyard Limited (PSL), an integrated
shipbuilding facility, is one of the largest in
Asia. The shipyard complex is located on the
South Western coast of Gujarat, about 130km
from Bhavnagar to its east, and Diu about
90km to its west.
Spread over an aggregate area of 198.92
hectares (approximately 491.53 acres),
comprising a SEZ unit spread over 95
hectares (approximately 234.75 acres), it has
more than 100 cranes delivered by all leading
Indian crane manufactures. The plant was
commissioned by mid 2009 and PSL
immediately realized the crucial role cranes
play in shipbuilding.
In October 2009, needing strong after market
services, PSL turned to ElectroMech to
support 61 of their critical Double Girder, Semi
Gantry and Goliath Cranes. Pipavav
demanded minimum down time till March 2010 and upkeep of
cranes of all makes such as ElectroMech, and its competitors,
cranes ranging from 3.5MT up to 150MT SWL. Cranedge, the
latest initiative of ElectroMech had just been launched with a
mission to offer professional services for cranes of all makes. This
was the moment of truth. Sensing the big moment and realizing
that Pipavav had confidence in ElectroMech, we at Cranedge
picked up the gauntlet and went
ahead.
In consu l ta t ion w i th the
operations & maintenance
departments of the customer,
Cranedge deputed expert
engineers to be located at
the plant. Cr i t ical spares
requirement was evaluated and
organized. Working on a sixteen-
hour basis, Cranedge drew up an
action plan for each of the cranes.
The daily maintenance and weekly
preventive protocol was defined
and followed meticulously to avoid
any major breakdowns.
After initial hiccups, the plan got
working and it proved to be a huge
learning experience for the young
organization.
The customer’s confidence in Cranedge was further
demonstrated when they asked us to continue maintaining the
cranes beyond March. It is a privilege to be associated with
giants like Pipavav and it is a firm resolve to improve
performance to establish Cranedge as a leading organization
providing all services for overhead cranes.
cranedge
2
PIPAVAV and its logo are the trademark of Pipavav Shipyards Ltd.
37
July 2010
cranedge
Shipbuilding in India
About Bharati Shipyard Ltd.
Global shipbuilding investment has reached an all-time high and
order books are full to the extent that International yards are
refusing to accept orders for delivery before 2012. The
overworked European and East Asian yards have inadvertently
offered India an entry point into this lucrative market. Hence,
India has started on a solid footing, with its focus on the offshore
segment, followed by bulk carriers and containers, ranking it
ninth by investment in the shipbuilding sector. Going by the
present growth trends, the industry, with a current order book of
$3.7 billion, is projected to grow at a compounded annual growth
rate (CAGR) of 30 per cent, burgeoning to $22.1 billion by 2020.
Proposed capacity additions by various shipyards are expected to
move the country up in the global rankings and India can surely
compete on costs and deliver quality ships
on schedule by leveraging its vast pool of
skilled manpower.
Bharati Shipyard Ltd. (BSL) is the foremost
privately operated shipyard in terms of
shipbuilding facilities in India. BSL has
earned its reputation by constructing a
large array of specialized sophisticated
vessels for diverse offshore, coastal and
the marine market sectors. The BSL
p roduc t range i n c l udes h i gh l y
maneuverable and power-packed offshore vessels including
AHTS, PSVs and MSVs of varying bollard pulls, Tractor and ASD
tugs, state-of-the-art dredgers, deep sea fishing vessels, cargo
and container ships, tankers and Ro- Ro Vessels.
Bharati has four shipyards under operation - Goa, Ratnagiri,
Ghodbunder near Mumbai, and Kolkata - and has invested about
$150 million. Currently BSL has an order book of about $980
million and seventy-five per cent of these orders are for export.
Bharati shipyard is undertaking a Greenfield project at Dabhol
spread over 300 acres of land on the banks of the river Vashishti
wherein most modern infrastructural facilities for shipbuilding
are being created. The Shipyard is designed by First Marine
International of UK. The yard will have capacity to build among
other vessels, Jack-up Drill Rigs, Offshore Structures and ships
up to 100,000 DWT. For this, BSL had
purchased a shipbuilding yard from
Swan Hunter (NE) Ltd., Newcastle, UK
with all equipment in as-is-where-is
condition and moved it to their new
site in Dabhol.
Swan Hunter (NE) Ltd. is a renowned
shipbuilder in Europe existing since
1880, operating out of a 40 acre yard
in Wallsend, on the banks of the river
Tyne. The yard is now owned by the
Nor th Tynes ide Counc i l and
shipbuilding activities have ceased
there. However, Swan Hunter
continues to provide engineering, design and management
support to the shipbuilding and offshore industry.
38
Partners in progress
Cranedge at Bharati Shipyard Ltd.
i
BEST OF
Compendium 2009 to 2013
Cranedge - scope of work at Bharati Shipyard Ltd.
cranedge
A new challenge for Cranedge
Shortly before the summer of 2010,
Cranedge received a request from BSL,
who needed an all-encompassing
solution to erect and commission two
used cranes that had been procured by
them. The Cranedge team held an
internal review and planned their visit to Dabhol on the Konkan
coast where Bharati Shipyard Ltd. is located. The equipment,
which included 7 cranes had been in storage for 10 months and
initially BSL required Cranedge to refurbish and erect two
55/10.10MT Morris make EOT cranes. As a first step to erecting
the cranes, team Cranedge proposed to undertake a detailed
health check up of the cranes, constituting an inspection of
mechanical and electrical assemblies. This approach was
immediately accepted by the BSL senior management. The
inspection and health check up of the cranes was conducted over
a seven-day period and on 8 June, 2010, the Cranedge team
submitted a report along with an offer for the overhauling along
with various components which
needed to be replaced. The report
recommended cleaning, servicing
and lubrication of all the major
components such as gearboxes and
motors of both cranes. Electricals and
the electrical panel were to be refurbished and several
components such as limit switches, cable trolleys and wire ropes
which were either damaged or missing were to be replaced. In
addition to these corrective measures, the report also suggested
the addition of features such as gravity limit switches, radio
remote controls and anti-collision devices to the cranes.
Impressed by the Cranedge approach, BSL entrusted Cranedge
to supply all the parts and spares required to bring the cranes
into operational readiness.
Once the initial order had been executed to BSL's satisfaction,
they engaged ElecrtoMech to refurbish the remaining 5 cranes,
certainly making us partners in their progress.
n 55/10/10MT, 30m span, 23m height of lift DG EOT Crane - 2nos
Complete overhauling, assembly, erection, commissioning, electrical circuit modifications were done as per our logic to start the 55/10/10MT crane
n 30MT, 30m span, 23m height of lift DG EOT Crane - 1no
Complete overhauling, assembly, erection, commissioning
Make-Herbert's MORRIS, England. Year of manufacture -1969
Make-Carruther, England. Year of manufacture -1969
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n 10MT, 29m span, 21m height of lift DG EOT Crane - 1no
Complete overhauling, assembly, erection, commissioning
n 10MT, 29m span, 21m height of lift DG EOT Crane - 1no
Complete overhauling, assembly, erection, commissioning
n 6MT & 8MT - Deck Cranes on Floating Dock - Supply of CRD with CRD cable, installation at site and commissioning
Make-Carruther, England. Year of manufacture-1969
Make-Demag. Year of manufacture -1982
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All spares related to overhauling were supplied by Cranedge.
39
July 2010
Gestamp saved 60% through re-engineering and reallocation of existing cranes
40
BEST OF
Compendium 2009 to 2013
Gestamp Automotive is an international group dedicated to the
design, development and manufacture of metal components and
structural systems for the automotive industry. Today, Gestamp
Automotive is present in 22 countries and has 95 production
centres (49 plants in West Europe, 15 plants in East Europe, 8
plants in North America, 9 plants in South America, 14 plants in
Asia) and 13 R&D centres, and has over 25,000 employees. One
such plant of Gestamp Automotive India is in Chakan, near Pune
in India.
This plant presently has 5 ElectroMech EOT cranes on their press
shop, which are performing extremely well and to the
satisfaction of the customer for the last 5 years. However, there
was a change in the handling requirement due to an increase in
the production and die maintenance activity.
The cranes being used presently are -
n Bay 1 (Blanking line) 32/16MT DGEOT Cranes-2 Nos.
n Bay 2 (Line 1) 50/15MT DGEOT Crane-1 No.
n Bay 3 (Line 2) 50/15MT DGEOT Crane-1 No.
n Bay 4 (Line 3) 50/15MT DGEOT Crane-1 No.
utilised and a 50/15t crane was not essential in Bay 3 (Line 2) as
die handling demanded no more than 30t capacity. Hence, the
following suggestions were made to the client.
n One new 32t crab would be added to the existing 32/16MT
blanking line crane
n Shifting of another 32/16MT crane in bay 3 (Line 2) as the
total die capacity in line 3 was not more than 30MT
n Shifting of existing 50/15MT crane from Bay 3 (Line 2) to
Bay 2 (Line 1) to meet their requirements
The most interesting part of the proposal was that the entire
investment in the project was just 40% of the cost of a new
crane. The client was definitely impressed with this ingenious
solution and opted for it. After making all the initial preparations,
the required cranes were re-engineered and reallocation of
cranes was done based on the client's requirement. This was
quite a herculean task, but with the help of a large team of
engineers and contractors we completed this task in just 6 days.
We sincerely thank team Gestamp Automotive India for involving
us in this challenging project and trusting our solutions providing
capability.
With the change in the production requirement and die
maintenance activities, Gestamp required 2 cranes of 50/15MT
in Line 1 bay. Hence, they approached Cranedge for their
following requirements.
n Dismantling of 32/16MT crane from blanking line (Bay 1)
n Upgrading one existing 32/16MT crane to 50/16MT capacity
n Re-erection of modified 50/16MT crane in Line 1 (Bay 2)
n Upgrading one existing blanking line crane to 32/32MT
capacity
Based on the above enquiry, Cranedge evaluated the possibility
of converting 32/16MT to 50/16MT crane and found that
technically this modification was not feasible.
A completely new crane for Bay 2 was then considered, however
this option proved to be beyond their allocated budget for this
upgrade. The client approached Cranedge again for solving this
problem. Looking at the challenge involved in the project, the
Cranedge team decided to conduct a thorough audit of all the
cranes on the shop-floor. A careful study of the optimum usage
pattern revealed that the Blanking line 32/16t crane was not fully
Project highlights
Phenomenal saving of 60% of
investment in a new crane.
Proper utilisation of cranes.
The problem related to production
is solved successfully in minimum
possible time.
Gestamp saved 60% through re-engineering and reallocation of existing cranes
Cranedge team conducted
a thorough audit of all their cranes.
Suggestions were made to the client,
which proved greatly worthy.
41
December 2012
Gearbox
Wheel block
42
BEST OF
Compendium 2009 to 2013
Before After
Before After
Crab
Before After
The Hindustan Construction Company (HCC) specialises in
engineering and construction of complex infrastructure projects
and has executed a large number of India's landmark
infrastructure projects. HCC has been awarded some major
contracts by Delhi Metro Rail Corporation (DMRC) and for the
execution of these projects, they require various material
handling equipments.
One such 25MT double girder gantry crane at their Mundka site,
supplied by a European manufacturer was lying unused for
several years. When the need for such a crane arose on a new
project site, the HCC team intended to assess the possibility of
refurbishing and using this crane. Knowing that the Cranedge
team of experts is well versed with cranes of all makes, HCC
approached us to carry out the task. The Cranedge team first
conducted a Crane Health Assessment to evaluate the possibility
of reusing the crane by refurbishing and bringing it back to the
original condition without compromising on safety and
performance.
The Crane Health Assessment report prepared after thorough
evaluation and analysis revealed that most of the components
were completely rusted and moving components were jammed
because of rust and grime. This included key components and
various sub-assemblies such as the crab assembly, wheel
assemblies for long travel & cross travel, rope drum, lower block,
etc. A few control panel covers and the wiring inside the panel
was completely missing. The gearbox was in a relatively good
condition, but needed cleaning and oil change, whereas the
operator cabin was in a completely derelict condition.
A new lease of life to a worn out crane of HCC
For refurbishing this crane properly, we decided to bring the key
parts such as the crab assembly, long travel wheel blocks with
motors and the operator cabin to our Pimpri, Pune factory. The
entire work was completed to great satisfaction of the client and
trials and tests of major components were conducted in our
factory for rigorous performance.
Another factor that demanded attention was that the crane had
been supplied by the OEM with motors compatible with 60Hz
power supply. However, these kind of motors typically overheat
when subjected to the standard Indian 50Hz power supply. On
Cranedge’s recommendation, Variable Frequency Drives were
added for all motors to avoid overheating.
The HCC team was extremely happy with the solution and
services of Cranedge. HCC was able to save a considerable
amount of money thanks to the methodical approach and proper
engineering solutions from Cranedge to grant a new lease of life
to the completely worn out crane. The modification of the
existing trolley has resulted in a huge direct saving for HCC both
in terms of costs and time. Had HCC procured a new trolley to
match the application and fitment on the crane, it would have
cost them at least 4 to 5 times more! At the same time, the
modification undertaken by Cranedge has saved the customer at
least 12 weeks of valuable time which, when calculated over the
project time line is a significant and crucial saving.
September 2013
43
For private circulation only. In-house publication of ElectroMech , Pune. Material Handling Systems (India) Pvt. Ltd. © copyright 2013All logos and monograms used in this newsletter are registered trademarks of respective companies.
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ElectroMech Material Handling Systems (India) Pvt. Ltd.
www.emech.in
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Corporate Office & Plant Gat No. 316, At post Kasar Amboli, Tal. Mulshi,Dist. Pune 412 111 INDIATelefax : +91-20-6654 2222 E-mail : [email protected] |
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Tel. : +971-4-8857466
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