First Single Failure Proof Crane For Nuclear Reactor Dome Delivered To Kakrapar Atomic Power Project

Transcription

1 Newsetter Award winning soution for tunneing operation Soution for Thermax Babcock & Wicox to reduce project costs Tower cranes for India s argest cooing towers First Singe Faiure Proof Crane For Nucear Reactor Dome Deivered To Kakrapar Atomic Power Project

2 ACHIEVEMENTS Contents EectroMech FZE receives a major order from Air Liquide Group of France From MD s desk Story of unfaiing commitment to deiver first Singe Faiure Proof EOT Crane to NPCIL CMI FPE trusts our soutions capabiity Prestigious order from Mazgaon Dock Limited How project costs can be saved by invoving EectroMech at pant designing stage A testimony at Thermax Babcock & Wicox Ltd., Pune Forging reationship A pate fu of chaenges Zoomion Tower Cranes for one of India s argest Cooing Towers A new ease of ife to a worn out crane for HCC s DMRC project Cranedge introduces unmatched, ocaised services for Zoomion Tower Cranes Award-winning soution for tunneing operations Our customers reaffirm our positioning Soutions, Service, Satisfaction Thermax Babcock & Wicox reposes its trust in EectroMech Zoomion - EectroMech Tower Cranes make a debut at bc India, Soutions Service Satisfaction Receives a major order from Air Liquide Group of France Air Liquide Group is a major payer in the oi & gas sector as we as heath & environment with operations in over 80 countries. It is the word eader in gases for industry, heath and environment. The Group offers innovative soutions based on continuousy enhanced technoogies for cod box manufacturing which is used in Air Separation Units / Cryogenic Air Separation Units (ASUs). In a major breakthrough, our subsidiary, EectroMech FZE, Dubai bagged a major order worth approx. INR 200 miion for 29 EOT Cranes from the French mutinationa, Air Liquide Group. The order was received against tough competition from severa mutinationa companies. Our compete scope is for the manufacture, suppy, erection, commissioning, testing and certification of 29 EOT Cranes. The cranes to be suppied 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 wi be instaed in their pant in RAK Maritime City which is the atest and most advanced maritime free zone to open in the United Arab Emirates. The Air Liquide Group pant is spread over 36 acres and the faciity wi be used for the manufacturing of fabricated meta products, structures, tanks, reservoirs and containers or in short cryogenic vesses. This chaenging project wi be competed during FY successfuy. 02

3 MD s DESK Take my word! Dear customers, coeagues, business associates and we-wishers of EectroMech, A of us are going through a historicay significant phase for the goba economy in genera and the Indian economy in particuar. Many years hence, peope wi refect back upon these times and a great dea wi be written about the period. In retrospect, everyone woud have aready had a hande on the situation, but when one is navigating through the turbuent times, one unfortunatey does not have the uxury of driving whie ooking into the rear view mirror. One has to focus on the immediate task at hand and focus on creating a brighter future. On this background, it gives me immense peasure to famiiarise a of you with the achievements of EectroMech in this period. The theme of the current issue that has emerged unwittingy is TECHNOLOGY - wherein we have been proudy associated with designing, manufacturing, suppying and commissioning some truy technicay advanced soutions for our customers. EectroMech FZE, our subsidiary in UAE continues to fy our fag high by securing a very prestigious order for Air Liquide Group s atest pant in Ras A Khaimah. Pease read more about this prestigious order which was won against stiff competition posed by other mutinationa crane companies. We are proud to present to you EectroMech s distinction of being the first in India to indigenousy design, manufacture and suppy a very unique Singe Faiure Proof 60t EOT crane to Nucear Power Corporation s power pant in Kakrapar, Gujarat. Aso read in this issue about severa prestigious orders we have received from severa customers across India who repose their faith in EectroMech and our soutions for their diverse handing needs. EectroMech has aways prided itsef in being a soutions provider and a partner that works with its cients to design, deveop and execute crane systems that not ony address the requirements of the cients, but aso does so in an optimum manner. Read about how EectroMech has heped the joint venture of Thermax Babcock & Wicox to put up effective and optimum crane systems for their ambitious word-cass super critica boier pant near Pune. In the ast issue, we mentioned about our Joint Venture with Zoomion for Tower Cranes. In this issue, we are proud to present our successes in this Joint Venture by showcasing a project wherein we suppied 2 nos. of TCT Fat Top Tower Cranes for buiding India s taest cooing towers in a power pant project being executed by Nagarjuna Construction Company. Our services subsidiary, Cranedge, true to its phiosophy - upkeep, upgrade, upraise - heped one of our prestigious cients, Hindustan Construction Company by breathing a new ife in their od cranes which have been redepoyed for their construction project of the Dehi Metro Rai. However, one of the most important achievements of EectroMech has been reserved for the ast as the trump card! EectroMech has been recognised for its technoogica competence and its capabiities in depoying unique soutions for the requirement of tunneing contractors, by Manufacturing Today through an award for Exceence in Innovation. We are extremey proud to be the recipients of such recognition and are ooking forward to winning severa such awards in the future. As aways, I wish you a a happy reading and want to thank you a for your continued patronage of EectroMech. Tushar Mehendae Managing Director 03

4 TECHNOLOGY Nucear Power Corporation of India Limited (NPCIL) is a Pubic Sector Enterprise under the administrative contro of the Department of Atomic Energy (DAE), Government of India. It was estabished in 1987 with the objective of operating atomic power stations and impementing atomic power projects for generation of eectricity. It is responsibe for design, construction, commissioning and operation of nucear 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 capabiity to design, manufacture and commission 29 EOT cranes according to the critica requirements of the project whie being abe to adhere to stringent quaity norms. The cranes are to be instaed at crucia ocations in the reactor buiding, reactor auxiiary workshop and mechanica workshop of the nucear pant. The scope of the work aso incudes the designing of three critica Singe Faiure Proof Cranes (SFPs). EectroMech - Seected as a most reiabe project partner The order was received after a thorough technica and commercia evauation of the bid, which was foowed by a factory visit by a cross-functiona team from NPCIL to evauate our infrastructure and capabiities to execute the order. Satisfied with the capabiity and competency of EectroMech, NPCIL paced the package order on EectroMech in the month of August The tota scope of the work incudes design, manufacture, inspection, assemby, shop testing, packing & forwarding, safe deivery to site, unoading, storing, handing at site, erection, fina testing commissioning and handing over of cranes as per NPCIL specifications. This order incudes: Ø Singe Faiure Proof Cranes - 3 nos. Ø Doube Girder EOT Cranes - 6 nos. Ø Singe Girder Undersung Cranes - 6 nos. Ø Gantry Cranes - 4 nos. Ø Manuay Operated Cranes - 6 nos. Ø Chain Hoists - 4 nos. Among these, one of the most chaenging requirements was that of the 60MT Singe Faiure Proof Crane to be instaed in the reactor buiding. Technica specifications of the 60MT Singe Faiure Proof Crane Ø Crane SWL: 60MT Ø Span: 21m Ø HOL: 38m Ø Cass of duty: M7 Ø Operation: Cabin, Radio Remote Contro & Pendant Ø Crane weight: 80MT Ø Crab weight: 30MT Ø Hook: 60MT Ramshorn Type Singe Faiure Proof Hook 04

5 In a major internationa bid, EectroMech won an order to suppy 29 EOT cranes to Nucear Power Corporation of India (NPCIL) for their Kakrapar Atomic Power Project (KAPP) near Surat in Gujarat. This order incudes 3 Singe Faiure Proof (SFP) Cranes. Story of unfaiing commitment to deiver first Singe Faiure Proof EOT Crane to NPCIL What is a Singe Faiure Proof Crane? A Singe Faiure Proof Crane has redundant systems & mechanisms buit into it, so that shoud one system or mechanism fai, the backup system ensures that the work cyce is competed. In the case of these cranes, it means that if a oad carrying system or mechanism suffers a faiure, the fu oad is taken by the backup or redundant mechanism. This, in turn, prevents any major catastrophe in case of faiure of any oad carrying component in the system. Appication The first crane suppied is mainy to be used for handing Primary Cooant Pump Motors, which are ocated exacty above the reactor. The secondary appication is for erection, maintenance reated activities of a the equipments within the reactor buiding. 05

6 TECHNOLOGY Project chaenges Why is this required? This crane wi operate at the top of the Reactor Buiding dome, directy above the reactor which is the heart of a nucear power pant. The ocation of the crane thereby demands a very high eve of safety, necessitating the need for a Singe Faiure Proof Crane. How is this achieved? The required redundancy is achieved by using two independent oad paths through two rope drums. Both the rope drums are driven by separate gearboxes and motors, synchronised to ensure equa dispacement of wire rope in each oad path. Each oad path is designed to hod the rated oad. Both the wire ropes reevings are taken on aternate pueys to maintain equiibrium of oad in case of faiure of one rope system. The hooks used are of dua design with dua attaching points thereby if one attachment fais, the other oad path continues to support the oad without excessive drop or swing. Design One of the biggest chaenges for the designers was that this Singe Faiure Proof Crane for the 700MWe reactor was to be made with the same dimensiona constraints as a reguar 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 whie meeting the dimensiona requirement. Finay, after months of painstaking efforts, dozens of proposas and severa brainstorming sessions, our design team aong with the NPCIL design team narrowed down to a doube-decked arrangement of the troey mechanism. The design of this troey having a height of approximatey 6.5m and sitting on top of the reactor buiding was successfuy undertaken by our design team. This new concept was endorsed by the NPCIL team, so much so that the same concept wi be adopted in unit 7 of their Rajasthan Atomic Power Pant as we. Seismic Design Design to ensure structura integrity during a seismic event was caed for. The crane structura needed to be designed for Safe Shutdown Earthquake (SSE) and Operating Base Earthquake (OBE) standards as per the furnished Foor Response Spectra. For the design and quaification of the pant the Safe Shutdown Earthquake (SSE) standard is adopted. In simpe anguage, this means, in the eventuaity of an earthquake it must be possibe to 06

7 shut down the pant and equipment safey. Simiary, the intensity of the Operating Base Earthquake (OBE) is reated to the production period of the Nucear Power Pant. After an OBE, it shoud be possibe to shut down the pant safey and further operation of the pant and equipment shoud be possibe after checking and a certain amount of repair work. The Foor Response Spectra is tabuated data that gives the acceeration forces that may act on the crane in the event of an earthquake. These acceeration vaues are a function of equipment frequency and the eevation (i.e. crane ocation) amongst many other factors. By using this data given by NPCIL for the particuar site ocation, the structuras of the crane were quaified accordingy. The EectroMech design was reviewed by the NPCIL design team and handed over to a third party for anaysis using software to simuate more virtua conditions. Finay, after 12 months of detaied engineering and anaysis, the structura design was approved. Procurement, Quaity and Production The specia design caed for use of specia / non-standard materias. For exampe, MS pates of grade E350 instead of conventiona grade E250 were used for girder fabrication, square tubes were used for troey fabrication and caiper brakes were used, to mention a few. WPS PQR were re-estabished to meet the customer requirement as per ASME. Above a, a stringent quaity pan was foowed whereby materia at each stage of its production cyce - from raw materia to finished component, was tested to meet the highest quaity standards. Obviousy, this coudn t be achieved without a very efficient procurement, quaity and production team. Setting new records at EectroMech Ø First Singe Faiure Proof EOT Crane suppy by EectroMech Ø First suppy to a nucear power pant by EectroMech The first Singe Faiure Proof (SFP) Crane was manufactured and despatched in March This was tested for fu oad and overoad in our factory before despatch in the presence of a speciaist team across NPCIL, QS Pune and NPCIL Mumbai. Severa tests were conducted by simuating even the rare possibiities and our cranes satisfactoriy passed a of them. The remaining 2 Singe Faiure Proof Cranes wi be suppied during this financia year. Singe Faiure Proof EOT Crane for NPCIL 07

8 TECHNOLOGY CMI FPE trusts our soutions capabiity EectroMech deveops Pot handing crane with unique design by using 2 hoists on a singe beam CMI FPE Limited - formery Fat Products Equipments India Ltd. was incorporated in The company, over the ast 22 years, has acquired a goba eadership position in the design, manufacture, erection and commissioning of cod roing mi compexes and auxiiary equipments for the cod roing industry and the meta processing industry. The Begian Group CMI (Cockeri Maintenance & Ingénierie) competed the acquisition of Fat Products Equipments India Limited in 2008 and has now been renamed CMI FPE Limited. The principa activities of the company comprise manufacturing and instaation of cod roing mis compexes, processing ines, chemica processes, therma processes and automation equipments for ferrous and nonferrous industries wordwide. As of today, CMI FPE Limited has a goba footprint across Asia, Africa, Midde East, Europe, North America, South America and Russia. The chaenge CMI FPE is currenty working on a stee mi project for JSW Stee Ltd. at Tarapur, Thane. Whie working on this project, a big chaenge was posed by the handing requirement at the gavanising pant. The company was ooking for a Pot handing crane of suitabe design to be fitted exacty above the zinc pot. What is a Pot crane? Working and uses These types of cranes are paced above the pots in gavanising pants. It is primariy a maintenance crane, used to maintain and repace the gavanising equipment such as ros and sits when required. The space constraint is high, and precise hook positioning is required as the hook needs to be positioned exacty above the zinc pot. EectroMech soution Having experienced our soutions capabiity previousy, CMI FPE approached us to design a unique soution for their current chaenge. The end cient, JSW stee further attested this decision. After carefuy studying the process and the requirements, our design team deveoped a soution which was a perfect fit for their requirement. The design is very different from a conventiona DG EOT crane. The crane has 2 hoists of 7.5MT capacity each, mounted on cantiever beams hanging on the crab. The hoists were modified to suit this particuar handing requirement. This design has been made for the specific appication, considering the critica end approach requirements. The crane offers a span of 8m and ifting height of 18m. The overa system, in spite of the customised design, proved to be an economica soution for the cient. This crane was under commissioning at the time of going to print. 08

9 ACHIEVEMENTS Prestigious order from Mazgaon Dock Limited Inteigent design for overcoming space constraint to hande heavy oads Mazagon Dock Limited, Mumbai, an ISO 9001:2008 company is one of the eading shipbuiding and offshore fabrication yards in India. The yard was estabished in the 18th century, and over 200 pus eventfu years, has earned a reputation for quaity work and estabished a tradition of skied and resourcefu service to the shipping word in genera and the Indian Navy, Coast Guards & ONGC in particuar. After 1960, Mazagon Dock grew rapidy to become a premier warship buiding yard in India, producing sophisticated warships for the Navy and offshore structures for the ONGC. It has grown from a singe unit, sma ship repair company, into a muti-unit and muti-product company, with a significant rise in production, use of m o d e r n t e c h n o o g y a n d sophistication of products. The company s current portfoio of designs spans a wide range of products for both domestic and overseas cients. The chaenge Mazagon Dock is in the process of expanding its faciity to manufacture submarines for the Indian Navy. This is a very prestigious, chaenging and critica project for the Indian Ministry of Defence. Handing requirements in this pant vary from a few tonnes to as high as 300 tonnes. Needess to say, safe handing of these critica components is of utmost importance. The frequency of utiisation and the operating speeds are very high. Further compicating these chaenges is the fact that space avaiabiity is a great constraint in this pant. Keeping this in mind, extensive engineering has been done to optimise the crane dimensions, to ensure maximum and effective space utiisation. EectroMech soution After a thorough assessment of various crane manufacturers in India, Mazagon Dock Limited seected EectroMech to design, manufacture and commission the cranes for this new submarine manufacturing unit. EectroMech has designed 3-tier cranes to suit the cient requirement. This type of design wi ensure compact construction of the cranes to fit into the imited space avaiabe. We wi be suppying 7 heavy-duty cranes. The cient being a Defence organisation, the manufactured cranes wi be undergoing cose monitoring and quaity checks from the officias of the Defence Ministry. The order wi be executed during the year 2014 and we are confident of meeting the expectations of the cient. Detais of the order Ø 150/30MT Semi-Goiath Cranes, Span 16m, HOL 22m-2 nos. Ø 60/20MT Semi-Goiath 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. 09

10 ACHIEVEMENTS T hermax Ltd., headquartered in Pune, has been providing engineering soutions for decades to the energy and environment sectors. One of its biggest divisions suppies boiers to the power sector. The company recenty entered into a joint venture with Babcock & Wicox (USA), a goba eader in the power generation industry, to manufacture super critica boiers for the power sector. The Thermax Babcock & Wicox (TBW) pant is spread over 100 acres of and at Shirwa near Pune. The manufacturing faciities are spit into 3 units; a 25,000 sq.m Section shop, a 16,000 sq.m Pane shop and a 18,000 sq.m Header shop. EectroMech has been suppying cranes to a of Thermax factories as we as their projects. The Thermax factory in Chinchwad, Pune has severa cranes from EectroMech and these are used for various appications ike oading, unoading, handing, assemby work, etc. Satisfied with their past experience of using EectroMech cranes, TBW approached EectroMech at the panning stage itsef to discuss the crane requirements for this new pant. En e r g y S o u t i o n s buiding structure and roof itsef, the entire oad of the crane as we as the job being handed is borne by the factory coumns. Invoving us at the factory panning stage is beneficia to a cient as the structura engineer can optimise the factory buiding based on the whee oads and crane dimensions provided by us. This aso aows us to provide inputs on the workfow, so as to optimise the choice of cranes to keep costs ow whie achieving maximum resource utiisation. Saving on project costs The work of the TBW factory buiding started amost two years ago and foowing a consutative approach, EectroMech designed a soution that was economica, had advanced features, matched speed, technica specifications and other parameters of the crane such as the geometries, whee oads, etc. An apt exampe of the benefit of invoving us during the panning stage is seen in the pant s section shop. The highest capacity crane is 50MT, which woud ogicay require the entire factory buiding to be designed for the oads exerted by this crane. How project costs can be saved A tes At the new TBW pant, 34 EectroMech cranes with capacities ranging from 10MT to 50MT integrate the entire handing operations on three shop-foors. This covers handing right from raw materia storage to the fina despatch, incuding severa fabrication and assemby stations. The interesting part of this entire project was the invovement of EectroMech right from the project conception and designing stage of the pant buiding. Consideration of overhead cranes in the pant is crucia in determining the overa specifications of the buiding. This is because overhead cranes run on gantry girders that are supported by the buiding structure. In addition to the However, during detaied anaysis of the cient s work fow, it was apparent that the 50MT job woud never traverse the entire ength of the shop foor. This aowed the structure to be optimised so that ony the necessary portion has been buit to take the oad from the 50 MT crane. Safety imit switches ensure that the 50 MT crane does not trave with its fu oad to other parts of the shop. This soution gave TBW substantia saving in their structura cost for this shop. Reduced maintenance EectroMech advised TBW to opt for a power suppy system, especiay for the outdoor duty gantry cranes, that is more 10 Photo courtesy: Voge Business Media India Pvt. Ltd.

11 reiabe and has zero maintenance compared to what is used traditionay. Typicay, for a gantry crane, one uses cabe reeing drums. The cabe reeing drum mechanism itsef can prove to be probematic in some cases as it increases maintenance. Again, because we were invoved with the customer from the beginning, we were abe to factor in, at the time of construction itsef, a way to use reguar shrouded bus bar for suppying power to the outdoor gantry cranes. By this, we have eiminated a ot of hasses which might have arisen in the future had we resorted to the cabe reeing drum concept. This approach has aso ed to further reductions in the project cost. ean manufacturing phiosophy dictates its reduction. By taking cognisance of what needs to be done on a shop-foor, arranging processes accordingy and by optimising speeds and geometries of cranes, materia handing time can be drasticay reduced. This needs to be panned in the eary stages of the project to derive maximum advantage. Power saving Thermax has aways used conventiona cranes of the oder generation of technoogy, based on the oder Russian designs in their oder pants. Cranes from EectroMech used at the super critica boier pant are more compact, efficient and ighter in weight. These cranes are reiabe with practicay no breakdowns and minima requirement in reguar maintenance. These cranes are aso inverter-driven. Hence, there is better contro on various by invoving EectroMech at pant designing stage timony at Thermax Babcock & Wicox Ltd., Pune parameters ike smoothness of operation, precise contro on speeds. Energy efficiency is further enhanced as cranes take ony as much power as is required. If one were to combine the tota power consumption of a the cranes used throughout the TBW factory, it woud be observed that there is a reduction of at east percent over conventiona cranes. Faster handing. Higher profits. Higher safety EectroMech has aso suppied TBW with unique soutions ike wa traveing cranes. On a shop-foor, with respect to the principes of ean manufacturing, waiting time is one of the prime sources of waste. Wa traveing cranes aow workers to service workstations individuay without using cranes on the top. Waiting time for the crane is thus eiminated and productivity of the individua workstation is enhanced. This is a much better soution than a semi-gantry crane, in which one end carriage runs on the gantry girder, whie on the other side a eg runs on the foor. Having an end carriage running on the factory foor, creates a safety hazard due to the possibiities of coisions with men, machines and materia. Rai tracks or supports woud aso be needed on the ground, increasing the civi cost. Wa traveing cranes have no egs and trave in the air independenty on their own supporting structure integrated with the factory buiding, thus enabing efficient and safe ayout of the workstation. Integrating wa traveing cranes into the ayout was ony possibe because EectroMech was invoved in the project from the factory panning stage. Customer satisfaction Though materia handing forms a critica part of any workshop, Divisiona Manager-Manufacturing, Thermax Babcock & Wicox Energy Soutions Pvt. Ltd., Mr. Rajeev Sondur seconds the fact that incuding EectroMech from the start provided numerous benefits. He said, The company was abe to fine tune our pant ayout to ensure maximum space utiisation and save on our asset costs. Adding further vaue is the EectroMech factory, which uses amost every type of crane that we manufacture, acts as a showcase. This aows customers to experience a new soution that we may recommend to them, buiding their faith in the usefuness of the product. We are indeed very thankfu to the TBW team for reposing their trust in our soutions approach and capabiity and for invoving us at the project panning and buiding designing stage. Chaenges Thermax Babcock & Wicox (TBW) wanted a materia handing system that was technicay proven, matched their appications and was cost-efficient. Soution and Resuts Wa traveing cranes were suggested by EectroMech to TBW for carrying out their operations effectivey; various zone protection systems were introduced which heped them save their structura cost. Inverter drives were used to save on power consumption. 11

12 ACHIEVEMENTS Forging reationship EectroMech receives a prestigious order for 26 cranes from RKFL, Jamshedpur Ramkrishna Forgings Ltd., Jamshedpur (RKFL) has panned an ambitious expansion project in the form of a new forging shop. The project wi prove to be the biggest-ever investment at the major stee hub of India. It is noteworthy that RKFL has a remarkabe tendency of going in for new trends in technoogy, adopting new soutions and giving a modern touch to its forging activities. RKFL seected EectroMech and ABUS for this project based on their exceent experience with us in the past which prompted them to reaffirm their trust in EectroMech. This major order comprises 26 cranes that range in capacity from 2MT to 100MT. These cranes wi be used for handing raw materia and forging materia such as arge dies weighing 100MT each. EectroMech wi mainy harness the dependabe ABUS range of products for the task. The speciaty of the order paced on EectroMech ies in the width of the range of ABUS cranes to be provided. The prestigious order wi be competed successfuy by the end of December Thermax Babcock & Wicox reposes its trust in EectroMech Awards another contract for 11 Doube Girder Goiath Cranes for their Shirwa pant Satisfied with the performance and service of the 32 cranes instaed at their Shirwa, Pune pant, Thermax Babcock & Wicox Energy Soutions Pvt. Ltd. awarded another contract for design, manufacturing, instaation and commissioning of 11 Doube Girder Goiath Cranes. These cranes wi be mainy empoyed for outdoor materia handing in their state-of-the-art super critica boier manufacturing faciity spread over more than 100 acres of and at Shirwa near Pune. The specifications of the cranes are as beow, Capacity Span HOL Quantity 5MT 42.0m 10m 2 10MT 42.5m 10m 7 20MT 43.0m 10m 2 The order wi be executed by December We thank the entire team of Thermax Babcock & Wicox Energy Soutions Pvt. Ltd. for their continued support and seecting us as their reiabe partner for materia handing requirements. 12

13 TECHNOLOGY A pate fu of chaenges One crane with 2 hoists avoids swing and aows higher span of Long Trave JSW Stee Ltd. is a we-known name in stee manufacturing in India. For their Tarapur pant, they were ooking for a suitabe system to hande stee pates and ong stee beams. These stee pates and beams, on coming out from a roing mi are stacked adjacent to the mi. The cient was ooking for a suitabe handing system which can efficienty hande and shift these pates to a nearby ocation. J S W e n g i n e e r s a p p r o a c h e d EectroMech to deveop a suitabe system for their unusua requirement. When our team studied the requirement, we discovered severa chaenges in the requirement. First of a, the ong pates and beams necessitated hooking at two points to avoid swinging. The heavy oads up to 20MT demanded use of doube girder cranes. The simpest soution woud have been to provide 2 Doube Girder EOT cranes which operate in tandem. But the space constraint in the pant rued out the possibiity of using 2 DG EOT cranes as this woud reduce the ong traverse span which woud not have met the cient's requirement. Customised soution for JSW Stee Ltd. As aways, out-of-the-box thinking by EectroMech design engineers provided a unique soution for this project chaenge. We designed one 20 MT DG EOT crane with 2 hoists of 10 MT capacity each mounted on it. The hoists are paced 1 meter apart. This aows hooking at 2 different points and the possibiity of jerks is competey eiminated. Speciay modified ABUS hoists which work in tandem were used for this appication. The use of ony one DG EOT crane aows a higher span for ong traverse, making optimum use of avaiabe shop-foor area, thus meeting the cient's requirement. Aso during routine operations, ony one crane operator is required instead of two needed by the conventiona system. Of course, using one crane of this type instead of two conventiona DGEOT cranes has aso reduced the equipment cost to the cient. The JSW team was extremey satisfied with our ingenious soution and the deight further enhanced when we commissioned the system within just 6 weeks from the confirmation of the order. 13

14 TECHNOLOGY Zoomion Tower Cranes for one of India s argest Cooing Towers Goba construction equipment giant Zoomion and EectroMech s Joint Venture partner in India for tower cranes has the distinction of having the second argest instaed base of tower cranes in India. Over 550 Zoomion tower cranes are in operation at various construction sites across the country. The Joint Venture company, Zoomion EectroMech India Pvt. Ltd. (ZEIPL) has been buiding on this formidabe base and recenty won an order for 2 TCT fat top tower cranes to be suppied to Nagarjuna Construction company (NCC), where they wi be used to buid one of India s argest cooing towers. The first of these two tower cranes was recenty deivered and commissioned. Hyderabad-based NCC has a diversified presence across the burgeoning and growing core sector covering various segments of infrastructure incuding the construction of buidings and housing, power, mining and raiways, among others. The company is everaging its rich expertise of the past years to address the job of projects execution at present with the soe objective of buiding India s future. NCC has an unmatched track record of stricty adhering to the project execution schedue without compromising on quaity. Being an important payer in the fied of power pant engineering and construction, the company has a portfoio of many BOT power projects. Currenty, it is in charge of constructing two Natura Draught Cooing Towers (NDCT) for the 1320MW coa-based therma power project on Muthukur Manda, Neore district of Andhra Pradesh. The cooing towers wi be 170m in height, with a base diameter of 145m and top diameter of 78m. To carry out the execution of 14

15 this chaenging project, NCC has chosen TCT Zoomion Fat Top Tower Cranes which is the highest capacity fat top tower crane in Zoomion s product portfoio. The crane has a maximum ifting capacity of 20t and tip oad of 2.7MT at the 75m jib end, or 3.2MT at the 70m jib end. The crane is instaed in the centre of the cooing tower. These innovative TCT Fat Top Tower Cranes are speciay designed for cooing tower appications. The biggest advantage they offer is that once the cooing tower construction has been competed, the crane can sef dismante one section at a time. This is very important, considering the fact that a 75m jib needs to be dismanted, whereas the top opening of the cooing tower in which the crane wi be standing is 78m in diameter. The two cranes are suppied with m height under hook, and have severa features, which incude VFD motion in a drives, provision of soft anchoring (sing support), enhanced drum capacity, ocaised 415V, 50Hz power connection, anemometer, jib & counter jib dismanting device and doube troey automatic reeving change system. Further, taking into account the typicay hostie conditions at therma power pant sites the cranes were speciay finished with a unique 'heavy anticorrosion coating scheme' which has been speciay deveoped by Zoomion. To support NCC in this project, ZEIPL has provided on-site training aong with a consumabes spare stock to guarantee crane performance and deveop customer speciaty. The Indian infrastructure construction market shows great interest in heavy capacity tower cranes, Zoomion-EectroMech has made it crysta cear that it offers an exceent soution to the emerging Indian infrastructure industry. Zoomion TCT Fat top Tower Cranes deivered to hep buid one of India s argest Cooing Towers H 78m Exit I.D. 170m tower height from basin si eve 9m Air inet Basin inside 145m Artist s impression. Not to scae. 15

16 SERVICE A new ease of ife to a worn out crane of HCC The Hindustan Construction Company (HCC) speciaises in engineering and construction of compex infrastructure projects and has executed a arge number of India's andmark infrastructure projects. HCC has been awarded some major contracts by Dehi Metro Rai Corporation (DMRC) and for the execution of these projects, they require various materia handing equipments. One such 25MT doube girder gantry crane at their Mundka site, suppied by a European manufacturer was ying unused for severa years. When the need for such a crane arose on a new project site, the HCC team intended to assess the possibiity of refurbishing and using this crane. Knowing that the Cranedge team of experts is we versed with cranes of a makes, HCC approached us to carry out the task. The Cranedge team first conducted a Crane Heath Assessment to evauate the possibiity of reusing the crane by refurbishing and bringing it back to the origina condition without compromising on safety and performance. The Crane Heath Assessment report prepared after thorough evauation and anaysis reveaed that most of the components were competey rusted and moving components were jammed because of rust and grime. This incuded key components and various sub-assembies such as the crab assemby, whee assembies for ong trave & cross trave, rope drum, ower bock, etc. A few contro pane covers and the wiring inside the pane was competey missing. The gearbox was in a reativey good condition, but needed ceaning and oi change, whereas the operator cabin was in a competey dereict condition. For refurbishing this crane propery, we decided to bring the key parts such as the crab assemby, ong trave whee bocks with motors and the operator cabin to our Pimpri, Pune factory. The entire work was competed to great satisfaction of the cient and trias and tests of major components were conducted in our factory for rigorous performance. Another factor that demanded attention was that the crane had been suppied by the OEM with motors compatibe with 60Hz power suppy. However, these kind of motors typicay overheat when subjected to the standard Indian 50Hz power suppy. On Cranedge s recommendation, Variabe Frequency Drives were added for a motors to avoid overheating. The HCC team was extremey happy with the soution and services of Cranedge. HCC was abe to save a considerabe Cranedge introduces unmatched, ocaised services for Zoomion Tower Cranes With over 550 instaations in India, Zoomion is a famiiar name for tower cranes in the country. Their word-cass quaity, wide ranging soutions and competitive pricing have estabished Zoomion as the word s argest manufacturer of tower cranes. The Zoomion EectroMech Joint Venture aims to cement the Zoomion brand in India further through best-in-cass eading products and services. Service for new as we as existing customers wi be provided by EectroMech s service subsidiary, Cranedge. To demonstrate our commitment to serve this market efficienty, Cranedge conducted its first Service Campaign aong with the new Joint Venture company, Zoomion EectroMech India Pvt. Ltd. (ZEIPL) On May 06, 2013 the Service Cruise was fagged-off from Pune and over the next two weeks, we met severa customers in Pune, Mumbai, Bangaore, Cochin, Chennai, Hyderabad and Dehi NCR. This service cruise was undertaken to meet existing Zoomion customers and introduce ourseves as the excusive partner for providing a compete range of services for Zoomion tower cranes. Project managers, equipment maintenance managers and tower crane operators were given a refresher programme on the superior features of Zoomion tower cranes. We conducted 'on-the-crane-training' covering operation, maintenance and 16

17 amount of money thanks to the methodica approach and proper engineering soutions from Cranedge to grant a new ease of ife to the competey worn out crane. The modification of the existing troey has resuted in a huge direct saving for HCC both in terms of costs and time. Had HCC procured a new troey to match the appication and fitment on the crane, it woud have cost them at east 4 to 5 times more! At the same time, the modification undertaken by Cranedge has saved the customer at east 12 weeks of vauabe time which, when cacuated over the project time ine is a significant and crucia saving. Crab Before After Gearbox Whee bock Before After Before After safety protoco for the operators foowed by an interactive session about their experiences whie using the existing tower cranes and coected vauabe feedback. Our cients were reassured of our presence and our ong-term commitment to serve them with great efficiency through a team of trained and competent technicians. Our nationwide network is a further assurance to render services wherever they are. Our customers can aways expect a wide range of services from us, incuding ready suppy of genuine spares, troube shooting, any type of repairs or breakdown services, Annua Maintenance Contracts, One Time Heath Checks, eectrica upgrades, operator training courses or any other technica support and consutancy on the seection, operation and maintenance of tower cranes. The response to our service campaign was overwheming. Our customers are deighted at the prospect of now being abe to associate with the OEM service organisation and not having to depend on oca sources. We woud ike to express our sincere thanks and gratitude to our customers for their strong support, co-operation and active participation in making this Service Cruise a very promising start to our endeavours. 17

18 AWARD A high-ift, high-speed crane in operation at an HCC Hydroeectric Power Project in Punatsangchhu, Bhutan Mr. AVR Murty, CEO, receiving the award on behaf of EectroMech Award-winning soution for tunneing operations Manufacturing today award for Exceence in Innovation in the SME category EectroMech is proud to have been awarded for our innovative soution provided for the execution of the Mumbai water suppy project. EectroMech, India's argest industria crane manufacturer and customised materia handing soutions provider was awarded the 'Exceence in Innovation' award in the SME category for its speciaised Tunne Mucking System at the Manufacturing Today awards 2012, conducted by Manufacturing Today, an ITP Pubication group magazine. Commenting on the occasion, Mr. Tushar Mehendae, Managing Director, EectroMech said, "We are very peased to receive the award for our path-breaking innovation. This award testifies that we continue to aign our innovation approach to meet our customer expectations. This unique Tunne Mucking System is a boon for projects which require rapid remova of overburden from tunneing or shaft excavation and has its own benefits as a specia purpose crane. We wi remain committed to our customers and continue to offer the best products." EectroMech's cients for its high-speed, high-ift Tunne Mucking Systems incude severa eading infrastructure majors such as Gammon, HCC, Unity, Pate Engineering, SOMA and IVRCL on sites in India and across the gobe. EectroMech's unique Tunne Mucking System has proved to be an innovation in various critica projects for rapid remova of overburden from tunneing or shaft excavation. The recent instaations for the Mumbai water suppy project invoved EectroMech's tunne mucking crane under the government's Jawahara Nehru Nationa Urban Renewa 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 namey, Soma Construction Company for Phase I (Gundovai to Thane) and to a Joint Venture of Unity Infraprojects Ltd. and IVRCL Ltd. for Phase II (Thane to Bhandup). Interestingy, EectroMech suppied tunne mucking cranes to both the companies, thus paying a crucia roe in BMC's ambitious 24x7 water suppy project. IVRCL & EectroMech teams 18

19 MARKETING Our customers reaffirm our positioning. * A recent customer satisfaction survey by Niesen reveas the fact. Customer satisfaction is a top priority for EectroMech. Every action, effort and the organisationa energy are directed towards keeping our customers satisfied. It is of course important to keep track of changing customer expectations and where we stand whie fufiing them. To achieve this, we interact with our customers on severa patforms such as conferences, exhibitions and customer visits by our saes team. This customer-centric approach has heped us win the trust of thousands of crane users in India and abroad. Satisfied with the EectroMech experience, our existing customers invariaby 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 ooking for better soutions, service and experience approach us as we. To further augment our efforts, a more systematic approach in this direction was recenty initiated by conducting a pan- India survey among our customers through Niesen, a premier goba market research organisation. The survey findings are very encouraging and have provided insight and cues for further improvements to exce in our fied of operations. According to this survey, the attributes about EectroMech most appreciated by our customers were: Ø The overa performance of our products Ø Domain knowedge and ski set of team members whie understanding customer requirements Ø Our abiity to provide customised soutions which are most reevant for a particuar appication Ø Professiona and ethica practices foowed by the company Ø The technica competency of our team of engineers Ø Our customer-oriented approach Over the years, we have evoved as a eading and capabe 'Soutions provider'. For this, we aways ensure strong technica and design support to our customers. To provide the most pertinent soutions, our R&D team is constanty exporing ways to improve our products and deiver a better customer experience. Apart from this, we ay a great emphasis on adopting most modern manufacturing practices which ensure high quaity and reiabiity of our cranes. This, in turn, transates into a greater benefit for our customers. According to them, the foowing are the important benefits with our crane systems. Ø Safety features of equipment Ø Smoothness and ow noise eves of equipment Ø Necessary safety and statutory reguations foowed by our instaation team *Source: Niesen Survey February 2013 (sponsored by EectroMech) Ø Ø Ø Apart from the above, customers have appreciated our systems during and after the tendering process. According to them, Ø Accuracy, competeness and timey submission of technica documentation are highy satisfactory Ø Interaction, courtesy and poiteness of the saes team are appreciabe Ø Majority of our customers aso admired our abiity to provide 24x7 service support Ø EectroMech depoys a we-trained and skied team of engineers and technicians on the fied to provide numerous trusted services Survey highights EectroMech is mainy known for providing customised soutions, technica competency, exceent product performance and customercentric approach. 9 out of 10 customers wi definitey recommend our cranes and services to other businesses. EectroMech has the highest reca amongst a the crane brands in India. A very encouraging comment received in response to the question, How ikey are you to recommend EectroMech and Cranedge Service to a business associate? For cacuating the Net Promoter score on a scae of 0 to 10 - EectroMech was rated 9. Aso, when the customer was asked for a 'top-of-the-mind' reca we were happy to know in terms of awareness EectroMech is the eading brand name for EOT cranes in India. At EectroMech, we have taken cognisance of a the feedback from our cients and are impementing certain changes to increase customer satisfaction. For exampe, Radio Remote Contros have been made standard across our range of cranes based on customer feedback during this survey. We thank a our customers for participating in this survey and provide us with their vauabe time and feedback. 19

20 EVENT Zoomion - EectroMech Tower Cranes make a debut at bc India, 2013 During the year 2012, EectroMech joined hands with the Chinese construction machinery giant to manufacture and se their range of tower cranes in India through a Joint Venture. With the formation of Zoomion EectroMech India Private Limited (ZEIPL), the construction industry in India can ook forward to having Zoomion s entire range of tower cranes as we as severa made for India modes avaiabe to them. They can aso count on the reiabe service support of our service subsidiary, Cranedge throughout India. Our sta spread over neary 4000sq.ft. in an open area was designed in an innovative way to make it more visitor-friendy. The sta was visited by a arge number of peope from construction and infrastructure industries. The entry of EectroMech into the tower crane market was enthusiasticay appreciated by severa of them. According to them, after-saesservice is a major acuna with most of the tower crane brands avaiabe in India and EectroMech can certainy score over them considering our experience in industria cranes services through an extensive nationwide network. Aso on dispay were EectroMech s Gantry cranes which are being extensivey used for construction of fyovers, eevated freeways, roads and bridges. Using the concept of gantry cranes, we have aso deveoped speciaised tunne mucking systems for remova of muck during shaft or tunneing operations. Severa such systems are aready operationa on various construction sites and infrastructure projects in India and abroad. EectroMech Editoria Team: Suhai Bajaj, Ruthu Devadiga, Ashwini Deshpande EectroMech Materia Handing Systems (India) Pvt. Ltd. Corporate Office & Pant Gat No. 316, At post Kasar Amboi, Ta. Mushi, Dist. Pune INDIA Teefax : E-mai : cranes@emech.in For private circuation ony. In-house pubication of EectroMech Materia Handing Systems (India) Pvt. Ltd., Pune. copyright 2013 A ogos and monograms used in this newsetter are registered trademarks of respective companies. Branch Offices Ahmedabad : Bengauru : Chennai : , Dehi : Kokata : Mumbai : Dubai EectroMech FZE : Concept & design : kaeidoscopeb2b.com EMPOWER 07 / / / Kaeidoscope