Hamari Suraksha
Q3 | FY19 | Issue 23
Contents
01 Hamari Suraksha – Safety
Essentials
02 Cranes & Lifting
03 EOT Cranes
04 Telescopic cranes
05 Wire rope
06 Best EHS practices
Rishi Nair (RE-IN EHS)
Ritesh Rajput (RC-IN GP EPC TS EHS)
Anubhav Sinha (SI RSS-MA IN EHS)
Daniel Wesley (RC-IN GP PG EHS)
Nisthu A.P (RC-IN EHS)
Sujay Kumar Sahu (RC-IN GP EPC TS EHS)
rishi.nair@siemens.com
ritesh.rajput@siemens.com
www.siemens.co.in
Hamari Suraksha – Safety Essential
EHS is a polestar for One of the Safety Essentials critically
any business, which emphasizes on Cranes and Liftings.
shows the path
This issue of Hamari Suraksha covers
through different
detailed guidelines for usage and
means to achieve
maintenance of cranes starting from its
excellence. Hamari Suraksha is one such
different types, its components, relevant
means to drive excellence which acts as
standard codes, guidelines on safe loads,
a learning platform for all of us to explore
inspection guidelines and specific
innovative practices in the industry and
precautionary check points. The present
know various best practices by our
issue also covers few best practices
colleagues across the company.
across the company.
Safety Essentials cover twelve of the most
significant safety risks faced by Siemens
employees and contractors. Together
with the Core behaviors, they constitute a
set of minimum requirements for
monitoring activities, processes and their
associated risks while working under
hazardous conditions. The Safety
Essentials aim to establish priorities about
the mitigation of safety risks, as well as to
make it easier for our employees and
contractors to focus on the fundamental
rules. They represent a concerted effort
to reduce serious incidents and to reach
our ambition of Zero Harm Culture.
 2 Hamari Suraksha
Safety essential – Cranes & Lifting
Points to remember
• Cranes and hoists used must have a valid periodic
certification, monthly inspection and a pre-use inspection.
• Never modify a crane or hoist’s structure, operational, or
safety equipment without approval of the manufacturer.
• During lifts, establish and mark exclusion zones preventing
access to non-lifting team members protecting them from
pinch points, and overhead hazards due to load.
• Keep yourself and others away from under a suspended
load. Do not get between a suspended or moving load, or a
crane’s structure, and any fixed object.
• Rigging must pass periodic inspections by a Competent
Person and a pre-use inspection by the rigger (slinger).
EOT Crane
EOT stands for Electric Overhead Traveling, so in essence this
is a moveable overhead crane that is powered by electronics.
1.
Overhead crane mechanical parts include three
mechanisms namely
• the lifting mechanism
• trolley traveling mechanism: used for lateral movement
with load
• crane traveling mechanism: used for the lifting trolley
and the items longitudinal movement, in order to
achieve handling, loading and unloading in a three-
dimensional space. Hoisting mechanism is used for
vertically lifting.
2. Overhead crane metal structure part consist of bridge
and trolley.
3. Overhead crane electrical parts consist of the electrical
What are the selection Criteria for EOT crane?
If we refer the IS 3177*& IS 13834 (part-5)**, duty cycle
[M1 to M8] of the EOT has been already defined. The
material to be lifted need to be assessed first.
• Ensure your lifting team is qualified and has someone
designated to direct the lift operation. Verify all operators,
riggers (slingers) and signalmen have the required
knowledge and skills for their assigned duties.
All lifts require planning; the more complex the lift, the more
planning required. Follow your plan, if something changes,
stop and re-plan your lift.
• Protect your rigging by using softeners to protect it from
damage due to friction or sharp edges.
• Know the weight of your load, and the capacity of your
lifting equipment based on the configuration of use. Never
use cranes, hoists or rigging in excess of their marked, rated
load limits.
• Control your load using taglines to prevent load swing and
to keep it stable.
Ensure you have clear communication. Use standard hand
signals. Use 3-way communication when communicating
signals verbally by repeating the message back and
acknowledging the response is correct.
• Do not free stuck/bound components using your crane. Free
stuck/bound components using chain falls, come-a-longs,
jacks, etc.
• You need a critical lift plan approved by a qualified person
for any lift using multiple cranes, any lift over an occupied
structure or public street, or when exceeding a percentage
of the crane’s total capacity that is designated by the person
directing the lift.
As per IS 3938***, for Electrical wire hoist the duty class
are defined as Design on Life Basis - Components designed
on the basis of life shall have a rated life of not less than
20 years of 250 days per year for Class I, 300 days per year
for Class 2, and 333 days per year for Classes 3 and 4.
When electrical braking is used, provision shall be
made to limit the current on reversal to a safe value.
 Hamari Suraksha 3

Effective means shall be provided for stopping the

motion in the event of a power failure and in the case Specification required for selecting the EOT Cranes
of an emergency.
1. Type of Girder and beam
Any motor having its power less than one-third that
of the largest motor and served by the same common 2. Duty cycle
overload release, shall be protected by a separate
overload release. 3. Safe Working Load

4. Weight of each component

References :
* IS 3177 (1999): Code of Practice for Electric Over- 5. Operating ( L.T./ C.T./ Hoist) Speed
head. Travelling Cranes and Gantry Cranes other than
Steel Work. 6. Clearance Diagram
** IS 13834-5: Cranes - Classification, Part 5: Overhead
7. Beam and Girder Span
travelling and portal bridge cranes
*** IS3938 : Specification Electric Wire Rope Hoist 8. Total lift

Parts of EOT Cranes

Mechanism Duty cycle Cyclic Starting

class number duration class
factor% (starts/hour)
M1 Upto 5 25 90
cycles 25

M2 Upto 5 25 90
cycles 25

M3 10 to 15 25 150
cycles 40

M4 16 to 20 25 150
cycles 40

M5 21 to 30 25/40 150/300
cycles 60

M6 31 to 40 40 300
cycles 60

M7 41 to 50 60 300
cycles 100

M8 51 to 60 60 300 / 600

Tests carried out on EOT Cranes

What are the tests carried out on EOT during its work lifecycle?

 All tests as per relevant Indian standards.

 Testing and certification by Licensed inspector as per factory act.

Tests should include the following in addition to tests specified by standards:

• Load test, overload test, Deflection test and movement test.
• Speed test at rated speed and rated load.
• Over load test: All crane movements to be tested at 25% over load to show capability of crane to handle overload
without any difficulty.
 4 Hamari Suraksha

A. Periodic inspection includes C. Load test examines the cranes ability to lift and move a
• Deformed, cracked or corroded members. load.
• Loose or missing bolts, nuts, pins or rivets. • Hoist the test load a distance to assure that the load is
supported.
• Cracked or worn sheaves and drums.
• Transport the test load by means of the trolley for the full
• Worn, cracked, or distorted parts.
length of the bridge.
• Excessive wear of brake system parts.
• Transport the test load by means of the bridge for the full
• Excessive wear of drive chain sprockets and excessive drive length of the runway.
chain stretch.
• Lower the test load and stop and hold the test load with
• Deterioration of controllers, master switches, contacts, the brakes.
limit switches, and push button stations.
• Gasoline, diesel, electric, or other power plants for proper Safe working load (SWL), in kN Test load, in kN
operation. 1 SWL ≤ 196 1.25 x SWL
• Motion-limit devices that interrupt power or cause a 2 196 < SWL ≤ 490 SWL + 49
warning to be activated. 3 SWL > 490 1.1 x SWL
• Rope reeving for compliance with crane manufacturers
design. D. Frequent Inspections should include:
• All function, instruction, caution, and warning labels or • Operating mechanisms for proper operation, proper
plates for legibility and replacement. adjustment, and unusual sounds.

B.
Operational testing are tests that examine the • Upper-Limit device(s) in accordance with ASME standards.
operation of all the crane parts without a load. • Tanks, Valves, pumps, lines and other parts of air or
• Lifting and lowering hydraulic systems for leakage.
• Trolley travel • Hooks and hook latches (if used) in accordance with ASME
• Bridge travel standards.
• Hoist-limit devices • Hoist ropes and end connections in accordance with ASME
• Travel-limiting devices standards.
• Locking and indicating devices • Rope and proper spooling on the drum(s) and sheave(s).

Telescopic Cranes Truck Mounted

Telescopic crane are those in which a hydraulic cylinder or
other powered mechanism extends or retracts the tubes to
increase or decrease the total length of the boom.
These types of booms are often used for construction
projects, rescue jobs.
Before When a lift needs to perform at site, Proper planning
must be made.
The planning stage mostly covers the
• Size & shape of the load which needs to be lifted
• Capacity of Crane used for lifting
• Lifting Plan
• Physical parameters of site (Topography, Wind speed)
• Attachments used for lifting (Chain sling, web sling)
• Certified Riggers & Crane Drivers
• Legal documents of Crane
• Risk assessment of the Site
 Hamari Suraksha 5

Lifting Plan

Lifting plan basically gives us an idea about the feasibility of

the lift before performing the real activity.
The plan must be made jointly with Engineers, supervisors,
Riggers & Crane operators.
The plan mainly includes the following
• Weight of load.
• Location of the load’s center of gravity.
• Overall maximum dimensions of the load.
• Boom Length.
• Radius of the lift.
After compiling these inputs, a computer generated plan is
made by keeping the crane open boom dimensions, Radius,
Load to be lifted & Tilt angle of boom w.r.t. to the building in
which the load has to be placed.
Once the lifting plan is in place then it can be compared with
the load chart of the crane. If the load chart doesn’t have the References :
load carrying capacity at certain boom length, then we need IS Standard 4573 -1982 specification for power driven
to go for a higher capacity crane. mobile cranes

Load Chart

The load charts are specific to the make, model and

configuration of a specific piece of equipment (Crane). Only
load charts that are found in the equipment operation manual
or posted by the manufacturer in the equipment should be
used. Don’t forget to include adjustments for buckets, boom
extensions, load blocks, hoisting rope and other attachments
that will alter the lifting capacity of the crane or equipment
used to perform the lift. By referring to the load chart, a crane
operator can determine what angle the boom will have to be
to ensure that he is directly above the load. Before lifting a
load with a crane, the operator must check the boom angle
indicator, which will provide the angle of the boom from
horizontal.
Every crane has a maximum boom angle. Beyond that the
boom mast will not tilt.
The SWL (Safe working load) will be clearly marked in Boom.
For example, Farana 15T represents the boom can lift a
14-ton load at 1.5 meter and 900 kg at 15.8 meter.
As the boom opens the load carrying capacity also decreases.
The overall status of boom while performing the operations
can be viewed in Safe load Indicator console located at
operator cabin.

“We are what we repeatedly do, excellence then, is not an act, but a habit”.
Aristotle (384 to 322 B.C.E.)
 6 Hamari Suraksha

Safety Features in Telescopic Crane 1. Safe load indicators

(SLI) gives us the current
Out rigger & Counter weights status of the crane boom
performance.
• Outriggers provide a solid base for the crane. Their
2. Safe load indicators give
purpose is to improve the stability of the crane during
us the Safe Work Load
operation.
Limit .
• An outrigger can be exerting hundreds of thousands of 3. Weight of Counter
pounds of force (PSI - KPSI) into the ground beneath the balance applied.
crane.
4. Weight of the Hook
• Lose soil / muddy soil increases the chance of toppling if arrangement.
proper outrigger supports are not provided.
5. Distance of center
• Hydraulic Controls are given with spirit level indicator to to center out rigger
check the levelness of the outriggers. support.

• Once the out riggers are set in proper manner (levelled)
we can see that the Tires of the vehicle will be lifted
up.
• Counterweights are used in cranes to counterbalance the
weight that resides under the hook.
Anti-two-block system: An anti-two-
block system is used to prevent or warn
the operator of a two-block condition
on a crane. Two-blocking is the
dangerous condition where the lower
hook block is raised until it contacts
any part of the boom tip hardware.
Two-blocking may occur while
• winching up
• telescoping the boom out

Out Rigger Counter Weights Without anti-two-block With anti-two-block installed

Wire Rope
Wire rope is a complex mechanical device that has many • Wires made from metal that form a singular strand
moving parts all working in tandem to help support and
• Multi-wire strands laid around a core in a helical pattern
move an object or load.
• A fiber or steel core
In the lifting and rigging industries, wire rope is attached to
a crane or hoist and fitted with swivels, shackles or hooks to
Types of Lay
attach to a load and move it in a controlled matter.
Cross Lay: In a Cross lay wire rope, each wire of different
Wire rope is usually made from carbon-steel wires with 0.35
layers makes point contact and has relatively large spaces
to 0.85 percent carbon.
between wires. These lay are very flexible and widely used in
slings that are exposed to bending fatigue.
Parallel Lay: They are formed due to linear contact between
strands by widening all the wires at the same pinch.
 Hamari Suraksha 7

Choice of Selection of Wire rope Understanding Wire Terminology 1” 6 x 25

• Strength Diameter = 1”
Number of Strands = 6
• Reserve Strength
Number of Wires Per Strand = 25
• Abrasion Resistance
• Crushing resistance References :
• Fatigue Resistance IS 2266: 2002 Steel Wire ropes for General Engineering
Purposes – Specification
• Bendability
IS 2365: 1977 Specification for Steel wire Suspension
• Stability ropes for lifts, escalators and hoists

Wire Rope Clamping Procedure

• Use Proper size of clamps as per Calculation for distance between the clamps
diameter of rope • D- is the diameter of the rope (Considering 3-inch diameter
• Minimum 3 nos of wire rope rope (D))
clamps are needed for any loop • 4,4,6 – are the constants figures
• Distances between clamps • 4*3=12 inch should be the distance between clamp 3 and 2
should be as per the Diameter of • 4*3 =12 inch should be the distance between clamp 3 and 1
rope • 6*3=18 inch should be the distance between clamp 1 and
dead end of the rope

Clamping Method & distance Calculation Correct Procedure for wire rope clamping

Apply the first cable clip one

base width from the dead end
of the wire rope. The U-part
goes over the dead end, while
the live end rests in the clip
saddle. Tighten the nuts evenly
to the recommended torque.

Apply the second clip as close

to the loop as possible. U-part Live End: It’s the extension of the rope after clamping.
is over the dead end. Turn nuts Dead End: It’s the End of the Wire rope.
firmly but do not tighten.

World Environment Day was

Apply tension and tighten all
nuts to recommended torque.
celebrated on 5th June 2019.
The topic for this year was
#beatairpollution. A competition
was held among all Office
locations, Project sites & Factories.
Look out in our next edition for
the WINNERS & more details of the
events.
 8 Hamari Suraksha

Congratulations Team India for receiving the Zero Harm Culture Label!!

The Zero Harm Culture Label shows that the organizational

units in the Country have successfully established the key
elements of the Zero Harm Culture @ Siemens approach in
a sustainable manner and that the first important milestone
on this journey has been reached. This is the result of the
concerted efforts and hard work across the entire cross section
of the employees of Siemens Limited, leading to their global
goal "One world, one life, we care".

“I express my deep gratitude to each one of you for creating

Left to right : Mr. Oliver Kraus, Global Safety Head;
Mr. Sunil Mathur, MD & CEO, Siemens Limited; Mr. Soumitra
Duttagupta, Head EHS India; Mr. Sunder Medur, Business
Administration, EHS India; Mr. Johannes Buchmann,
Program Manager, Zero Harm Culture@Siemens.
an “oasis in the middle of a desert”. Let’s together expand
this “oasis” and make it sustainable for our colleagues and
partners to benefit from and lead a healthy and safe life!
As responsible citizens of our great country, this is what we
can together give back to our stakeholders and the society.”
Mr. Duttagupta, Head EHS India

Best EHS Practices

Project Name: Barricading for Robot Movement

Safety Essential Focus Area: Machine Before After

guarding
Team: SI CP Switchgear Factory, Kalwa
Barricading for Robot Movement
of Engel 180 Ton implemented in
July 2018.
Protection of person from hazardous
Robot movement of Engle 180 Ton.
Sufficient space while working inside
fencing.

Project Name: N2 Purging System in Heat Treatment Shop

Safety Essential Focus Area: Before After

Potentially explosive gas & vapor
Team: MD Factory at Kharagpur
Replacement of portable cylinder with
Nitrogen storage tank, Uninterrupted
& reliable nitrogen supply during oil
quenching activity, Safe quenching
& Furnace operation, Proper pressure
adjustment with gauge facility.
 Hamari Suraksha 9

Project Name: Digital PPE Matrix Before After

Safety Essential Focus Area: Personal
protective equipment
Team: Neyveli, POC SLN
Improvising PPE sheet
matrix by making
Maintenance Jobs are carried out
digital that serves same
about 10- 15 km far. If employee
forget to take Job specific PPE, he had purpose but with its own
to return to site office which delays the advantages is all about
response time. this Digital PPE matrix.

Project Name: Employee Engagement & Branding

Focus Area: Engagement

Team: MO RS TD
All plant employees have participated in zero harm
culture program. Plant head and line managers
became ambassadors to promote ZHC awareness and
implementation in the plant.

Project Name: One Day Safety Officer (ODSO)

Focus Area: Team building

Team: DI CS
New concept of One Day Safety Officer (ODSO) implemented
in IPM sites. Every day one site colleague will act as “Safety
Officer” for that site – he will do all the activities of a safety
officer. By doing this every one will realize importance
of carrying out site activities in safe manner and in safe
environment at the end of day – he will report back to Site
Manager & Safety officer about his experiences and learnings.

Management System is driven by PDCA – 360 degrees, 4 stage controls

Hamari Suraksha is an e-bulletin published quarterly by EHS team of India. Please give your valuable suggestions and
feedback to the editors.