SAFETY IN EQUIPMENT DESIGN

By Equipment department

SAFETY IN EQUIPMENT DESIGN 1

 BUILDING ON PAST LEARNING

• Learning is a continuous process and thus before moving on to any new project,
As an Equipment team, we ensure that the past learning must be taken in to
account.
• As an Equipment team, we ensure the same as below standard practice

 Preparation of the lesson learnt sheet at the end of each project, which mainly
describes the lesson learnt during the last project in terms of safety,
constructability, accessibility, maintainability and design improvements.
 User feedbacks are taken for the past project learning / improvements for the
next projects.
 Discussions with OEM and sub-vendors for the latest developments /
improvements in the industry for the Equipment.
• Typical Lesson Learnt Sheet for Equipment Project
• Few examples of lesson learning & improvement considered in the latest
Equipment Projects are as below.
SAFETY IN EQUIPMENT DESIGN 2
Rail Replacement Trolley for RMQC :
First time design development across the
globe

Special design for replacement of trolley

short rail in RMQC

The platform is made in 3 parts and can be

stored easily when not in use.

Fast, easy and safe assembly on the ground

It can be lifted by the machinery house

service crane and put on the trolley rail.

It can be fixed with the main trolley and

travel to the desired location of the rail

The platform is adjustable designed for

different rail spans.

SAFETY IN EQUIPMENT DESIGN 3

Rail Replacement Trolley – Advantages :

High Safer
Reliability maintenance
and safety practices

In house Optimise
maintenance down time for
can be rail
carried out replacement

Save
Cost
scaffolding
effective
and other
solution
expenditure

SAFETY IN EQUIPMENT DESIGN 4

Auto Fire Fighting System:

Installation in STS E house

Auto operation

Pre alarm of fire

High fire extinguishment efficiency

Avoid system damage

Auto shut down of affected system

Low toxicity

Avoid false alarm

First time installation in ADANI cranes.

SAFETY IN EQUIPMENT DESIGN 5

Auto Fire Fighting System :

Key Benefits of the system

Reduction of Fast recovery

No electrical Uninterrupte No secondary
breakdown after a
conductivity d protection damage
times discharge

SAFETY IN EQUIPMENT DESIGN 6

Spreader Human Detection System:

Installation on STS
spreader

Ensure operational Safety

RFID base technology

Inform human presence

Detection range can be

define
– First time installation in India

SAFETY IN EQUIPMENT DESIGN 7

Spreader Human Detection System:

Key Benefits of the system

Detect any Ensure No Flexible

RFID base Fail safe
human human operators system
system system
presence safety intervention configuration

SAFETY IN EQUIPMENT DESIGN 8

Spreader Anti Fall Away System:

Installation on STS
spreader

Ensure operational Safety

Protect container falling

Fail safe sensor

technology

Detection of twin twenty

containers

SAFETY IN EQUIPMENT DESIGN 9

Spreader Anti Fall Away System:

Key Benefits of the system

Detect the
Avoid
gap No Automatic Provides only
toppling of Fail safe
between operators Hoist up hoist down
the system
two intervention stops permission
containers
containers

SAFETY IN EQUIPMENT DESIGN 10

Safety Man Cage :

43 feet modular man cage

Complying international standards.

E-stop for the personal safety

Internal opening and self-locking doors.

Self retracting lanyard (SRL), Safety

Chains

Life Buoys, Static SS line and fixed eye.

Twist lock Bins

Seating arrangement in each section.

Fork lifting arrangement.

SAFETY IN EQUIPMENT DESIGN 11

Man Cage :

Key Benefits of the system

Optimise
Safely lashing Optimise man Optimize Fail safe
operation
& De lashing power resources system
efficiency

SAFETY IN EQUIPMENT DESIGN 12

Ship to Boom Anti-Collision – Laser based
Installation in STS Boom

Fail safe system

Protect boom from ship collision

First time installation in ADANI cranes.

SAFETY IN EQUIPMENT DESIGN 13

Ship to Boom Anti-Collision – Digital:

Key Benefits of the system

Protect
from Wider Flexible No
Laser based Fail safe
collision detection system operators
system system
with any range configuration intervention
object

SAFETY IN EQUIPMENT DESIGN 14

Anti Truck Lifting System :

Installed on RTGC

Laser technology

Fully configuration with crane PLC

Hoisting stop within 40 cm within

chassis lift

SAFETY IN EQUIPMENT DESIGN 15

Anti Truck Lifting System – Key Features :

Protect Truck
Provides
lifting if twist
confidence to
lock is not
Operator
removed

Protects
Maximise Truck from
the output mechanical
damage

Improves the
safety in
Terminal

SAFETY IN EQUIPMENT DESIGN 16

Stack Profiling System:

Installed on RTGC

2D Scanner technology

Fully configuration with crane PLC

First time installation in India

SAFETY IN EQUIPMENT DESIGN 17

Stack Profiling System– Advantages :

Protection
Protect
from
from bay
Container
collision
collision

Real time
Enhance
monitoring
operation
of stack
safety
profile

Provide Enhance
yard stack operation
profiling efficiency

SAFETY IN EQUIPMENT DESIGN 18

 DRAWING APPROVAL PROCESS AND AS BUILD DRAWING :
USER CHECKS (AS
APPLICABLE)

THIRD PARTY
INSPECTION FABRICATION
INTER DISCIPLINARY
DRAWING LEAD ENGINEER CHECKS (AS CHECKS
APPLICABLE)
FROM OEM

DESIGN FABRICATION
CONSULTANT
REVIEW DRAWING AS-BUILT
DRG
SUBMISSION
YES NO
FEEDBACK / DRAWING
RESUBMISSION
OBSERVATION APPROVED

SAFETY IN EQUIPMENT DESIGN 19

 UNDERSTAND DESIGN ASPECTS
• Equipment are being designed as per the international design and safety
standard ensuring the safety, constructability and maintainability.

 Preparation of the technical specifications considering international design and

safety standard.
 Ensuring FEM standard requirement and its proof check using latest software
base analysis technology i,.e. FEA analysis, flow analysis etc.
 PEMA safety standard adoption, SOLAS requirement fulfilling in all the Cranes
 Ensure the design is carried out considering constructability, accessibility and
maintainability of the equipment.
 Ensuring the safety of the men, machine and material by ensuring the
implementation of codal requirement while designing the equipment.
 Ensuring proper interlocks and fail safe design considering double safety in the
high risk areas.
• Typical document - safety in Design STS RTG
SAFETY IN EQUIPMENT DESIGN 20
 COMPETENCY OF DESIGNER / REVIEWERS

• To ensure the safe and proper design of the Equipment, the competency of the
designer / reviewer is necessary.
• Below are the few aspects by which ensuring the same.

 Designer & reviewer CV needs to review and need to ensure that similar kind of
equipment experience of designing & reviewing team.

 Ensure the appointment of world renowned design review consultant for design
check. (i.e. CP & A, BMT WBM, TBA etc.) ensuring there are proven precedence,
track record and desired credentials.

 Ensuring the world renowned third party inspection agency for the inspection &
pre-shipment commissioning at the manufacturer’s work as well for site testing
and commissioning checks. (Lloyd's Register, Beuro Veritas, TUV Nord )
SAFETY IN EQUIPMENT DESIGN 21
 EQUIPMENT / FACILITY CHECK POINTS

• To ensure the safe and reliable working of the Equipment with maximum
availability and reliability during operation, various check points has been
ensured during each stage of the project.
• Below are the few aspects by which ensuring the same.

 Equipment Design to be reviewed and validated in house as well as by design

consultant confirming the TS requirement for any new design of the Equipment.
 Appointment of the third party inspection agency for inspection and validation
of critical quality, design and safety check points at each stage of the equipment
project.
 Preparation of the pre-shipment and site commissioning protocols to ensure the
design implementation in the equipment as well as ensuring each of the quality
and safety check points before handing over the equipment to end user.
• Typical document of Equipment Check Points

SAFETY IN EQUIPMENT DESIGN 22