Especially in recent years, with the restructuring of state-owned enterprises and the rapid rise of private enterprises, the demand for lifting machinery is increasing. According to the statistics of the increase of hoisting machinery in Jining from 2000 to 2005, it was 65438 0.6 times higher than that in 2000. However, the management level of lifting machinery users is relatively backward, resulting in more and more equipment accidents and safety accidents. The promulgation and implementation of the Regulations on Safety Supervision of Special Equipment in the State Council in 2003 showed that the state attached great importance to the safety management of hoisting machinery. Therefore, how to implement the spirit of the Regulations, manage cranes scientifically and comprehensively, give full play to the efficiency of cranes, strive to improve the technical quality and operation level of crane equipment, complete the construction, installation, production and loading and unloading tasks with high efficiency, high quality and low consumption, ensure safe production, obtain the best economic benefits, and promote the sustainable development of enterprise management are the tasks and objectives of crane safety technology management.
The safety management of special equipment users includes the whole process management of equipment selection demonstration, installation and debugging, inspection by special inspection institutions, formulation of safety management system, maintenance, operation transformation, overhaul and scrapping.
1 Selection, installation and inspection of hoisting machinery
1. 1 type selection
When purchasing hoisting machinery, enterprises should first consider the scope of use, working frequency, utilization rate, rated lifting weight and other factors of their own enterprises, and choose the crane of the working grade suitable for their own use requirements. Conduct market research according to the proposed technical parameters. The selected supplier must be a professional crane manufacturer with special equipment safety license. The matching of processing equipment, standardization of production and advanced products of manufacturers were investigated. After comparison, a crane with reasonable price, good quality, excellent performance and complete safety devices was selected.
After the arrival of the equipment, it is necessary to check whether the accompanying technical data are complete, whether the accompanying accessories, tools and accessories conform to the list, whether the equipment and accessories are damaged or defective, and make a record of unpacking acceptance.
1.2 installation company selection
The installation team of hoisting machinery can choose qualified manufacturers to form a one-stop service mode of manufacturing, installation and debugging. In addition, the selected installation unit must be a professional team with special equipment installation (maintenance) safety approval certificate issued by the provincial quality and technical supervision department, and have the installation qualification to install the corresponding lifting weight. After the installation unit is determined, assist the installation unit to handle the commencement report of special equipment before installation, and check whether the construction organization plan, installation equipment, installation procedures, technical requirements, acceptance records of concealed works during installation and self-inspection report of installation team meet the requirements. After the installation is completed, it is necessary to supervise the installation unit to conduct comprehensive self-inspection, operation test and load test, and report to the special equipment inspection agency for installation acceptance after confirming that the self-inspection is qualified. It can only be put into use after passing the acceptance and obtaining a safe use license. After acceptance, the user should file the random technical data, installation data, inspection report and other related technical data of the crane. The safety technical files of hoisting machinery also contain information such as regular inspection, overhaul, transformation and accident records in future use.
2 lifting machinery use management rules and regulations
We will fully implement the "Regulations on Safety Supervision of Special Equipment" and other laws and policies, adopt a series of technical, economic and organizational management measures, and use advanced scientific management means and methods to comprehensively manage the hoisting machinery, so as to achieve the whole process management such as careful planning, selective purchase, rational allocation, accurate installation, correct use, careful maintenance, scientific overhaul, safe production, regular inspection, timely transformation and timely scrapping. In order to obtain the economy of crane life cycle cost and the highest comprehensive efficiency, ensure safe operation and promote the production development, technological progress and efficient operation of enterprises.
2. 1 safety technical documents
Hoisting machinery enterprises should establish and improve equipment safety technical files, including hoisting machinery files:
(1) The factory technical data of hoisting machinery, product certificate, operation and maintenance instructions, drawings of wearing parts, electrical principles, layout of electrical components, necessary type test reports of safety accessories, supervision and inspection certificates and other relevant information.
(2) Technical data, installation location and start-up time required in the installation process.
(3) the acceptance certificate or periodic inspection report issued by the special equipment inspection agency.
(4) Records of daily maintenance, maintenance, overhaul, transformation, alteration, inspection and test.
(5) Records of equipment accidents and personal accidents.
(6) Equipment safety evaluation of the superior competent department.
(7) Maintenance and inspection records of special equipment and safety accessories, safety protection devices, measurement and control devices and related auxiliary instruments and meters.
2.2 hoisting machinery safety management system
To ensure the safe operation of hoisting machinery, it is necessary to have perfect management rules and regulations, so that operators have rules to follow and managers have laws to follow. Improve and implement the organization and management of special equipment, and equip with a strong professional management team to maintain relative stability and meet the requirements of management. The management system shall include the following contents:
(1) Emergency rescue plan for crane accidents.
(2) The post responsibility system between the functional management department and the driver.
(3) Technical regulations for safe operation.
(4) Maintenance, repair, modification and scrapping system.
(5) Daily inspection and regular inspection and maintenance system.
(6) Manage, operate and maintain the personnel training and assessment system.
(7) Operator succession system.
(8) The file management system of hoisting machinery safety technology.
2.3 emergency measures and rescue plans for special equipment accidents
According to Article 3 1 of the Regulations on Safety Supervision of Special Equipment, the user of special equipment shall formulate emergency measures and rescue plans for special equipment accidents. Units using special equipment shall set up an emergency rescue leading group with unit leaders as the team leader, special equipment safety management departments as the main body, and relevant departments to cooperate, and clarify the responsibilities, and the responsibilities shall be assigned to people. According to the use of special equipment in this unit, judge possible faults, dangers and accidents, and formulate countermeasures suitable for the characteristics of lifting machinery in this unit. The measures should include the principles of handling crane accidents, procedures, methods and steps taken in case of emergency, responsibilities and division of labor of personnel in relevant departments, etc. , and regularly organize on-site exercises.
3 hoisting machinery operation management
3. 1 operator management
Operators should learn and master the structure, working principle, technical performance, safety operation procedures, maintenance system and other related knowledge of the hoisting machinery used, as well as relevant national laws, regulations and standards. After being trained by the local technical supervision department and gaining theoretical knowledge and practical operation skills, they can only work at their posts after passing the examination.
3.2 "Three Fixed" Management of Hoisting Machinery
"Three Fixed" management is a system of fixed personnel, fixed machines and fixed posts. The "three-fixed" system of hoisting machinery is firstly the formulation of the system and the determination of the system form, in which the person and the machine are the basis. Everyone is required to have a post and responsibility, and the crane platform is operated and managed by someone: the responsibility of "fixing posts" is the guarantee.
3.3 Regular inspection and maintenance management
The user of hoisting machinery should regularly inspect and maintain the hoisting machinery in use, and formulate a regular inspection management system, including daily inspection, weekly inspection, monthly inspection and annual inspection, dynamically monitor the crane, and handle any abnormality at any time to ensure the safe operation of the hoisting machinery.
(1) Daily inspection.
The driver is responsible for the daily maintenance of the operation, mainly including cleaning and sanitation, lubricating transmission parts, adjustment and fastening. Test the sensitivity and reliability of the safety device through operation, and monitor whether there is abnormal sound during operation.
(2) weekly inspection.
Together with the driver * * *, the maintenance man mainly focuses on appearance inspection, checking the safety status of hook, fetching device and wire rope, the sensitivity and reliability of brake, clutch and emergency alarm device, and observing whether there is abnormal noise and overheating in the transmission parts through operation.
(3) Monthly inspection.
The inspection shall be organized by the equipment safety management department and jointly conducted by relevant personnel of the user department. In addition to the weekly inspection, the status of power system, hoisting mechanism, slewing mechanism, operating mechanism and hydraulic system of hoisting machinery should be mainly checked, worn, deformed, cracked and corroded parts should be replaced, and the reliability of feeder, controller, overload protection and safety protection device of electrical control system should be checked. Through trial operation, check the signs of failure caused by leakage, pressure, temperature, vibration and noise of hoisting machinery. Through observation, the structure, support and transmission parts of the crane are subjectively detected in the state, so as to understand and master the technical state of the whole crane and check and determine the fault source of abnormal phenomena.
(4) Annual inspection.
The unit leader shall organize the equipment safety management department to take the lead, in conjunction with relevant departments. In addition to the monthly inspection items, it mainly carries out technical parameter detection and reliability test for hoisting machinery. Through testing instruments, the wear of welding seams and tests of moving parts, various working mechanisms and metal structures of lifting machinery is detected, and the operating technical conditions of lifting equipment are evaluated through tests of safety devices and components. Arrange overhaul, renovation and update plans.
4 crane safety technical inspection content
There are two kinds of safety technical inspection methods for lifting machinery, one is sensory inspection; The other is to use test instruments to measure and control the equipment.
4. 1 sensory examination
The safety technical inspection of hoisting machinery is largely carried out by inspectors through watching, listening, smelling, asking and touching. Sensory inspection accounts for more than 70% of the total inspection items of lifting machinery stipulated in the Inspection Rules for Lifting Machinery (2002) No.296. Through seeing, hearing, smelling, asking and touching the crane, the crane is comprehensively and intuitively diagnosed to obtain the required information and data.
Look: According to the structural characteristics of hoisting machinery, the important transmission parts, the main points of load-bearing structure and the source of fault phenomena are observed visually.
Listen: Analyze whether the running sounds of various parts of lifting machinery and equipment are normal by hearing, judge abnormal sounds from parts, understand the reasons and find out the source of the disease.
Smell: identify the smell of moving parts of lifting machinery by smell, and identify overheated, worn and burnt parts.
Question: Ask the driver and relevant personnel about the fault points, process and types that are easy to occur during crane operation. Determine the safety technical status of the crane.
Touch: Touch the operating part of the crane by hand, and judge the fault location and nature according to the temperature change and vibration.
4.2 Inspection of test instruments
According to the development trend of hoisting machinery at home and abroad, modern application condition monitoring and fault diagnosis technology has been widely promoted in the design and use of hoisting machinery. In the running state of hoisting machinery, the monitoring and diagnosis instruments and expert monitoring system are used to inspect (supervise) the hoisting machinery, grasp the technical state of the crane at any time, predict the fault symptoms and causes of the whole machine or system, and nip the accident in the bud.
4.3 Safety inspection of common parts of crane
(1) hook.
Check whether the tag and anti-dropping device of the hook meet the requirements, and whether the hook has cracks, peeling and other defects; Whether the cross section of the hook is worn, the opening is enlarged and the torsional deformation exceeds the standard; Whether there are fatigue deformation and cracks on the neck and surface of the hook and the wear of related pins and sleeves.
(2) steel wire rope.
Check whether the specifications and models of wire rope matched with pulley disc meet the design requirements. Whether the steel wire rope fixing devices such as pressure plate, rope clamp and wedge at the fixed end of the steel wire rope meet the requirements. Whether the abrasion, broken wires, kinking, flattening, bending, broken strands and corrosion of steel wire rope exceed the standard.
(3) Braking device.
The setting of the brake, whether the type of the brake meets the design requirements, and whether the pull rod and spring of the brake have defects such as fatigue deformation and cracks; Whether the wear of pin shaft, spindle, brake wheel and brake friction plate exceeds the standard, and whether the hydraulic brake leaks oil; Whether the brake clearance adjustment and braking capacity meet the requirements.
(4) drums.
Whether there is fatigue crack or damage on the drum body and drum edge; Whether the wear of rope groove and barrel wall exceeds the standard; Whether the height of drum flange can match the number of layers of wire rope winding; Whether the rope arranger and the working conditions of the rope arranger meet the requirements;
(5) pulley.
Whether the pulley is equipped with anti-falling rope groove device; Whether there are cracks, broken edges, excessive wear, etc. The rope groove and rim of the pulley, and whether the pulley rotates flexibly.
(6) reducer.
Whether there are abnormal sounds such as severe metal rubbing sound, vibration and shell radiation when the reducer is running; Whether the shaft end seal is good, whether the fixing bolts are loose and defective, etc. ; Whether the selection of reducer lubricating oil, oil level, operation of vertical reducer lubricating oil pump and open gear transmission lubrication meet the requirements.
(7) wheels.
Whether there are fatigue cracks on the wheel tread and axle, and whether the wheel tread and axle wear exceeds the standard. Whether there is rail gnawing phenomenon in operation. What is the reason for gnawing at the track?
(8) coupling.
There are no defects in the coupling parts, no looseness in the connection and no running impact. Whether the wear of coupling, pin shaft, pin hole and buffer apron exceeds the standard. Whether the coupling is concentric with the two parts to be connected.
4.4 Inspection of crane safety protection device
(1) overload protection device.
Whether the overload protection device is sensitive and reliable, whether it meets the design requirements and the opening pressure of the hydraulic overload protection device; Whether the comprehensive error of mechanical, electronic and comprehensive overload protector alarm and cut off power supply meets the requirements.
(2) Torque limiter.
Torque limiter is a safety device for jib crane to prevent overload and overturning. Check the sensitivity and reliability of the torque limiter by amplification method or weighing method, and check whether the comprehensive error of the setting point of the torque limiter alarm and power cut-off is within the specified range.
(3) Limit position limiter.
Check whether the luffing mechanism, lifting mechanism and operating mechanism of lifting equipment can generate alarm signals when they reach the set position and distance, and automatically cut off the power source running in the dangerous direction.
(4) windproof device.
For cranes with the height of the articulated point at the boom root exceeding 50m, check the anemometer to see whether it can give an alarm accurately when it reaches the set wind speed or the working limit wind speed. Cranes operating in the open air and on the track should check whether the parts of rail clamps, iron shoes and anchoring devices are deformed or defective, and the reliability of their independent work. For the automatic rail clamp, when the sudden wind-proof device cooperates with the running brake of the cart, it is necessary to check the reliability of the wind-proof function and the electric interlocking switch function in the non-anchored state.
(5) Anti-tipping device.
For cranes with luffing jib and jib type, the reliability of anti-tilting device and the sensitivity of electric interlock should be checked, and the indication accuracy of luffing position and amplitude indicator should be checked.
(6) buffering.
For cranes with different models, different lifting weights and different running speeds, check whether the buffers are matched, whether the buffers are intact and whether both ends can touch the stops at the same time during operation.
(7) protection device.
Check whether all kinds of protective covers, guardrails, guard plates and ladders are in good condition. Whether the transmission device on the crane is complete and reliable, and the exposed open transmission device on the crane may cause winding injury; Whether the rotating parts such as coupling, sprocket, chain and transmission belt have protective covers, and whether the parts on pedestrian passages, ladders and cranes that may expose people have protective fences meet the requirements. The electrical equipment of the open-pit crane should have a rain cover.
4.5 Electrical control device
(1) control device.
Should check whether the electrical accessories are complete, whether the mechanical fixation is firm, no looseness, no jam; Whether the power supply cable is aging or bare; Insulation material should be good. No damage and deterioration; Bolt contacts, brushes and other connecting parts should be reliable; The electrical equipment and components selected on the crane should be suitable for the power supply, working environment and working conditions. When bare wires supply power, check whether the external paint and indicator settings meet the requirements; When supplying power to the flexible cable, check whether the cable is properly retracted; For the current collector, it is necessary to check that the length of the slide wire is not bent, and the contact is reliable and there is no jamming.
(2) Electrical protection.
The main isolating switch for easy operation should be set at the incoming line of the crane, and the emergency power-off switch should be set on the crane, and check whether the main power supply can be cut off. Check whether the power supply and mechanism of the crane have short circuit protection, voltage loss protection, zero position protection, overcurrent protection and overspeed and demagnetization protection of special cranes. Check the integrity and effectiveness of electrical interlocking, interlocking and self-locking protection devices. Check whether the insulation resistance of electrical circuit, grounding of electrical equipment and grounding resistance of metal structure meet the requirements. Metal structures such as metal shell, transformer core, metal insulation layer, threading metal trough and cable metal sheath of all electrical equipment on the crane shall be reliably grounded (connected to zero) for protection.
4.6 metal structure
Should check whether the main stress components have global or local instability, fatigue deformation, cracks, serious corrosion and other phenomena. Whether there is obvious deformation and crack in the connection and weld of metal structure. Bolts or riveting should be free of looseness, defects and other defects. Whether the high-strength bolt connection has sufficient pre-tightening force. The overall anticorrosive paint for metal structure is better.
4.7 Cab
Check that the suspension and support connection of the cab are firm and reliable, and the door lock and door electric interlock switch, insulating floor and dry powder of the cab should be fully configured and effective. For cranes working in dangerous environments such as dust, poison, radiation, noise and high temperature, it should be checked whether necessary protective devices are installed to protect the health of drivers. Cab lighting and maintenance lights must use safe voltage within 36V.
4.8 Safety signs
Check whether the crane hoisting sign and the safety inspection qualified sign of the technical supervision department are hung in an obvious position. Whether the trolley slide line, rail sweeping plate, cable drum, spreader, trolley, rail clamp, slide line protection plate, boom, crane balance arm, boom head, outrigger and end frame of bridge crane with pedestrian passage are painted with safety signs as required.
For more information about project/service/procurement bidding, and to improve the winning rate, please click on the bottom of official website Customer Service for free consultation:/#/? source=bdzd