As an indispensable and important piece of equipment in the industrial field, explosion-proof overhead cranes play a vital role in ensuring production safety and enhancing operational efficiency. These cranes are designed for operation in flammable and explosive environments, and a series of strict standards and specifications guarantee their stable operation under extreme conditions. From the basic overview to the design criteria, to the materials and corrosion prevention treatment, every step of the way is cohesive to the double consideration of safety and efficiency. In addition, the rigor of the testing and certification process not only ensures the compliance of the crane, but also provides strong support for its reliability in practical applications. An in-depth discussion of the explosion-proof overhead travelling crane standards is of great significance for understanding its working principle, optimizing the operation process and enhancing the level of safety management.
Explosion-proof overhead cranes, as a kind of professional engineering equipment, are custom-designed on the basis of ordinary overhead cranes for the special operational needs of explosive gas or steam environments. By adopting special material selection, circuit design, fire prevention measures and advanced control systems, these cranes ensure that they can effectively prevent explosions caused by electric sparks, high temperature surfaces or other potential sources of ignition during operation, especially when carrying out material handling and lifting operations.
Explosion-proof overhead cranes are meticulously divided into various types according to their structures and uses. The most common ones include single girder explosion-proof overhead travelling crane, which is generally suitable for relatively light load and small working space; double girder explosion-proof overhead travelling crane, which occupies a dominant position in heavy-duty operation with its strong carrying capacity and stable operation performance; and cantilever explosion-proof overhead travelling crane, which is favored in specific working conditions with its flexible operability and efficient working efficiency.
Explosion-proof overhead cranes are widely used in petroleum, chemical, pharmaceutical and military industries where there is a high risk of explosion because of their ability to work safely in flammable and explosive environments. In these industries, cranes are indispensable heavy equipment for material handling, equipment installation and dismantling, product manufacturing and other key aspects. Through the use of explosion-proof overhead cranes, enterprises can ensure safe production under the premise of improving work efficiency, reduce operational risks, and effectively prevent the occurrence of explosion accidents caused by equipment failure or operational errors.
Explosion-proof overhead cranes are used in the petroleum industry for the lifting of heavy equipment in oil well development, crude oil refining, chemical production, etc.; in the chemical industry, these cranes undertake the task of transferring all kinds of chemical raw materials, intermediate products and finished products; and in the pharmaceutical industry, they are responsible for the installation of precision instruments, the handling of pharmaceutical production equipment, and the transportation of finished and semi-finished products. In addition, in the military industry, explosion-proof overhead travelling cranes are essential to ensure the safety of military equipment manufacturing and testing process.
As the core component of explosion-proof overhead travelling crane, the design process of the electrical system must strictly follow the relevant safety norms and standards issued by the state and the industry. First of all, the electrical system must have excellent insulation performance, to ensure that in high temperature, high humidity, corrosion and other harsh environments can still maintain normal insulation resistance and dielectric strength, and effectively prevent electrical failures caused by insulation failure. Secondly, in order to meet the explosion-proof requirements, the design of the electrical system should use explosion-proof electrical equipment, such as explosion-proof switches, explosion-proof junction boxes, etc., to ensure safe operation in potentially explosive hazardous environments. In addition, it should also have a high level of protection, such as IP65 or higher, in order to resist the erosion of dust, moisture and other electrical equipment.
In terms of safety protection, the electrical system should be equipped with comprehensive overload protection and short circuit protection to prevent fire and other safety accidents caused by overload or circuit failure. At the same time, it should also have under-voltage protection, voltage loss protection, over-voltage protection and other safety measures to ensure the stability and reliability of the entire electrical system. Through these strict design standards and measures, the electrical system of explosion-proof overhead cranes can work reliably in various complicated and dangerous operating environments, providing strong guarantee for production safety and efficient operation.
Electrical system design standard table
| Standard Category | Specification | Note |
| Insulation properties | Excellent insulation resistance and dielectric strength | Ensure normal operation in high temperature, high humidity, corrosive environments, etc. |
| Explosion-proof requirements | Adoption of explosion-proof electrical equipment | Such as explosion-proof switches, explosion-proof junction boxes, etc. |
| Protection level | IP65 or higher | Resist the erosion of electrical equipment by dust, moisture, etc. |
| Overload protection | Perfect overload protection function | Prevent safety accidents such as fires caused by excessive loads |
| Short circuit protection | Perfect short circuit protection function | Prevent safety accidents such as fires caused by circuit failures |
| Undervoltage protection | With undervoltage protection function | Ensure the stability of the electrical system |
| Voltage loss protection | With voltage loss protection function | Ensure the stability of the electrical system |
| Overvoltage protection | With overvoltage protection function | Ensure the reliability of the electrical system |
Explosion-proof bridge crane safety performance standard table
| Standard Category | Specification | Note |
| Explosion-proof grade | Selection according to the degree of explosive hazard of the operating environment | Ensure safe operation in potentially explosive hazardous environments |
| Dustproof grade | Selection according to dust concentration | Ensure safe operation in environments with high dust concentrations |
| Sealing performance | Well sealed doors, windows, cable entrances, etc. | Prevent explosive gases or vapors from entering the crane interior |
| Emergency stop function | Equipped with emergency stop button | Immediate stoppage of all operating mechanisms and operations in the event of an emergency |
| Limit protection function | Installation of limit switches and limit devices | Prevent mechanical damage or safety accidents caused by excessive operation |
| Overspeed protection function | Set up the speed monitoring device and control logic | Prevent safety hazards caused by speeding |
| Explosion-proof materials | All structural parts are made of explosion-proof materials | Such as stainless steel, aluminum alloy, etc. |
| Sealing of connection parts | Adopt measures such as gaskets and sealants | Prevent explosive gases or steam from entering the interior of the crane through the connecting parts |
| Lubrication of moving parts | Use high-quality greases and lubricants | Ensure that moving parts maintain good lubrication and wear resistance during long-term operation |
The explosion-proof and dust-proof ratings of explosion-proof overhead cranes are important indicators of their safety performance. In order to ensure the safe and reliable operation of explosion-proof overhead travelling cranes in potentially explosive atmospheres and environments with high dust concentrations, it is crucial to select the appropriate explosion-proof and dust-proof ratings. Depending on the degree of explosive hazard and dust concentration in the operating environment, designers need to precisely determine the required explosion-proof and dust-proof ratings to ensure that the crane will not be exploded or damaged by external factors during operation.
During the design process, designers will take into full consideration the structure, material, process and other factors to ensure that the crane has good sealing performance and dustproof ability. At the same time, a series of measures will be taken to prevent explosive gases or vapors from entering the interior of the crane, such as the use of doors, windows, cable entrances with good sealing performance. In addition, a series of measures will be taken to ensure the long-term stable operation of the crane, such as regular inspection, maintenance, maintenance and so on. Through the implementation of these measures, it can ensure the safe and reliable operation of explosion-proof overhead cranes in potentially explosive hazardous environments and environments with high concentration of dust, and provide a strong guarantee for production safety and efficient operation.
The safety control system plays a vital role in the operation and running of explosion-proof overhead travelling crane, and its design must meet the requirements of high reliability, high safety and high degree of automation. In order to ensure the safety of operators and equipment, the system must have emergency stop function. In the event of an emergency, the operator can immediately stop all operating mechanisms and operations by pressing the Emergency Stop button, avoiding potential danger and damage.
In addition to the emergency stop function, the safety control system should also have a limit protection function. By setting limit switches at both ends of the running range of the bridge, and setting corresponding limit devices on the trolley and large trolley running mechanism, the system can automatically stop the crane when it runs to the limit position, preventing mechanical damage or safety accidents due to over-running. In addition, in order to prevent safety hazards caused by overspeed, the system should also have overspeed protection. By setting up speed monitoring devices and corresponding control logic, when the crane's operating speed exceeds the preset safety range, the system will automatically trigger an alarm and take deceleration measures to ensure that the equipment will not be damaged or cause safety accidents due to overspeed. These advanced safety control systems are designed to provide a full range of safety safeguards to ensure that explosion-proof overhead cranes can operate stably and safely in all kinds of harsh environments.
The structural design of an explosion-proof overhead travelling crane requires full consideration of its explosion-proof performance. In order to ensure safe and reliable operation in potentially explosive environments, all structural parts of the crane must be made of explosion-proof materials. Common explosion-proof materials include stainless steel, aluminum alloy and other materials with good corrosion resistance and high strength. These materials can resist the erosion of various harsh environments to ensure the long-term stable operation of the crane.
In addition to the use of explosion-proof materials, explosion-proof bridge crane connection parts also need to have good sealing performance. Through the use of sealing gaskets, sealant and other measures, can effectively prevent explosive gases or vapors through the connection parts into the crane. At the same time, in order to further enhance the sealing effect, designers will also take multiple sealing measures to ensure that in any case can effectively prevent the penetration of explosive gases. In addition, the moving parts of explosion-proof overhead cranes should also have good lubrication and wear resistance. Through the use of high quality grease and lubricant, as well as wear-resistant materials and surface treatment technology, it can ensure that the moving parts maintain good lubrication and wear-resistant performance in long-term operation. This can reduce the incidence of wear and failure and ensure the stability and reliability of the crane.
In the design and manufacture of explosion-proof overhead cranes, the choice of materials is critical, and need to follow certain principles. First of all, the material should have excellent mechanical properties, including high strength, good toughness and wear resistance to ensure that the crane can maintain stable performance when bearing heavy loads. Secondly, the material must also meet the requirements of explosion-proof performance to prevent accidents in a potentially explosive environment. In addition, since explosion-proof overhead cranes usually work in harsh environments, such as high temperature, high humidity, corrosive gases, etc., the material should have good corrosion resistance to resist the erosion of these environments. Finally, the selection of materials also needs to consider their economy and processability. Economy refers to the cost-effectiveness of the material, that is, without sacrificing the performance of the premise of minimizing costs. Machinability refers to the ease with which a material can be processed and manufactured to increase productivity and reduce manufacturing costs.
A range of anti-corrosion treatment measures are required to address the potential corrosion problems faced by explosion-proof overhead cranes. These measures include, but are not limited to, surface coating treatment, electrochemical protection, sand blasting and rust removal. Surface coating treatment is an effective anti-corrosion measure, by coating the surface of the material with a layer of anticorrosive coating, it can isolate air and moisture, thus preventing the material from corrosion. Electrochemical protection is the anodic oxidation or cathodic protection of metal surfaces by utilizing the principle of electrochemical reaction to enhance the corrosion resistance of metals. Sandblasting and descaling is a method of cleaning the metal surface, which can remove the surface oxidized skin, rust and other impurities, and improve the roughness of the surface, so as to better combine with the paint or protective agent and improve the corrosion protection effect. The service life and safety of cranes can be significantly improved through reasonable anti-corrosion treatment.
Testing of explosion-proof overhead travelling crane is an important means to ensure its safety performance. Testing procedures should include appearance inspection, electrical system testing, explosion-proof performance testing and other aspects. Appearance inspection is mainly to confirm whether the structure and parts of the crane are intact and undamaged, with or without deformation, cracks and other problems. Through observation and inspection, you can understand the appearance quality and use of the crane. Electrical system inspection is the key link to ensure that the crane's electrical system and control equipment work properly. The inspection includes the integrity of wires, cables, switches, controllers and other components, as well as the insulation and grounding performance of electrical equipment. Through the electrical system testing, potential electrical failures and safety hazards can be found and resolved in a timely manner. Explosion-proof performance testing is an important test of explosion-proof overhead cranes, mainly to detect whether the explosion-proof structure of the crane, explosion-proof electrical equipment meets the explosion-proof requirements. Through the explosion-proof performance testing, you can ensure that the crane can operate safely and reliably in a flammable and explosive environment. Testing requirements should strictly follow the relevant national and industry standards to ensure that the crane's performance indicators are in line with the provisions.
Certification of explosion-proof overhead cranes is necessary to ensure their legal use and compliant operation. Certification standards should be based on national and industry-related regulations and standards, including explosion-proof performance certification, safety performance certification and other aspects. Explosion-proof performance certification is mainly to confirm that the explosion-proof structure of the crane, explosion-proof electrical equipment to meet the explosion-proof requirements. Safety performance certification is to confirm that the crane's various safety protection devices, structural strength, stability and so on whether it meets the relevant standards. Certification process includes application, review, testing, auditing and other aspects. The application process requires the submission of relevant information and documents, including business license, production license, product technical documents. The review is mainly to confirm the authenticity and completeness of the application information, as well as whether the production conditions and quality system of the enterprise meet the requirements. The testing session is to confirm whether the performance indexes of the products comply with the relevant standards through actual testing and inspection. Audit link is to review and evaluate the test results to confirm whether the product meets the certification requirements.
In order to ensure the long-term stable operation of explosion-proof overhead cranes, strict maintenance and overhaul regulations should be formulated. These regulations should include regular maintenance, inspection, repair and other aspects to ensure that the crane's performance indicators always maintain a good state. Regular maintenance is an important means to keep the crane in good operating condition, including cleaning, lubrication, fastening and other aspects. Through regular maintenance, potential problems and hidden dangers can be found and solved in time to extend the service life of the crane. Inspection link includes daily inspection, regular inspection and special inspection and other aspects, mainly to confirm whether the crane's various performance indicators meet the requirements, there are no abnormalities and potential safety hazards. Maintenance is to repair and replace the faulty and problematic components, including fault diagnosis, maintenance program development, maintenance implementation and other aspects. Maintenance regulations should specify the maintenance cycle, content, method and other requirements to ensure the standardization and effectiveness of maintenance work. In addition, the maintenance record file is an important part of the maintenance and overhaul provisions, through the establishment of a perfect maintenance record file, you can record the crane's operating conditions, faults, maintenance history and other information, so as to facilitate the timely discovery and resolution of potential safety hazards.
The working environment conditions of explosion-proof overhead cranes have an important impact on their safety performance and service life. In order to ensure the normal operation and safety of explosion-proof overhead cranes, it is necessary to carry out strict requirements and monitoring of its working environment conditions.
For indoor working environments, in addition to ensuring good ventilation and lighting conditions, the concentration of explosive gases or vapors needs to be regularly tested and cleaned up to avoid any potential risk of explosion. At the same time, the building structure of the workshop or plant should have sufficient strength and stability to withstand the impact and pressure of explosive gases or vapors. In addition, the indoor environment should be kept relatively dry to prevent problems such as corrosion and electrical short circuits. Compared with the indoor environment, the outdoor working environment is more complex and variable. When used outdoors, explosion-proof overhead cranes need to withstand the influence of various natural factors, such as wind load, rain load, snow load, solar radiation and so on. In order to ensure the stability and safety of the crane, these natural factors must be fully considered and evaluated. For example, in terms of wind load, cranes should have sufficient wind resistance to avoid structural damage or overturning due to strong winds. In terms of rain load, cranes should have waterproof sealing performance to prevent rainwater from intruding into the electrical system or causing structural damage. In addition, for factors such as snow load and solar radiation, cranes should have cold and heat resistance to adapt to temperature changes in the outdoor environment.
Temperature and humidity are important factors affecting the safety performance of explosion-proof overhead cranes. For the normal operation and safety of explosion-proof overhead cranes, the temperature and humidity of the environment in which they are located need to be controlled within the appropriate range. Excessive temperature may lead to overheating or damage to the crane electrical system. In a high temperature environment, the insulation of electrical equipment decreases, which can easily lead to safety accidents such as electrical short circuit or fire. In addition, high temperature may also make the lubricant thin, affecting the lubrication effect of the crane and accelerating the wear and tear of mechanical parts. On the other hand, excessive humidity is also detrimental to the operation of explosion-proof overhead cranes. In a humid environment, electrical equipment is susceptible to moisture erosion, which may lead to problems such as insulation degradation and circuit failure. In addition, excessive humidity may also trigger corrosion problems, causing damage to the structural components and connection parts of the crane. In order to ensure the normal operation and safety of explosion-proof overhead cranes, it is necessary to set a reasonable range of temperature and humidity according to its specific model and use environment. In the high temperature environment, cooling measures should be taken such as increasing ventilation, setting sunshade facilities, etc.; in the humid environment, moisture-proof measures should be taken such as increasing drying equipment, strengthening the sealing and so on. At the same time, it is also necessary to regularly check and maintain the status of the crane electrical system and structural components to ensure their normal operation and safe use.
Altitude and air pressure also have a certain impact on the performance and service life of explosion-proof overhead cranes. As the altitude increases the atmospheric pressure and oxygen content gradually reduces and may lead to crane electrical system performance degradation or failure. High altitude climate and environmental conditions are often more severe, such as thin air, wind, low temperature, etc., these factors may have an adverse effect on the normal operation of explosion-proof overhead travelling crane. In order to ensure the normal use of cranes in high-altitude areas, it is first necessary to fully investigate and analyze the local geographic environment and climatic conditions. According to the actual situation in high-altitude areas, the crane's electrical system, lubrication system, cooling system and other corresponding adjustment and optimization. For example, strengthen the insulation of the electrical system to reduce the working load and other measures to adapt to the special environmental conditions of high-altitude areas. In addition, the use of explosion-proof overhead cranes at high altitude also need to pay attention to strengthen the inspection and maintenance of equipment to ensure that the equipment is always in good operating condition at the same time, but also pay attention to the operator's training and safety education to improve the skill level of the operator and safety awareness to ensure the use of explosion-proof overhead cranes at high altitude areas of safety and reliability!
In short, the explosion-proof bridge crane working environment conditions have an important impact on its safety performance and service life. In the actual application of the need to be based on the specific circumstances of the comprehensive consideration and take appropriate measures to ensure its normal operation and safety and extend the service life.
As a special equipment, the operator of an explosion-protected overhead travelling crane must have a nationally recognized qualification, which usually requires professional training and assessment procedures. Operators not only need to master the operation of explosion-proof overhead travelling cranes, but also have a thorough understanding of the structural principles, performance parameters, limitations of use and safety regulations. The training content should cover the basic operation of the equipment, special working conditions of the control skills, common fault diagnosis and treatment, emergency response strategy, etc., to ensure that the operator can skillfully and accurately manage the equipment, and in a variety of complex working conditions to make reasonable judgments and proper disposal.
In the course of operation, operators must strictly abide by the national and industry safety regulations and operating procedures promulgated by the state, which are designed to minimize the occurrence of safety accidents and safeguard the safety and order of the working environment. Operators not only need to wear standard safety protection equipment, such as helmets, protective glasses, protective gloves, etc., to prevent bodily injury due to accidents, but also should carry out regular safety inspections and maintenance of the crane to ensure that its safety features are always in a good and effective state.
In the actual operation process, the operator should fully understand and adapt to the specific environmental conditions of the operating site, always remain vigilant, timely detection and elimination of potential safety hazards. For example, when using explosion-proof overhead cranes in flammable and explosive environments, it is necessary to ensure that there is no open fire or other hazardous sources that may cause explosions in the operation area, and to maintain adequate ventilation conditions. At the same time, for different lifting tasks and cargo characteristics, operators should flexibly adjust the operation strategy to ensure the safety and stability of the whole lifting process.
In order to effectively cope with possible emergencies and contingencies, enterprises should formulate detailed emergency measures in advance, covering emergency stopping procedures, personnel evacuation programs, fire fighting measures and other key aspects. In addition, it is also necessary to establish a sound emergency plan and emergency response mechanism to ensure that rapid and effective action can be taken in emergencies to minimize casualties and property damage. Strengthening emergency management and training not only improves the emergency handling ability and self-rescue and mutual rescue ability of operators, but also helps to enhance the overall production safety and security capacity of the enterprise, ensuring that when faced with an emergency situation, it can respond quickly and in an orderly manner to reduce the impact of potential risks.
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