As an indispensable heavy equipment in industrial production, the formulation and implementation of safe operating procedures for bridge cranes are crucial to ensuring production safety and preventing accidents. These procedures not only cover every operating detail of the crane from starting to stopping, but also go deep into multiple levels such as daily maintenance, troubleshooting, and operator qualification management. Understanding and strictly abiding by these procedures means that potential safety risks can be minimized while ensuring production efficiency. From a comprehensive safety inspection before operation to a rapid shutdown in an emergency, every step must be accurate. In addition, continuous safety training for operators and the establishment of a complete safety management system are also an indispensable part of ensuring the safe operation of cranes.
Before starting the crane, the operator must conduct a comprehensive safety inspection. This includes a detailed inspection of the crane’s electrical system, mechanical components, brakes, hooks and wire ropes to ensure that all components are in good condition without wear, breakage or abnormalities. At the same time, it is also necessary to confirm that the ground in the operating area is flat and free of obstacles, and that the crane track is clean and intact, laying a solid foundation for safe operation. When checking the electrical system, it is necessary to observe whether the indicator lights and instruments on the control panel are working properly, check whether the wires and cables are damaged or exposed, and check whether the power supply and voltage are stable and reliable. When checking mechanical parts, it is necessary to observe whether the connections of each component are tight, whether the rotating parts are flexible, and whether the moving parts are stable. When checking the brake device, it is necessary to observe whether the brake is working normally and whether the gap between the brake pad and the brake disc is appropriate. When checking the hook and wire rope, it is necessary to observe whether the hook has cracks or deformation, and whether the wire rope has wear or breakage.
When starting the crane, the operator should follow the established procedures, turn on the control power first, and then gradually start each operating mechanism. During the operation of the crane, pay close attention to the indications of each instrument to ensure that the crane runs smoothly and without abnormal sounds. When stopping the operation, the hoisting object must be placed securely first, and then the operating mechanisms must be closed in turn, and finally the control power supply must be cut off. The entire operation process should be smooth and orderly, avoiding sudden start and stop to reduce the impact and wear on the crane. When starting the crane, the operator should ensure that the control power is turned on and the start sequence of each operating mechanism is correct. During the operation of the crane, the operator should always pay attention to whether the indications of each instrument are normal. If any abnormal situation is found, it should be handled in time. When stopping the operation, the operator should first place the hoisted object securely, and then turn off each operating mechanism and cut off the control power supply in turn. The entire operation process should be smooth and orderly, avoiding sudden start and stop to reduce the impact and wear on the crane.
Lifting operations are the core link of crane operation. Operators need to select appropriate lifting equipment according to the weight, shape and size of the hoisted object, and ensure that the hook is firmly connected to the hoisted object. During the lifting process, the operating speed of the crane should be strictly controlled to keep the hoisted object rising, falling and moving smoothly. At the same time, the operator needs to pay attention to the dynamics of the hoisted object at all times to avoid collisions with surrounding equipment, personnel or buildings. In the lifting operation, the operator needs to select appropriate lifting equipment and lifting equipment combinations according to the weight, shape and size of the hoisted object. During the lifting process, the operator should always pay attention to the dynamics of the hoisted object and avoid collisions with surrounding equipment, personnel or buildings.
In the face of emergency situations, such as crane out of control, electrical failure or personal injury, the operator should immediately take shutdown measures. This includes quickly cutting off the control power supply and using the emergency stop button or manual brake device to stop the crane from running. After the emergency shutdown, the operator needs to report the accident to the relevant department in a timely manner and assist in handling the accident to ensure the safety of personnel and reduce losses. When facing an emergency, the operator should quickly cut off the control power supply to stop the operation of the crane. At the same time, press the emergency stop button or use the manual brake device to ensure the immediate stop of the crane. After the emergency shutdown, the operator needs to immediately report the accident to the relevant department and assist in handling the accident to ensure the safety of personnel and reduce losses.
Operators must undergo systematic crane operation training from professional training institutions, pass strict assessment procedures, and obtain a crane operation certificate issued by relevant national or local departments before they can engage in actual crane operation. At the same time, in order to ensure that the technical level and safety awareness of operators are always in line with equipment updates and technological progress, enterprises must also establish a regular review mechanism, requiring operators to regularly participate in training and re-assessment to maintain the validity of their professional qualifications. In addition, for new or transferred crane operators, enterprises should implement a strict pre-job training and assessment system to ensure that they fully understand and master the safety operating procedures and technical requirements required for new jobs.
For the maintenance of cranes, enterprises should establish a comprehensive and detailed regular maintenance and maintenance system, which must clearly specify the maintenance cycle (such as daily, weekly, monthly, quarterly or annually, etc.), specific content and implementation standards. The system should cover the inspection, cleaning, lubrication, and tightening of various components and systems of the crane, such as insulation resistance testing of the electrical system, wear and damage inspection of mechanical components, performance testing and adjustment of the brake device, and functional verification and replacement of all safety protection devices when necessary. At the same time, operators should strictly perform various maintenance tasks in accordance with the system requirements during daily use, and form written records for traceability and review.
The enterprise should establish a complete safety inspection and hidden danger investigation mechanism, and regularly organize professional and technical personnel to conduct a comprehensive and detailed safety assessment of the crane. This includes but is not limited to an in-depth inspection of the crane’s electrical system, covering the integrity and operating status of key components such as cable lines, control cabinets, and motors; wear and damage inspection of mechanical components, such as the condition of vulnerable parts such as steel cables, pulleys, and bearings; performance testing and adjustment of the brake device to ensure that the brake system can work accurately and effectively under various working conditions; functional verification and replacement of all safety protection devices when necessary, such as overload protection, limit switches, and guardrails. In addition, enterprises also need to pay attention to the environmental safety of the operating area and check for any factors that may affect the safe operation of the crane, such as ensuring that there is no accumulation of debris in the operating area, the ground is flat and has no potholes, and there is sufficient lighting and a wide field of vision. For any safety hazards found, enterprises must attach great importance to them, immediately formulate rectification measures and strictly implement them to ensure the safe operation of the crane.
Qualification requirements for crane operators
| Project | Qualification Requirements | Note |
| Training Institutions | Professional training institutions | Must undergo systematic training |
| Operation certificate | Issued by relevant national or local departments | You can get it after passing the assessment |
| Regular review | Regular training and re-assessment | Maintain professional qualifications and effectiveness |
| Pre-job training | New employees or transfer personnel are required to participate | Ensure understanding and mastery of safe operating procedures and technical requirements |
Crane safety inspection and hidden danger investigation project list
| Inspection items | Inspection content | Note |
| Electrical system | The integrity and operating status of cable lines, control cabinets, motors, etc. | Deep inspection |
| Mechanical Components | Wear and damage of cables, pulleys, bearings, etc. | Wearing parts inspection |
| Braking device | Performance testing and adjustment to ensure accurate and effective operation | Performance Testing |
| Safety protection device | Function verification of overload protection, limit switch, guardrail, etc. | Replace if necessary |
| Operating area environment | No debris accumulation, flat ground, sufficient lighting, wide field of vision, etc. | Ensure safe operation |
| Hidden danger investigation and rectification | When hidden dangers are discovered, corrective measures are immediately formulated and implemented | Ensure safe operation of cranes |
In order to effectively deal with possible crane safety accidents, enterprises should formulate detailed and highly operational safety accident emergency plans. The plan should include accident reporting procedures, emergency rescue measures and personnel evacuation plans. After the plan is formulated, the company needs to organize emergency drills regularly to familiarize operators with and master emergency handling processes and methods, and improve their emergency response capabilities and practical operation skills. At the same time, simulation drills can also test the feasibility and effectiveness of the plan, prompting enterprises to continuously improve and optimize the emergency plan system.
During the operation of the crane, the operator must strictly abide by the working load limit of the equipment and must not overload the operation. Before performing the lifting task, the weight, shape and size of the hoisting object should be accurately assessed, and the appropriate hoisting equipment and lifting plan should be selected accordingly. Ensure that the connection between the hook and the hoisting object is firm and reliable to avoid falling or dumping accidents caused by poor connection. During use, pay close attention to the dynamics of the hoisted objects, adjust the operating speed of the crane in time according to the actual situation, ensure the smooth operation of the hoisted objects, and avoid excessive swing amplitude due to excessive speed, which may cause collision or overturning and other safety accidents.
The running tracks and limit devices of the crane are important guarantees for its safe operation. The operator should conduct a comprehensive inspection of the running tracks before daily operations, clean up the debris and obstacles on the tracks, and ensure that the tracks are flat and unobstructed to prevent the crane from running unsteadily or getting stuck due to uneven tracks. At the same time, the sensitivity and reliability of the limit devices should be tested regularly to ensure that they can issue an alarm and stop running in time when the crane reaches the limit position, so as to avoid equipment damage or safety accidents caused by excessive operation.
During the operation of the crane, the operator needs to be vigilant at all times and pay close attention to the surrounding environment. Through effective communication and coordination, ensure a safe distance from surrounding equipment, personnel and buildings to prevent collision accidents. For special operations that require crossing obstacles, the operator should conduct detailed on-site surveys and assessments in advance to plan a reasonable operation route. When crossing obstacles, ensure that the height, speed and direction of the crane are precisely controlled to avoid collisions or overturning accidents caused by operational errors.
Under severe weather conditions, such as strong winds, heavy rains, lightning, etc., the operation safety of the crane will be seriously affected. Enterprises should formulate strict operation restriction regulations to clearly prohibit or restrict the operation of cranes in severe weather. Operators should also pay close attention to weather forecasts and on-site conditions. Once the weather deteriorates, they should immediately stop operations and take necessary protective measures to ensure the safety of personnel and equipment. At the same time, enterprises should also establish a complete emergency plan system so that they can respond quickly and take effective measures to deal with emergencies.
Operators need to clean, lubricate, tighten and inspect the crane every day. This includes a comprehensive inspection of the electrical system, mechanical parts, brake devices, safety protection devices, etc., as well as cleaning and lubrication of rails, limit devices, etc. During the cleaning process, care must be taken not to allow water or other liquids to enter the crane’s electrical system to avoid short circuits or other electrical failures. During the lubrication process, it is necessary to select appropriate lubricating oil or grease according to the crane’s instruction manual and replace it regularly. During the tightening process, it is necessary to check whether all connectors are loose or worn, and replace or reinforce them in time if necessary.
Cranes may have various faults during operation, such as electrical faults, mechanical faults, brake failures, etc. Operators need to have certain fault diagnosis and troubleshooting capabilities, be able to quickly identify fault phenomena, analyze the causes of faults, and take effective measures to eliminate them. Electrical failures may include motor failure, controller failure, line failure, etc. Mechanical failures may include bearing failure, gear failure, chain failure, etc. Braking failure may include brake pad wear, brake fluid leakage, brake system failure, etc. After discovering the fault, the operator should take timely measures to stop the operation of the crane and contact professionals for repairs as soon as possible.
To ensure that the maintenance of the crane is effectively implemented, the enterprise should establish a complete maintenance record and file management system. Operators must record the content, time, personnel and other information of each maintenance in a timely manner in accordance with the requirements of the system, and organize and analyze the records regularly. Through maintenance records and file management, the operating status and maintenance history of the crane can be fully understood, providing strong support for future maintenance and troubleshooting. At the same time, the service life and potential problems of the crane can be predicted, providing strong protection for the production and safety of the enterprise.
The enterprise must ensure that the crane operator fully understands and is proficient in all safety procedures and standards related to crane operation. This includes but is not limited to basic operating specifications, such as the correct start-up, operation, and stop procedures, as well as the operating sequence to be followed under various working conditions; safety management systems, such as the use of personal protective equipment, equipment maintenance procedures, emergency response measures in dangerous situations, etc.; operating safety precautions, such as the bundling method of hoisted objects, stability control during hoisting, and safe isolation of the operating area.
To achieve this goal, enterprises should establish a normalized safety education mechanism and regularly organize operators to conduct theoretical learning and practical operation training. Through holding special lectures, seminars, simulated practical operations and other forms of training activities, operators can fully understand and internalize the requirements of safety operating procedures. At the same time, enterprises also need to design and implement a strict assessment system, which not only examines the operators’ mastery of theoretical knowledge, but also examines their skills in actual operations and their ability to deal with complex situations.
In addition, enterprises should establish a complete assessment result feedback mechanism, record and analyze the results of each assessment in detail, point out the advantages and disadvantages, and formulate rectification measures for existing problems, so as to truly promote learning through examination and ensure security through learning. Only in this way can we ensure that crane operators strictly abide by safety operating procedures in their daily work and effectively prevent the occurrence of safety accidents.
In order to effectively improve the practical operation skills of crane operators, enterprises should regularly organize training and drills that simulate actual work scenarios. Such training should cover the standardized process of starting and stopping the crane, as well as various complex situations in lifting operations, such as precise grasping of objects, stability control during transportation, and accurate judgment of lifting positions. Through training and drills that simulate actual work scenarios, operators can repeatedly practice and verify in a simulated environment, thereby deepening their understanding and mastery of actual operation processes and improving their ability to respond to emergencies.
Safety awareness is the core element that guides crane operators to operate safely. Enterprises should continue to cultivate and improve the safety awareness of operators through various forms. Regularly carry out safety education activities, such as organizing special lectures and case analysis meetings, so that operators can have a deep understanding of the hazards and preventive measures of safety accidents; carry out accident case analysis activities to allow operators to learn lessons from actual cases and improve their own safety awareness; hold safety knowledge competitions to stimulate operators’ learning interest and enthusiasm. At the same time, encourage operators to actively participate in the company’s safety culture construction activities, such as safety publicity week, safety creativity competition, etc., to form a good safety culture atmosphere. By continuously cultivating and improving the safety awareness of crane operators, their sense of responsibility and self-protection awareness can be further enhanced to ensure the safe operation of cranes.
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