As an important equipment in modern industrial production, the development and implementation of the special construction program for electric double girder overhead cranes is directly related to production efficiency and safety performance. The program aims to ensure the stability and reliability of the crane in installation, commissioning and subsequent operation, and to meet the actual needs of the project through refined construction processes and technical requirements. The program covers the whole process from equipment selection to installation and commissioning, not only focusing on technical details, but also emphasizing the importance of construction organization and management, as well as the perfection of safety risk assessment and countermeasures. Through the scientific construction plan, it aims to realize the efficient, safe and stable operation of the electric double girder overhead travelling crane, and provide solid guarantee for industrial production.
As an indispensable logistics and lifting equipment in modern industrial environment, the careful design and effective implementation of electric double girder overhead travelling crane is crucial for the whole project. This special construction program depicts in detail the various aspects and steps of electric double girder overhead travelling crane installation, including but not limited to preliminary preparation, foundation construction, equipment lifting, electrical connection, commissioning and inspection, etc., to ensure that every aspect complies with the relevant national standards and specifications. Meanwhile, safety risk management is particularly emphasized in the program, where possible risk factors are identified and assessed in advance, and targeted preventive measures are taken to ensure a safe and error-free construction process. In addition, quality control measures are also the key contents of this program, which ensure the quality of electric double girder overhead travelling crane installation meets the design requirements and industry standards through strict quality inspection and acceptance procedures, so as to provide a solid guarantee for the smooth completion of the project and long-term stable operation.
This project focuses on the upgrading of the production line of a large manufacturing enterprise, in which the installation and upgrading of the electric double girder overhead travelling crane is a key part of the project. As the core equipment for material handling, the crane's operation efficiency directly affects the smoothness of the entire production line and product output, while its safety performance is also related to the safety of production operations and the safety of employees' lives and properties. Therefore, the implementation of this project is extremely difficult and high precision requirements, must be strictly in accordance with the state, the industry and the enterprise internal control system of the technical specifications set out in the construction, to ensure that the quality of the crane installation to meet the design expectations, so as to protect the high efficiency, stability and safety of enterprise production.
The construction site is located in the enterprise existing plant, the surrounding environment is complex and numerous equipment, the construction process needs to fully consider how to effectively protect the surrounding equipment safety measures to prevent accidental damage or failure caused by construction operations. At the same time, the impact of the construction on the existing production line operation must be fully assessed to take a scientific and reasonable construction strategy and scheduling program to minimize the construction of the production activities caused by the loss of downtime. Given the limited space at the site, fine management and efficient execution are essential, including but not limited to measures such as reasonable construction sequencing, scientific scheduling of construction machinery, and optimization of transportation routes, in order to maximize construction efficiency.
This project must strictly follow a series of relevant standards and specifications issued by the state and the industry during the construction process, such as the Crane Design Code (GB/T 3811-2008). These specifications cover many aspects of the crane's structural design, strength calculation, selection of components, installation and commissioning, etc., to ensure that the equipment meets the functional requirements while having sufficient strength and stability. In addition, “Crane Installation and Acceptance Code” (GB 50278-2010) is also an important basis for guiding the installation work, which stipulates the preparatory work before the installation of cranes, the quality control points during the installation process and the acceptance inspection items after the installation, aiming to ensure that the installation of cranes is correct and safe. Crane Safety Regulations are guidelines for operators to use and maintain cranes correctly, aiming to reduce operational risks and ensure personnel safety and equipment integrity. During the construction process, equipment selection, installation accuracy and commissioning parameters must be strictly controlled to ensure that the crane meets the design requirements, thus providing a strong guarantee for the safe production and efficient operation of the enterprise.
In order to ensure that the construction activities of this project are carried out in an efficient and orderly manner, and to achieve the expected project quality standards and safety objectives, a professional and efficient construction team will be carefully assembled. The team will cover a number of key positions, such as project manager, technical manager, safety supervisor, quality inspector and various specialized construction teams. The project manager, as the core leader of the project, will be fully responsible for the management of the project schedule, cost, quality and risk to ensure that the project progresses smoothly according to the set objectives. The technical manager is responsible for the design optimization and technical guidance of the construction plan, providing scientific and reasonable technical support for the on-site construction. The Safety Supervisor is responsible for the safety management of the construction site, implementing all safety rules and regulations, and preventing safety accidents. The quality inspector is responsible for supervising the construction quality throughout the whole process, implementing strict quality inspection procedures to ensure that each process meets the specification requirements. Each specialized construction team, led by the team leader, operates carefully according to the requirements of construction specifications and operation instructions to ensure that each project task can be completed on time and in good quality.
According to the overall requirements of the project, make a detailed construction progress plan. The plan will be refined to each sub-part of the project, specifying the time nodes and critical paths of each task. In order to ensure that the construction progress advances according to the plan, construction coordination meetings will be held regularly to gather the strength of all parties to jointly discuss and solve the problems arising in the construction process. At the same time, with the help of advanced information management tools, real-time monitoring of construction progress, early warning of possible problems, timely adjustment of construction programs and resource allocation to ensure that the entire project can be successfully completed within the scheduled construction period.
The establishment of a perfect quality control system and safety supervision mechanism is the basis for ensuring the smooth progress of construction. In order to achieve high quality standards, a rigorous quality management system and operating procedures will be formulated, and a specialized quality management department will be set up to strictly control every aspect of the construction process. Through regular quality inspections and assessments, we will respond quickly to problems identified and take effective measures to rectify them, ensuring that the quality of construction is always kept within control. At the same time, we attach great importance to the safety management of the construction site, implement national laws and regulations and industry standards on production safety, set up full-time safety management personnel, and are fully responsible for the safety supervision and inspection of the construction site. Through regular organization of safety education and training, emergency drills and other activities to improve the safety awareness and self-protection ability of all construction personnel, to prevent the occurrence of various types of safety accidents.
According to the requirements of the project, select the suitable model of electric double girder overhead travelling crane. Considering the actual demand of the project, working environment, working intensity and other factors, carry out strict equipment inspection. The inspection includes the appearance of the equipment, structural integrity, electrical components and transmission devices, etc., to ensure that the equipment meets the design requirements and is not damaged. Carry out detailed inspections on each component of the equipment to ensure that it meets the design requirements.
According to the equipment installation manual and construction drawings, make a detailed installation process and technology. Firstly, carry out the foundation construction to ensure that the foundation is level, stable and meets the design requirements. Next, carry out the installation of the main structure, including the installation and fixing of the bridge, running mechanism and other components, to ensure that the dimensions of its verticality, horizontality and span are in accordance with the specifications. Then the electrical system installation is carried out, including cable wiring, wiring of electrical components, etc., to ensure that the line connection is reliable and safe. Finally, debugging and testing, including no-load test, full-load test and various function tests, to ensure that the performance indicators of the crane to meet the design requirements. Strict control of installation accuracy is required during construction to ensure smooth, safe and reliable operation of the crane.
After completing the installation, the commissioning and testing of the crane. Through commissioning and testing, the performance of the crane can be fully assessed whether it meets the design requirements. First of all, the no-load test, through the simulation of the actual working conditions of the no-load operation, observation and recording of the crane's operating status, including operating speed, stability and other indicators. Then full-load test, by simulating the actual working conditions of full-load operation, observe and record the crane's operating status, including operating speed, stability and other indicators. In addition, it is also necessary to carry out various functional tests, including the crane's various action tests, safety protection device tests, etc., to ensure that the crane's various functions are normal and reliable. At the same time, it is vital to conduct a comprehensive test of the electrical system. Check the electrical components to confirm whether their working condition is normal and whether the line connection is reliable. Through testing to find and eliminate potential safety hazards, to ensure that the electrical system can work stably and reliably.
In the crane installation project, foundation design and construction is the crucial first link. First of all, according to the technical parameters and load capacity of the selected crane model, accurate foundation design is carried out. The design includes but is not limited to: the calculation and optimization of foundation dimensions, such as length, width and depth, etc., in order to ensure sufficient strength and stability; the determination of the burial depth, which needs to take into account the soil bearing capacity, water table, permafrost, etc., to ensure that the foundation is embedded in the underground part of the sufficient safety; the design of the reinforcement configuration, including the specification of the reinforcement, the spacing, and the anchoring length, etc., in order to meet the foundation structure in the stressed state of the Deformation and crack control requirements.
In the construction process, the foundation construction needs to be carried out in strict accordance with the design program, and each step from earth excavation, formwork installation, concrete pouring to maintenance needs to be strictly controlled for quality. Particular attention should be paid to ensure that the foundation position is accurate and the elevation is appropriate to avoid uneven settlement and other problems. At the same time, the construction materials used, such as concrete and steel reinforcement, should be quality inspected to ensure that they meet the design requirements and national standards.
The installation of the main structure is one of the key steps in crane construction. During the installation process, the first task is to ensure the safety and reliability of the components such as main girder, end girder, trolley frame, etc. during transportation and lifting to avoid the impact of collision, deformation and other problems affecting the overall structural accuracy. After lifting into position, professional equipment is used to carry out the connection and fastening operations between the components, including the precise control of the pre-tensioning force of the high-strength bolts and the quality inspection of the welded joints, to ensure that they meet the stress distribution and deformation control standards required by the design.
After the completion of the installation of the main structure, the overall performance of the crane also needs to be tested and debugged, such as measuring its geometric dimensions are in line with the standard, whether the running track is straight and smooth, as well as whether the action of the working mechanism is accurate. These measures together guarantee the stability and safety of the main structure of the crane, providing a solid foundation for subsequent operations.
The installation and commissioning of the electrical system is directly related to the degree of automation, operational efficiency and safety of the crane. In the installation process, operate in strict accordance with the electrical safety regulations, from the selection of electrical components, procurement, transportation, storage to on-site installation, to ensure that they are intact, the specifications and models meet the design requirements. During installation, the electrical components are reasonably laid out so that they are easy to maintain and repair; the line connections should be connected by reliable connection methods, such as crimping, welding, etc., and insulated to prevent short-circuit faults from occurring.
In the commissioning stage, the electrical system is subject to comprehensive and detailed commissioning and testing work. This includes but is not limited to: checking the stability of the power supply system to ensure that the voltage, current and other parameters in line with the operational requirements of the equipment; the control system for the joint commissioning test, to verify its control accuracy and response speed; through the actual operation of the test, to verify that the various protection functions are effective and reliable. Only when all the electrical parameters meet the design requirements and the system runs stably can the installation and commissioning of the electrical system be considered successfully completed.
During the start-up phase of a construction project, safety risk identification should be carried out systematically, covering, but not limited to, work-at-height safety risks, such as falls from height and object strikes; electrical safety risks, including the safety performance of temporary electrical facilities, the laying specifications for wires and cables, and fire and leakage prevention measures for electrical equipment; and mechanical injury risks, such as types of injuries caused by extrusion, cutting, and collision in the course of operation of construction machinery. In addition, according to the specific construction environment and operational characteristics, the safety risks caused by factors such as restricted space operations, chemical use, and cross operations should be considered comprehensively. Through a careful assessment of the types and severity of each type of risk, the risk level is determined and a corresponding risk management strategy is formulated based on the order of priority.
Security Risk Identification and Assessment Form
| Type of risk | Risk description | Risk level | Basis of assessment |
| Working at height | Falling from heights, object impact | High | Working height, protective measures, historical accident records |
| Mechanical damage | Squeezing, cutting, impact, etc. during the operation of construction machinery | Medium | Type of machinery, operating procedures, safety precautions |
| Confined space | Asphyxiation, poisoning, explosion, etc. due to work in confined spaces | High | Operating environment, ventilation facilities, operating permit system |
| Cross-work | Collision, interference, etc. caused by simultaneous operation of multiple work types | Medium | Delineation of operating areas, coordination of operating hours, safety warning signs |
Security Risk Response Measures and Plan Form
| Type of risk | Response measures | Plan content |
| Working at height | Installation of safety rails, provision of seat belts, medical examinations and training | Emergency organization, rescue process, medical rescue contact |
| Electrical safety | Regular inspection and maintenance, adherence to electrical standards, and preparation of fire-fighting equipment | Emergency plan for electrical fires, emergency power-off procedures, fire drills |
| Mechanical damage | Develop safety operating procedures, pre job training, and set up warning signs | Emergency plan for mechanical injury, emergency shutdown process, and treatment of injured personnel |
| Confined space | Work permit system, ventilation facilities, safety monitoring | Restricted space rescue plan, gas detection process, emergency escape route |
| Chemical use | Safe operating procedures, storage isolation, waste disposal | Emergency plan for chemical leakage, personal protective equipment, and disposal of leaked materials |
| Cross-work | Delineation of operating areas, coordination of operating hours, safety warnings | Cross-operational coordination plans, emergency communication links, personnel evacuation plans |
Targeted countermeasures and detailed plans are formulated for identified safety risks. For example, for the risk of working at height, measures such as setting up safety guardrails, equipping safety belts, and conducting medical checkups and training in advance can be taken; for the risk of electrical safety, regular inspection and maintenance of electrical facilities, strict enforcement of electricity use norms, and preparation of necessary fire-fighting equipment should be ensured; for the risk of mechanical injuries, safety operation procedures, pre-service training, and warning signs should be formulated, and so on. In addition, an emergency rescue plan should be established to clarify the emergency organization, rescue process, resource deployment plan, etc., to ensure a rapid response in case of emergencies, and effectively reduce accidental losses and adverse effects.
Construct a perfect safety monitoring system and use modern information technology to realize 24-hour real-time monitoring and early warning of the construction site. For example, installing monitoring cameras, configuring intelligent sensor alarm system and other equipment, timely detection and early warning of potential safety risks. At the same time, regular safety training and drilling activities are organized to improve the safety awareness and emergency response capability of construction personnel and enhance their ability to save themselves and each other when facing unexpected situations. When a safety accident or risk event occurs, it is possible to quickly activate the emergency response plan, organize professional rescue forces to deal with it, and minimize casualties and property losses.
During the construction process, in order to ensure the construction quality and project quality, it is necessary to establish a perfect quality management process and system. The process starts from the formulation of quality plan, and the detailed quality objectives, quality control measures and expected results are formulated according to the project contract, design documents and relevant national laws and regulations. During the construction process, quality control points are reasonably set up, including key work processes, special processes and hidden works, etc., and strict process monitoring and on-site management are implemented. Regular quality inspection and acceptance, including self-inspection, mutual inspection, special inspection and third-party testing and other means, timely rectification of the problems found to ensure that the construction quality meets the design requirements and industry standards.
In the construction process, in order to ensure that the construction quality meets the design requirements and industry standards, it is necessary to develop detailed acceptance criteria and procedures. Acceptance criteria should include the appearance of equipment, structural integrity, electrical system performance and various functional tests. Acceptance procedures include application, review, on-site inspection, data review, assessment and feedback. In the acceptance process, the acceptance criteria and procedures should be strictly followed to ensure that the crane meets the design requirements and acceptance criteria.
In the construction process, quality problems will inevitably occur. In the face of quality problems, timely measures must be taken to rectify. First of all, the cause of the problem should be analyzed to find out the root cause of the problem. Secondly, make a rectification program, clear rectification goals and measures. Finally, implement the rectification measures, review and acceptance of the rectified quality to ensure that the quality problems are completely solved. At the same time, quality management and the implementation of rectification measures should be strengthened to ensure the steady improvement of construction quality.
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