Railway overhead cranes and gantry cranes are indispensable large-scale equipment in railway construction and maintenance. Their operating efficiency and safety are directly related to the smooth progress of engineering projects. This operation instruction aims to standardize the use of cranes in railway construction through a set of detailed and standardized operating procedures to ensure that every lifting operation can be completed accurately and safely. Whether it is the preparation, execution or closing stage of the lifting operation, this instruction provides clear steps and standards to improve the operating standardization of operators, reduce the risk of accidents, and improve overall operating efficiency. By following the contents of this book, railway builders will be able to better control these heavy equipment and contribute to the smooth progress of railway projects.
This operation instruction is specially formulated to standardize the operating procedures of railway overhead cranes and gantry cranes, aiming to ensure the goal of safety and efficiency throughout the operation process. It is applicable to all personnel involved in the operation of overhead cranes and gantry cranes in the railway system, including but not limited to crane operators, drivers and signalmen, etc., and provides comprehensive and detailed guidance and reference for daily operations. By following this instruction, it is aimed to improve operating efficiency, reduce safety risks, and ensure the smooth operation of the railway transportation system.
The preparation of this guidebook strictly follows the relevant standards and specifications such as the "Safety Operation Procedures for Railway Hoisting Machinery" and the "Safety Management Regulations for Hoisting Machinery Operations" to ensure that all operation links meet national and industry safety standards. At the same time, combined with the actual working situation, the operation process has been optimized and refined to improve the operation efficiency.
Overhead crane: An important lifting equipment, usually spanning a fixed track, with horizontal movement and vertical lifting functions. It is mainly used for cargo handling and hoisting operations in warehouses, workshops and other places, and is widely used in various industrial fields.
Gantry crane: A lifting equipment with a bridge-like structure, but unlike a overhead crane, the two ends of a gantry crane are supported on ground tracks. This design makes the gantry crane suitable for loading and unloading operations of large cargo, especially in places where space is limited or a large distance needs to be crossed.
Snagging and hanging: In lifting operations, the process of correctly connecting the sling to the object to be lifted is called snagging and hanging. This step is essential to ensure safety and stability during the lifting process. Correct methods of adding and hanging cables can prevent the slings from slipping or falling off from the hoisted objects, thus avoiding accidents.
Before performing any lifting operation, the staff must conduct a comprehensive and detailed safety inspection of the operation site. First, clear all obstacles in the operation area, including debris, oil stains, water accumulation, etc., to ensure that the crane will not be blocked or cause accidents due to obstacles during operation. At the same time, according to the actual operation needs, a detailed operation plan is formulated to clarify the specific weight, size, location and target lifting height of the hoisted objects and other key information. Combined with the actual situation on site, a safe and efficient lifting plan is formulated, and it is ensured that all personnel involved in the operation clearly understand and comply with the operation plan.
Based on the site inspection and operation plan, it is crucial to conduct a comprehensive safety inspection of the crane. First, carefully inspect the key components of the crane, including but not limited to the hook, wire rope, brake device, hydraulic system, electrical control system, etc. Confirm that the hook is not deformed or worn, the wire rope is not broken or worn, and the brake device is sensitive and reliable to ensure that objects will not accidentally fall off or get out of control during the lifting process. For cranes that have been in use for a long time or whose maintenance status is unknown, comprehensive inspection and maintenance should be carried out when necessary to ensure that they are in good working condition.
After confirming that all the inspections of the crane are correct, turn on the power and start the crane control system. According to the operating procedures, gradually release the wind-proof brake device to ensure that the brake system can work normally and can be quickly started when needed to prevent the crane from moving or overturning due to strong winds or other external factors. After completing the power on and wind-proof brake device release, confirm again that all personnel involved in the operation are in place, and strictly follow each step of the operation plan to ensure the safety and smooth progress of the entire lifting operation.
When performing lifting operations, a set of rigorous standard procedures should be strictly followed to ensure the safety, efficiency and order of the entire lifting process. First of all, "trial lifting first, then formal lifting" is one of the basic principles of lifting operations. This principle aims to verify and debug the performance of the crane and slings through preliminary trial lifting operations to ensure that they are in good working condition before formal lifting.
During the trial lifting stage, the operator needs to slowly lift the cargo and closely observe the working conditions of the various parts of the crane, including but not limited to whether the lifting and rotation of the hook is flexible, whether the wire rope is worn or broken, and whether the entire sling combination is stable and reliable. In particular, during the lifting and lowering process, the cargo should maintain vertical movement to avoid swaying or tilting, so as not to cause excessive pressure on the sling or cause the cargo to fall off. Only after confirming that there is no abnormality in the crane and sling, can the formal lifting operation be carried out.
Adding and hanging ropes are important links in lifting operations, and their operations must be strictly carried out in accordance with relevant safety operating procedures. Before adding and hanging ropes, the operator should conduct a comprehensive and detailed inspection of the slings to confirm that they are intact and the specifications and models meet the requirements. At the same time, it is necessary to ensure that the center of gravity of the object to be lifted is in a reasonable position to facilitate the correct connection and fixation of the slings.
During the process of adding and hanging ropes, the operation must be carried out strictly in accordance with the command of the signalman. The signalman should use standard and clear instructions, such as "up", "down", "forward", "backward", etc., to ensure that the operator accurately understands his intentions. The operator should use special tools for rigging and hanging operations, and avoid direct contact with the slings with hands or other parts of the body to prevent accidents such as slippage and breakage that may cause injuries.
The lifting stage is the core part of the lifting operation, and a series of operating specifications need to be strictly followed. First of all, the crane driver must maintain close communication and cooperation with the signalman to ensure that the information transmission between the two parties is accurate. The instructions issued by the signalman must be clear and accurate to avoid misunderstandings or misleading.
During the trial lifting stage, the driver should lift the cargo slowly according to the instructions of the signalman, while paying close attention to the working status of each component of the crane and the balance and stability of the cargo. If any abnormal situation is found, such as hook shaking, severe wear of the wire rope, tilting of the cargo, etc., the lifting should be stopped immediately and the fault should be checked. Formal lifting operations shall not be carried out before the fault is eliminated.
During formal lifting, the driver should maintain a stable speed to lift the cargo to avoid shaking or falling of the cargo due to sudden start and stop. At the same time, pay attention to the surrounding environment and the trajectory of the goods to ensure that the goods will not collide or rub against other objects during transportation.
The lifting stage is one of the key links in lifting operations. During the lifting process, the crane driver must always be highly vigilant and pay close attention to the state of the goods and changes in the surrounding environment. The goods should be kept stable and in uniform motion during transportation to avoid shaking or falling off due to excessive speed or instability. At the same time, pay attention to keeping a safe distance from other objects to prevent collision or friction that may cause damage to the goods or safety accidents.
When the goods arrive at the designated location, the driver should accurately judge and slowly lower the goods to the target location. During the unloading process, pay attention to avoid severe collision or friction between the goods and the ground or other objects to cause damage. After unloading, the fixed state of the sling should be released in time to prepare for the next operation.
When performing lifting operations, crane operators must first ensure that the selection and use of slings comply with relevant national safety regulations, can bear the weight of the objects to be lifted, and have a clear understanding of possible special lifting requirements. During the hanging stage, crane operators should be proficient in the skills of adding ropes, such as using the correct rope knotting method (such as adjusting the tightness of the basket screw, using special slings, etc.) to ensure a stable and safe connection between the slings and the objects to be lifted. At the same time, during the operation, crane operators need to remain highly vigilant, always pay attention to the surrounding environment and the status of the goods, and be able to flexibly respond to possible emergencies, such as cargo shaking, sling damage, etc.
As a professional operator of heavy equipment, crane drivers must strictly abide by various operating procedures and safety systems. Before starting and operating the crane, the driver should conduct a comprehensive inspection of the equipment, confirm that all performance indicators meet the requirements, and be familiar with and understand the instructions issued by the signalman. During the operation, the driver needs to pay close attention to the various instructions issued by the signalman, such as ready, start hoisting, stop operation, etc., and ensure that they are fully understood before executing the corresponding actions. At the same time, the driver must always pay attention to the status of the goods, such as the weight, size, center of gravity position, etc. of the goods, and reasonably adjust the operation trajectory and speed of the crane to ensure that the goods are always in a safe state during the entire hoisting process.
As an important coordinator of on-site operation, the signalman's main responsibility is to accurately convey instructions to the crane driver. Before the start of operation, the signaler should communicate with the driver to ensure that both parties have a common understanding of the operation process and safety requirements. During the command process, the signaler needs to use standardized hand gestures, oral commands or semaphore to clearly express the intention, and pay close attention to the crane's operating status and changes in the surrounding environment. Once abnormalities or hidden safety hazards are found, the signaler should immediately issue an emergency stop signal and take measures to investigate and deal with them.
When all positions work together, operating procedures and personal safety protection measures must be strictly observed. Staff at each position should have a high degree of safety awareness and responsibility, and always pay attention to their own safety and that of others. If any abnormal situation or safety hazard (such as equipment failure, abnormal shaking of goods, environmental changes, etc.) is encountered in the course of operation, all personnel present should immediately execute the emergency stop signal. Once this signal is given, it means that all work must be immediately interrupted and a full safety check and hidden danger investigation must be carried out.
In the event of safety hazards in the working environment, staff must strictly observe safety operating procedures and wear personal safety protection tools, such as safety helmets, safety belts, protective glasses, etc., to ensure personal safety. Safety helmets can effectively prevent accidental head injuries, safety belts can provide body protection when working at height and prevent falling accidents, while protective glasses can block splash damage to the eyes. At the same time, the company should establish a perfect management system for labor protection products, and regularly inspect, replace and maintain the labor protection products to ensure that they are always in good working condition and provide employees with a safe and comfortable working environment.
In order to ensure the safety of operation, it must be strictly prohibited to operate with the same vehicle, i.e., to carry both people and goods on the same means of transportation. This kind of behavior is very easy to cause safety accidents due to personnel misoperation or equipment failure, which brings serious threat to staff's life and property. Therefore, the company should formulate a strict safety management system, explicitly prohibit the operation of people and machines on the same vehicle, and set up obvious safety warning signs at the operation site to remind the personnel to stay alert and away from the source of danger. At the same time, it should strengthen the safety education and training for the operating personnel, improve their safety awareness and operation skills, and ensure that they can consciously abide by the safety rules and regulations.
When working at night, the lighting equipment must be sufficient and reasonably laid out to ensure that the working area has enough brightness so that the workers can clearly recognize the working environment and the operating objects, thus avoiding safety accidents caused by poor visibility. In order to further improve the visibility of the work area and warning effect, should also be set in the work site warning lights and reflective signs and other equipment. These measures can not only provide a good working environment for the staff, but also effectively improve operational safety and efficiency.
When lifting operations are carried out in windy weather, the relevant safety regulations and operating procedures should be strictly adhered to. As excessive wind may adversely affect the stability and safety of the equipment, lifting operations should be suspended to avoid equipment failure or safety accidents. Before deciding to resume the operation, the crane must be thoroughly inspected and tested to ensure that all its performance indicators are in line with safety standards and work requirements. This includes a detailed inspection of the crane's structural stability, hydraulic system, electrical system, brake system, etc., and confirmation of the integrity of the spreader and rigging. Only when the crane is in good condition and ensures that all safety facilities are effective can the lifting operation continue. In addition, the company should establish a sound wind monitoring and warning mechanism to keep abreast of weather changes so that emergency measures can be taken when necessary to ensure the safety of staff and the integrity of equipment.
Provisions for operations under different weather conditions
| Weather Conditions | Job Type | Safety regulations and measures | Note |
| Strong windy weather | Lifting operations | Suspend operations and comprehensively check crane stability, hydraulic system, electrical system, brake system, etc. | Excessive winds may adversely affect the stability of the equipment |
| _ | _ | Establish a wind monitoring and early warning mechanism to keep abreast of weather changes | _ |
| At night | All assignments | Adequate lighting equipment and reasonable layout, warning lights and reflective signs are set | Improve the visibility and warning effect of the work area |
| _ | _ | Ensure that the working area has sufficient brightness, so that staff can clearly identify the environment | _ |
| _（Other） | _ | Strictly observe the safety operation procedures and wear personal safety protection tools | Such as safety helmets, safety belts, protective glasses, etc. |
| _ | _ | Human-machine operation is prohibited from running in the same vehicle, and obvious safety warning signs are set | Improve personnel safety awareness and operational skills |
Operational safety management and protective measures
| Security management measures | Description | Implementation Objects | Note |
| Safety operating procedures | Strictly abide by to ensure the safety of operations | All staff | Including the wearing of personal protective tools, etc. |
| Labor protection product management | Regular inspection, replacement and maintenance | Labor protection products | Ensure that the product is in good working condition |
| Man-machine operation in the same vehicle is prohibited | It is strictly prohibited to carry people and cargo on the same means of transport at the same time | Transportation operators | Prevent safety accidents caused by misoperation or equipment failure |
| Safety warning sign setting | Set up obvious safety warning signs at the work site | Work site | Remind personnel to stay alert and stay away from danger sources |
| Safety education and training | Strengthen safety education and training for workers | Workers | Improve safety awareness and operational skills |
| Emergency measures formulation | Formulate emergency measures, grasp weather changes, and ensure the safety of personnel and equipment | Company management | Especially for severe weather such as strong winds |
When abnormal and faulty phenomena are found in the equipment during daily operation or inspection, such as abnormal operation, performance degradation, functional failure, etc., the operation of the equipment should be stopped immediately to ensure that the equipment is in a safe state, and a detailed report should be made immediately to the higher management, equipment maintenance department or relevant technical personnel. The content of the report should include key information such as the specific performance of the equipment failure, the time of occurrence, location, the scope of influence and the preliminary judgment of the cause of the failure.
Upon receipt of the equipment failure report, the relevant department should quickly start the emergency response mechanism, and according to the preset emergency plan and equipment maintenance process, dispatch technicians or maintenance teams with professional qualifications to the scene for emergency investigation and repair work. These professionals need to carry the necessary testing tools and replacement parts to find out the root cause of the fault as quickly as possible and take effective repair measures.
During the repair process, all personnel involved in the repair must strictly abide by the safety operating procedures to ensure that the operation is safe and error-free. After the repair is completed, a comprehensive functional test and performance verification of the equipment is required to confirm that the equipment has been restored to its normal operating state and meets all the performance index requirements before the repair process is ended and the equipment is put back into use.
When an equipment failure cannot be repaired within a short period of time, or when the repair cost is high and the period is long, and production or operation is urgently required to continue, alternative equipment can be considered to temporarily maintain operation continuity. The premise of using alternative equipment is that the alternative equipment itself must comply with the relevant national safety standards and industry norms to ensure that it does not pose potential risks to personnel safety and equipment in the process of its use.
A thorough and detailed safety check and functional verification must be carried out by professional personnel before it is formally put into use. This includes, but is not limited to, confirming whether the functional indicators of the alternative equipment meet the standards, whether the operating interface is friendly and easy to use, and whether the interface connection with the original equipment is tight and reliable. At the same time, it is also necessary to ensure that the consumables and accessories used in the replacement equipment are purchased through formal channels, are of reliable quality, and meet environmental and health standards.
During the use of alternative equipment, the relevant management department should carry out continuous monitoring and management, regular review and maintenance work, to prevent new safety hazards or accelerate the damage of the original equipment due to short-term use of alternative equipment. Once the repair of the original equipment is completed, the use of the alternative equipment should be stopped immediately, and the acceptance and handover of the original equipment should be carried out according to the normal process to ensure the safety and stability of the whole production and operation process.
For operators of alternative equipment, they are not only required to have corresponding operation qualification certificates or skill certificates to prove that they have the professional skills and knowledge to handle the equipment, but also to receive detailed safety education and job training before actual operation. Such training should cover the structural principles of the equipment, operating procedures, emergency response, etc., so that operators fully understand and master the functions of the alternative equipment and operating methods.
In addition, the end of the training should also be examined or evaluated to confirm whether the operating personnel have really reached the required skill level, and only qualified personnel can be formally on duty to operate alternative equipment. In practice, the enterprise should also organize regular retraining and assessment to ensure that the skills of the operators are always compatible with the requirements of the alternative equipment, to minimize the risk of operational errors, to ensure the safety and efficiency of production operations.
At the end of the operation, the operator should turn off the power supply of the crane in accordance with the relevant operating procedures and safety standards to ensure that the equipment is in a safe state and avoid accidents caused by misoperation. Operators also need to use the sling for proper storage, to avoid injuries or equipment damage caused by sling mess. Conduct a comprehensive and detailed inspection of the crane, including but not limited to structural components, electrical system, hydraulic system, lubrication system, etc., to ensure that it is in good working condition.
At the end of the operation, the operator needs to carry out a comprehensive organization and cleaning of the operating site, tools and equipment back to the position. This is not only conducive to keep the work area neat and orderly, convenient for the next operation to carry out quickly, but also effective in preventing safety hazards caused by lost or dislocated tools. During the process of tidying up and closing down, the operator should make sure that all equipment and tools have been returned to their correct positions and are in a safe condition.
In order to ensure effective maintenance and troubleshooting of equipment, operators need to keep detailed records of the work process and equipment status. This not only helps to identify and deal with problems in time, but also provides an important basis for preventive maintenance of the equipment. In the shift handover, the operator should inform the successor of the operation records and equipment status in detail to ensure the accuracy and completeness of the information transfer. At the same time, it is also necessary to provide safety guidance and reminders to the successor, so that he or she understands the safety precautions and potential risks in the process of operation, and ensures the safety and smooth progress of the next operation.
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