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.
Safety tools and labor protection products
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.
Safety warning to prevent the operation of man and machine in the same vehicle
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.
Night operation and lighting requirements
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.
Windy weather operation regulations
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
Troubleshooting and alternative equipment use
Equipment fault reporting and repair process
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.
Alternative equipment use regulations and inspections
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.
Qualification Requirements for Operators of Substitute Equipment
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.
End-of-operation and organization
End-of-operation procedures and requirements
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.
Tidy up and return equipment to its place
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.
Work Records and Shift Handover Regulations
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.
Standardized operation instructions for railway overhead cranes and gantry cranes