Arching and reinforcement scheme for double-girder overhead crane

 As an important equipment in industrial production, the stability and safety of double girder overhead cranes are directly related to production efficiency and personnel safety. However, in the process of carrying heavy loads and frequent operation for a long time, some cranes have arching phenomenon, which not only affects the normal operation of the equipment, but also sows potential safety hazards. The emergence of arching problems is often accompanied by a decline in structural strength, so it is particularly important to find and implement effective reinforcement programs. In this paper, we will discuss the detection and analysis methods of double girder overhead travelling crane arching problems, and on this basis, we propose a set of scientific and reasonable reinforcement program, which aims to provide a strong guarantee for the smooth progress of industrial production.

Project background and crane technical parameters

In modern industrial production, double girder overhead travelling crane as a key equipment for heavy material handling, its structural stability and safety is crucial. This project analyzes and reinforces the arching phenomenon of double girder overhead travelling crane in a factory. Double girder overhead travelling crane plays a key role in industrial production due to its advantages of large span, high strength and good stability, especially in large factories, ports, yards and other scenarios where heavy materials need to be handled frequently, its efficient and safe operation is of decisive significance to maintain the stability of the production line and the efficiency of logistics.

The double girder overhead travelling crane in this project showed obvious arching phenomenon during actual operation. Arching phenomenon refers to the upward or downward bending deformation of the main girder when the crane is lifting or lowering heavy loads, which may lead to structural instability in serious cases, not only affecting the normal operation of the equipment, but also causing safety accidents. In view of this, the project team has thoroughly studied the design drawings and technical parameters of the crane, combined with the actual situation on site, and formulated a set of perfect reinforcement program aimed at improving the structural stability of the crane, eliminating potential safety hazards, and ensuring its long-term stability and efficient operation.

The main technical parameters of the crane include: span of 30 meters, lifting height of 16 meters, rated lifting capacity of 50 tons, working environment temperature range of -20 ℃ to 40 ℃, and need to withstand frequent heavy-duty operations. These parameters not only reflect the crane's strong load-bearing capacity and flexible operating range, but also its structural design, material selection and manufacturing process put forward strict requirements. However, in the actual operation process, due to the influence of various factors, such as long time high load operation, wear and tear of parts, improper maintenance, etc., resulting in the emergence of arching problems. The emergence of arching phenomenon not only affects the normal operation of the crane, but also poses a potential threat to productivity and safety. Therefore, this project aims to solve this problem by reinforcing the crane to ensure its long-term stable and efficient operation.

Crane main technical parameters table

Technical Parameters	Value/Description
Crane Type	Double girder overhead crane
Span	30 meters
Lifting height	16 meters
Rated lifting capacity	50 ton
Main application scenarios	Large factories, ports, cargo yards
Design Features	Large span, high strength, good stability
Frequently asked questions	Arching phenomenon (bending deformation of the main beam)
Reinforcement purpose	Improve structural stability and eliminate safety hazards

Crane Arching Problem Analysis and Reinforcement Solutions

Dimension of analysis	Description
Definition of Arching	Upward or downward bending deformation of the main beam when the crane is lifting or lowering a heavy load
Causes of arching	Prolonged high load operation, wear and tear of parts, improper maintenance, etc.
Arching effects	Affects the normal operation of the equipment and may cause safety accidents
Basis for the development of the reinforcement program	Design drawings, technical parameters, actual site conditions
Reinforcement program objectives	Eliminates arching and improves structural stability
Expected effects of reinforcement	Ensure long-term stable and efficient operation of cranes

Detection and Analysis of Arching Problems

Detection and Measurement of Arching Problems

The discovery of the arching problem comes from the careful observation and rigorous measurement of the crane structure. With rich experience and professional knowledge, the technicians quickly captured the obvious upward bending phenomenon in the span center of the crane main girder through visual observation, which is the so-called “arching” problem. In order to accurately quantify the extent of this phenomenon, the technicians used advanced laser rangefinders and displacement sensors for accurate measurement.

During the measurement process, the technicians set up measurement points in the middle of the main girder span, 1/4 span and the end section, and recorded the displacement changes at each point under static and dynamic loads. These data clearly showed that the upward displacement of the mid-span part under the maximum working load reached 20 millimeters, far exceeding the safety standard. This finding provides strong data support for the subsequent mechanical analysis and calculation.

Mechanical Analysis and Calculation of Arching Problem

Based on the detected data, the technicians carried out in-depth mechanical analysis and calculation. They found that the arching problem is mainly caused by two reasons: firstly, the crane has been subjected to heavy loads for a long time, resulting in fatigue accumulation of the metal structure; secondly, the crane has been subjected to uneven loads and vibrations in the course of use, which further aggravates the deformation of the structure.

In order to reveal the mechanical mechanism of the arching problem more intuitively, the technicians used advanced finite element analysis software to model and simulate the crane structure. By simulating the stress distribution and deformation under different working conditions, they found that the simulation results were highly consistent with the actual test results, which further verified the mechanical mechanism of the arching problem. Through these analyses and calculations, the technicians were able to more accurately predict and prevent the occurrence of the arching problem, providing a strong guarantee for the safe use of the crane.

Selection and Design of Reinforcement Options for Crane Structure Arching Problems

Overview and selection of existing reinforcement methods

In the existing reinforcement technology for crane structure arching problem, it mainly includes welding reinforcement, bolting reinforcement and prestressing reinforcement and other common programs. The advantage of welding reinforcement is its high strength, which can effectively resist the arching deformation, but this method also has obvious limitations. Welding stresses and high temperatures generated during the welding process may cause irreversible damage to the original structure, affecting the overall performance and service life of the structure. In addition, welding operations usually need to be carried out on site, making it difficult to ensure the consistency and controllability of construction quality.

Compared with welding reinforcement, the bolted reinforcement method is characterized by convenient construction and easy operation. However, this method also has certain limitations. Bolted connections may loosen during long-term use due to vibration, impact and other factors, thus affecting the reinforcement effect and the stability of the structure. In addition, the strength of bolted connections is usually lower than that of welded connections, which may make it difficult to achieve the desired reinforcement effect for large or heavy crane structures.

Considering the reinforcement effect, construction difficulty, cost and long-term stability, the project decided to adopt the prestressing reinforcement method as the main reinforcement program. By applying prestressing force inside the structure, pre-stressing reinforcement can make the structure produce anti-arch effect under the action of external force, so as to offset the arching deformation and improve the stiffness and stability of the structure. Compared with welded and bolted reinforcement, prestressing reinforcement has higher strength and stability, while the construction difficulty and cost are relatively low.

Comparison Chart of Reinforcement Methods

Improved Prestressing Tension Reinforcement Methods

The traditional pre-stressing reinforcement method, although effective, still has some limitations in practice. In order to further improve the reinforcement effect and construction efficiency, this project proposes an improved prestressed string tensioning reinforcement method. The method adopts high-strength steel strands as prestressing tendons, which have high strength and durability and can better meet the reinforcement requirements.

At the same time, adjustable tensioning devices are set at both ends of the strand to realize accurate reinforcement of the crane structure by precisely controlling the tension force and direction. The adjustable tensioning device can be adjusted according to the actual demand, making the tensioning process more flexible and accurate. In order to ensure that the reinforcement effect meets expectations, real-time monitoring of structural deformation and prestress changes during the tensioning process. Through the analysis of the monitoring data, the tensioning parameters can be adjusted in time to ensure that the structural deformation is effectively controlled.

In addition, we also adopted optimized design and construction process to further improve the reinforcement effect and construction efficiency. Through finite element analysis and other means of fine simulation and analysis of the structure, a more reasonable reinforcement scheme is formulated. A series of measures are taken during construction to minimize the interference and damage to the original structure. For example, advanced cutting and fixing techniques are used to minimize damage to the structure, and computer-aided design and robotic construction techniques are used to improve construction accuracy and efficiency.

Prestressed string reinforcement method flow

Implementation and operation of crane reinforcement program

Preparation before reinforcement

Before reinforcing the crane, a comprehensive and detailed inspection must be carried out. First of all, the structure of the crane is thoroughly inspected to ensure that the structure is intact and free from any potential safety hazards. Key components such as main beams, supporting structures and connecting parts are thoroughly inspected to make sure that there are no cracks, deformations or other defects that may affect the reinforcement effect. In order to formulate a scientific and reasonable reinforcement program, it is necessary to conduct a comprehensive and in-depth analysis based on the inspection results and the actual condition of the crane, combined with relevant design codes and standards. On this basis, the development of a targeted, practical and feasible reinforcement program. The program should elaborate the specific steps of construction, methods, precautions and expected results. Technical briefing for the construction team, so that it fully understands the specific content of the reinforcement program, mastering the reinforcement methods and operational procedures. Ensure that the construction process can be carried out in strict accordance with the requirements of the program to ensure the safety and quality of the construction process.

Installation and tensioning of reinforcement devices

In the installation process of the reinforcement device, the process requirements must be strictly followed. First of all, the anchorage and tensioning device of prestressing tendons are set in the span center part of the crane main beam. The anchorages of the prestressing tendons should be installed accurately to ensure a close fit with the main girder structure without any gap or looseness. The tensioning device should have sufficient strength and stability to effectively transmit the prestressing force. Pass the high-strength strand through the anchorage and connect it to the tensioning device. During the tensioning process, adopt a graded tensioning method to gradually increase the tensioning force. After each stage of tensioning, it should be kept for a period of time to observe the deformation of the structure and the change of prestress. The structural deformation and prestress change are monitored at the same time to ensure that the tensioning process is smooth and controllable.

Adjustment and acceptance after reinforcement

After the reinforcement is completed, the crane is fully inspected and adjusted. First, ensure that all reinforcement devices are installed correctly and the tensioning force meets the design requirements. Conduct dynamic and static load tests on the crane to verify the reinforcement effect. In the dynamic load test, simulate various load situations under actual working conditions, and observe the crane's operating status and performance indexes under dynamic conditions. The dynamic load test can assess the load carrying capacity and stability of the reinforced crane, as well as whether the working condition of each component is normal. In static load test, static load is applied to the crane to observe its deformation and stress distribution under static load. The static load test can assess whether the stiffness and strength of the reinforced crane meet the design requirements. The test results show that the displacement change in the span center of the main beam of the reinforced crane is significantly reduced, and the structural stability is significantly improved. It meets the expected target of reinforcement effect.

Reinforcement Effect Evaluation and Long-term Stability Guarantee

Evaluation Method of Reinforcement Effect

The assessment of reinforcement effect is mainly based on the indicators of structural deformation, stress distribution and bearing capacity. Laser range finder and stress-strain sensor are used for long-term monitoring of the reinforced crane structure. The monitoring data are regularly collected and analyzed to assess whether the reinforcement effect meets the expectation, and potential problems are detected in time. At the same time, according to the assessment results, optimize and adjust the parts that do not meet the expected effect, and re-monitor and assess until the requirements are met.

Long-term Stability Guarantee Measures

To ensure the long-term stability of the reinforcement effect, the following measures are taken:

First, a regular inspection and maintenance system is established to carry out regular inspection and maintenance of the reinforcement device to ensure that it is in good working condition. At the same time, regular inspections of the crane structure are carried out to detect and deal with potential problems in time.

Second, strengthen the training and management of crane operators, improve the skill level and safety awareness of operators, and avoid overloading and improper operation. At the same time, establish operating procedures and record systems to record and manage the operation process to ensure that the operation meets the specification requirements.

Third, establish a structural health monitoring system to monitor the status of the crane structure in real time, including structural deformation, stress distribution and bearing capacity and other indicators. Through real-time monitoring data, potential problems are found and dealt with in time to ensure the long-term stability of the reinforcement effect and the safe operation of the crane. At the same time, based on the monitoring results, the reinforcement effect is continuously evaluated and optimized and adjusted.

Long term stability assurance strategy diagram

Arching and reinforcement scheme for double-girder overhead crane

Metallurgical Crane Retrofit Construction Program

 Metallurgical crane as a key equipment in industrial production, its performance and safety directly affect the production efficiency and operational safety. With the continuous progress of technology and production demand, it is particularly important to renovate and upgrade the existing metallurgical cranes. This construction program aims to improve the crane's load-bearing capacity, operational stability and intelligence level through systematic renovation measures, so as to meet the high standard requirements of modern production. The transformation process will cover a variety of aspects from pre-construction preparation to construction steps, quality control, safety and maintenance, etc., to ensure that the transformation project can be carried out smoothly and achieve the expected transformation effect.

Construction program overview and objectives

Metallurgical cranes, as the key equipment in the fields of iron and steel smelting, heavy material handling, etc., their performance and safety directly affect the production efficiency and personnel safety. Therefore, it is particularly important to carry out a comprehensive assessment and upgrade of the metallurgical crane retrofit construction program. The purpose of this retrofit construction program is to comprehensively evaluate and upgrade the existing metallurgical cranes to improve their load-bearing capacity, handling accuracy and operational stability, and at the same time, strengthen the safety performance, to ensure that the equipment maintains a highly efficient and reliable state in the long-term operation.

The goal of this renovation program is to realize the efficient operation of cranes in complex operating environments, reduce the failure rate, extend the service life of the equipment, and provide a solid guarantee for the safe production of the enterprise. Through the transformation of metallurgical cranes, the reliability and safety of the equipment will be improved, maintenance costs will be reduced and production efficiency will be increased. During the transformation process, the structure, electrical system, hydraulic system and lubrication system of the equipment will be comprehensively evaluated and upgraded to ensure that the performance indexes of the equipment meet the national standards and requirements of the enterprise.

Overall framework of the construction program

Pre-construction preparation and evaluation

Existing equipment condition assessment

Before construction, the first need for metallurgical cranes to carry out a comprehensive and detailed assessment of the current situation. This stage aims to accurately grasp the actual operating conditions of the equipment, to provide a scientific basis for the subsequent transformation design, construction program development and equipment maintenance. The assessment work covers a number of key aspects:

• Main Structure Inspection: Conduct a comprehensive inspection of the metal structure of the crane, including but not limited to the main girder, end girder, running rail and other major load-bearing components. These parts are inspected for fatigue deformation, cracks, weld quality problems or serious corrosion, etc. Potential structural hazards are revealed through non-destructive testing techniques such as ultrasonic testing and magnetic particle testing.
• Transmission system assessment: the transmission system is the core part of the work of metallurgical cranes, including motors, reducers, couplings, brakes and other components. It is necessary to check the working efficiency of each component, such as whether there is excessive wear, poor lubrication, loose fasteners and other problems, to ensure that it can maintain stable and reliable operation in high-intensity work.
• Electrical control system analysis: Evaluate the working condition of the electrical control system, including the control system cabinet, frequency converter, sensors, contactors and other key components. Confirm whether they meet the design requirements and whether there are problems such as aging, damage or performance degradation to ensure that the crane's automated operation and safety protection functions operate normally.
• Verification of safety devices: Check and test all kinds of safety protection devices, such as overload protection, travel limit switches, emergency stop buttons, anti-collision devices, etc., to ensure that these devices are able to play the expected protective role at critical moments and effectively prevent accidents from occurring.

Through the above professional and exhaustive assessment process, first-hand data on the current condition of metallurgical cranes can be collected, providing precise input conditions for the subsequent retrofit design program, ensuring that the retrofitted cranes can better adapt to the production requirements, while guaranteeing their safe, efficient and stable operation.

Construction Team Formation and Training

During the pre-construction preparation phase, an experienced and skilled construction team needs to be carefully assembled. The team members should cover a wide range of specialties, including but not limited to mechanical engineers, electrical engineers and safety supervisors and other key roles. The team members should have rich experience in metallurgical crane retrofitting and be able to accurately understand and implement the requirements of the relevant retrofitting program.

To ensure the efficiency and safety of the construction process, all team members must receive rigorous training and education prior to construction. The training shall include, but not limited to, the specific implementation steps of the retrofit program, detailed description of the operation process, as well as the learning and rehearsal of safety norms and emergency handling measures. Through training, team members should be able to familiarize themselves with the key aspects and technical requirements of the retrofit project to ensure that they are able to operate in strict accordance with the specifications during the construction process to avoid potential safety risks and quality problems.

In addition, team members need to understand and familiarize themselves with relevant safety regulations and operating procedures, including but not limited to safety management regulations at the workplace, proper operation of equipment, and emergency handling procedures in case of emergency. The learning and mastery of these knowledge can help reduce the safety risks and quality problems during the construction process and ensure the smooth progress of the construction process.

Through scientific and reasonable team formation and rigorous and meticulous pre-construction training, the construction efficiency and quality level can be effectively improved to ensure the successful implementation of the metallurgical crane renovation project. At the same time, this also helps to ensure the safety and quality of the construction process, laying a solid foundation for subsequent production and operation.

Construction team members and responsibilities

Team members	Area of specialization	Main responsibilities
Mechanical engineer	Mechanical engineering	Responsible for the inspection of the main structure of metallurgical cranes, evaluation of the drive train and implementation of the mechanical part of the retrofit program.
Electrical Engineer	Electrical engineering	Responsible for electrical control system analysis, selection and installation of electrical components, and commissioning of automation operations
Safety commissioner	Security engineering	Responsible for verification of safety devices, safety supervision during construction and development and implementation of emergency measures.
Project manager	Project management	Responsible for the overall project schedule control, resource allocation and communication and coordination with all parties.
Quality Inspector	Quality management	Responsible for quality inspection and acceptance during the construction process to ensure that the construction quality meets the design requirements and national standards.

Pre-construction key tasks and responsible persons

Mission content	Person in charge	Key points
Assessment of the current situation	Mechanical Engineer, Electrical Engineer	Comprehensive inspection of the main structure, transmission system, electrical control system, and safety devices
Team Formation	Project manager	Formation of a construction team with experts in various fields, such as mechanical, electrical, safety, etc.
Team Training	Safety Supervisor, Project Manager	Training on the implementation steps of the retrofit program, operational procedures, safety norms and emergency response measures
Procurement of materials	Project Manager/Purchasing Specialist	Procurement of key components such as high-strength steel, wear-resistant bearings, advanced electrical components, etc., to ensure quality
Tool Preparation	Project Manager/Tool Manager	Prepare tools and equipment such as cranes, welding machines, electric wrenches, etc., and inspect and maintain them

Construction materials and tools preparation

During the pre-construction preparation phase, it is necessary to purchase all types of materials needed in advance according to the specific requirements of the retrofit program. These materials include, but are not limited to, high-strength steel, wear-resistant bearings, advanced electrical components and other key components. During the procurement process, the quality of materials should be strictly controlled to ensure that all materials comply with national standards and design requirements. At the same time, adequate construction tools and equipment, such as cranes, welding machines, electric wrenches, etc., need to be prepared. These tools and equipment need to be carefully inspected and maintained to ensure that they can operate normally and are safe and reliable in the construction process.

Remodeling Construction Steps and Processes

Demolition and Cleanup

Before starting any remodeling work, it is important to ensure that safety measures are strictly in place. For crane dismantling work, the first step is to turn off the power and disconnect all electrical connections to prevent accidental starting or risk of electric shock. The crane is then dismantled step by step according to a carefully pre-planned dismantling sequence. During the disassembly process, special attention should be paid to protecting the surrounding environment, preventing debris generated during disassembly from splashing and injuring people, and avoiding pollution or damage to the surrounding environment.

After the disassembly of the components is completed, it is necessary to carry out a thorough cleaning process for each of the dismantled components. This includes the removal of oil, rust, and other impurities that may affect the performance of the component. Thorough cleaning provides a good basis for subsequent replacement, upgrading and maintenance work, ensuring that these parts can be reassembled into an efficient, safe and reliable crane.

Replacement and upgrading of key components

After the disassembly and cleaning work is completed, the critical components identified in the assessment report as having severe wear and degraded performance will be replaced one by one. These components may include, but are not limited to, driveshafts, gearboxes, brakes, etc. The replacement of these components will be carried out in accordance with the manufacturer's specifications or industry standards to ensure the compatibility and matching of the new components with other components of the original crane.

In addition to upgrading and replacing the original components, the main structure of the crane will be strengthened as necessary. This may involve welding, grinding, repairing or replacing structural components to enhance their load-bearing capacity and service life. Meanwhile, for the crane's electrical control system, advanced frequency conversion speed control system, PLC control system and other modern technologies will be introduced to achieve more precise control and higher operational efficiency.

Control system modification and optimization

During the renovation and construction process, the electrical control system of the crane is comprehensively and meticulously upgraded. Advanced control algorithms and sensor technology are adopted to realize intelligent control and management of the crane. By optimizing the control logic, the response speed and stability of the crane are improved, so that it is more accurate and efficient in performing operational tasks. At the same time, it reduces unnecessary operation steps and the incidence of faults, and improves the overall operational efficiency.

In order to realize the remote monitoring and fault diagnosis function, it is necessary to deploy the corresponding communication network and data processing equipment in the transformation process. Operation and maintenance personnel through real-time access to the crane's operating data and status information, can quickly locate and solve potential problems, thereby greatly improving the efficiency and accuracy of equipment maintenance. This remote monitoring and fault diagnosis function can not only prevent the occurrence of equipment failure, but also effectively reduce maintenance costs and improve the target of maintenance.

Safety device installation and commissioning

In the transformation construction process, special attention is paid to the installation and commissioning of safety devices. This is because the safety device is a key component for safeguarding the safety of personnel and equipment during crane operation. During the renovation process, all kinds of safety protection facilities such as fall prevention devices, limit switches, overload protection devices, etc. will be updated in accordance with the latest safety standards and regulatory requirements.

Rigorous testing and calibration work is required for the updated safety devices. This includes verifying the effectiveness of the fall arrest device to ensure that it can reliably stop the fall of the spreader in case of emergency; carrying out several tests on the limit switch to verify its accuracy and stability of operation; and carrying out loading tests on the overload protection device to ensure that it can give a timely alarm and take protective measures when it detects an overload, and so on. Only after strict testing and calibration of the safety devices can be put into use to ensure that the modified crane fully meets the requirements of the relevant national safety standards.

Construction Quality Control and Safety

Quality Control Standards and Measures

In the remodeling project, in order to ensure the quality of the construction process and final results, a series of high-standard quality control standards and measures must be formulated and strictly implemented. First of all, these standards should cover all aspects of the project, including but not limited to material procurement and acceptance, construction process, quality control testing items and evaluation methods, etc., to ensure that the entire renovation process is in strict compliance with relevant national laws, regulations and industry norms, and to realize a seamless transition from the design blueprints to the actual implementation. During the construction process, a comprehensive and rigorous inspection and acceptance system must be implemented, and the key processes and hidden works should be supervised from the side to ensure that each link meets the predetermined requirements. At the same time, the construction details and acceptance information of all key processes and hidden works are kept through detailed records for later review and traceability, providing a strong guarantee for the durable and stable operation of the whole renovation project.

Construction safety management system and standardization

The establishment of a sound construction safety management system and norms is the cornerstone to ensure the safety of the renovation project. First of all, it is necessary to clarify the safety responsibilities and operating procedures of all construction personnel to ensure that each personnel is clear about his or her own scope of responsibility and operating requirements. Through regular safety education and training and skills training, improve the safety awareness of all construction personnel to ensure that they have the necessary safety knowledge and operational skills. At the same time, set up a specialized safety supervision team, responsible for conducting regular comprehensive and detailed safety inspections and assessments of the construction site. The supervision team should pay close attention to the environment, equipment, personnel and other aspects of the construction site, timely detection and elimination of potential safety hazards, to ensure that the construction process is carried out in a safe and orderly manner.

Construction process monitoring and recording

Adopting advanced monitoring technology to monitor and record the construction process in real time is an important means to ensure the quality and safety of the remodeling project. Through the installation of high-definition cameras, intelligent sensors and other advanced equipment at the construction site, the dynamic image of the construction site, temperature, humidity, wind speed, vibration and other parameters can be obtained in real time to provide a strong guarantee for the standardization and safety of the construction process. At the same time, the establishment of a specialized construction record file, the construction process of important events, key data, inspection and acceptance of the results of the detailed information recorded, for the subsequent acceptance of the work to provide a reliable basis.

Construction Acceptance and Maintenance

Acceptance criteria for transformation effect

After the completion of crane transformation, in order to ensure that it can be safely and efficiently put into use, it is necessary to develop a set of detailed and rigorous acceptance criteria and procedures. First of all, from the bearing capacity to carry out rigorous testing, through scientific methods to verify whether the transformed crane can withstand the intended load weight, and to ensure that in a long period of high-intensity operations can still maintain a stable performance. Secondly, the handling accuracy of the crane is finely calibrated to check whether the operating systems are sensitive, reliable and responsive in order to minimize operating errors and improve operational efficiency and safety. In addition, it is necessary to carry out comprehensive and detailed functional tests on the crane's safety devices, including but not limited to limit switches, overload protection, emergency stop devices, etc., to ensure that in the event of an abnormal situation, the power source can be quickly cut off or issue warning signals to effectively prevent accidents.

After completing the above series of professional tests, it is also necessary to invite qualified third-party testing organizations to carry out independent and objective testing and evaluation of the retrofitted crane. Such a practice aims to ensure the fairness and accuracy of the acceptance results and avoid misjudgment caused by subjective factors or improper operation. The third-party testing organization will review the performance indicators of the crane in accordance with relevant national regulations and industry standards, and issue an authoritative test report to provide strong data support for the final confirmation of whether the crane meets the design requirements and national standards.

Post maintenance and upkeep plan

In order to ensure the stability and safety of crane performance in the long-term use of the process, it is necessary to develop a comprehensive post maintenance and maintenance program. First of all, the crane should be regularly maintained and maintained, including lubrication, fastening, cleaning and other work. Lubrication is an important measure to ensure the normal operation of the crane components, regular inspection and replacement of lubricants can effectively reduce friction and wear, and extend the life of the equipment. Fastening work is also essential, due to vibration and load pressure, bolts, nuts and other connecting parts may be loose, timely inspection and fastening of these parts can prevent mechanical failure caused by loosening. Keeping the crane clean is also very important, regular cleaning of dirt and dust on the surface of the equipment can improve the appearance of the equipment aesthetics, but also helps to dissipate heat and reduce wear and tear.

In addition to regular maintenance and repair, it is also necessary to establish an equipment maintenance file. By recording the details of each maintenance and repair, including information on replaced parts, repair history, troubleshooting, etc., it can provide a strong guarantee for the long-term operation of the equipment. These records can not only facilitate managers to understand the condition and maintenance history of the equipment, but also provide a reference and basis for subsequent repair and maintenance. Through the implementation of these measures, it can ensure that cranes maintain stable performance and safety during long-term use.

Metallurgical Crane Retrofit Construction Program

Special construction program for electric double girder overhead cranes

 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.

Construction program overview

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.

Overall framework of construction plan

Project Overview and Construction Conditions

Project Background and Importance

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.

Construction environment analysis

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.

Technical Requirements and Standards

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.

Construction Organization and Management

Construction process and management process

Construction Team Formation and Assignment of Duties

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.

Construction progress plan and node control

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.

Quality control and safety supervision

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.

Electric Double Girder Overhead Crane Installation and Construction

Equipment Selection and Inspection

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.

Installation process and technology

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.

Commissioning and testing

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.

Specialized construction program design and implementation

Foundation design and construction

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.

Crane main structure installation

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.

Electrical system installation and commissioning

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.

Safety Risk Assessment and Response

Safety Risk Identification and Assessment

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

Countermeasures and Pre-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.

Safety monitoring and emergency response

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.

Construction quality management and acceptance standards

Quality Management Process and System

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.

Acceptance standards and procedures

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.

Quality problems and corrective measures

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.

Special construction program for electric double girder overhead cranes