1.1. To the control of hoists and rigging work Persons at least 18 years of age who have been specially trained and certified in accordance with the above Rules and who have a mark to this effect on their knowledge test certificate may be admitted.
1.2. Lifting mechanisms (hoists, winches) must be maintained and operated in accordance with the "Rules for Construction and Safe Operation" lifting cranes" and "Rules safe work with tools and accessories."
1.3. Hoists in use must indicate the name of the enterprise, inventory number, load capacity and the date of the next technical examination.
1.4. Repair and maintenance of electric hoists must be carried out by electrical personnel with a group not lower than III. Workers of the main professions, which by the nature of the work performed are related to the operation of hoists, must be trained in a related profession according to a special program. They must be certified by the qualification commission and the certificate contains a record of permission to perform slinging work.
1.5. The housings of electric hoists must be grounded. The body of the push-button control device of a hoist controlled from the floor must be made of insulating material, or grounded by at least two conductors, a cable on which the push-button device is suspended can be used as one of the grounding conductors.
1.6. Launchers manual control hoists must be suspended on a steel cable of such length that the mechanism can be controlled while being at a safe distance from the load being lifted. If the control device is located less than 0.5 m from the floor, it should be suspended on a hook attached to a cable at a height of 1-1.5 m.
1.7. Electric hoists must be equipped with limit switches to automatically stop the hoisting mechanism lifting body. When lifting a load with electric hoists, it is prohibited to bring the hook cage to the limit switch and use the latter for automatic stopping.
1.8. Electric hoists must be equipped with two brakes: electromagnetic and load-resistant. The braking reserve coefficient of an electromagnetic brake must be at least 1.25, and of a load-bearing brake 1.1. Electric hoists must be equipped with a load limiter and a lower position limiter for the hook suspension.
1.9. The lifting mechanism of manual hoists must be equipped with an automatic load-bearing brake. The brake must ensure smooth lowering of the load when the traction wheel rotates under the influence of traction force and automatic stopping of the load when its action ceases. 1.10. It is prohibited to attach hand hoists to pipelines and their hangers.
1.11. Testing of stationary hoists is carried out at the site of their installation; portable hoists for testing are suspended from a tripod or some other structure.
1.12. Hoists must undergo a full technical inspection at least once every 12 months.
1.13. An extraordinary full technical examination of lifting mechanisms should be carried out after their reconstruction or repair metal structures mechanisms with replacement of design elements or units, overhaul or changing mechanisms, replacing a hook.
1.14. The technical examination must be carried out by an engineer and technical worker who supervises lifting mechanisms at the enterprise, with the participation of the person responsible for their good condition.
1.15. Static testing of lifting mechanisms is carried out with a load 25% greater than their rated lifting capacity in order to check the strength of the mechanisms and their individual elements. In a static test, the test load is raised to a height of 100 mm and held in this position for 10 minutes.
1.16. A lifting mechanism that can withstand the static test is subjected to a dynamic test.
1.17. Dynamic testing of a lifting mechanism must be carried out with a load 10% greater than the rated lifting capacity of the mechanism in order to check the operation of its brakes.
The braking reserve coefficient, depending on the operating mode and type of mechanism drive, should be 1.5-2.5.
1.18. Dynamic tests consist of repeated (at least 6 times) raising to a height of at least 1 m and lowering the test load.
1.19. During dynamic tests, brakes, limit switches, and smooth operation of the load and traction chains are checked. In case of detection of runs, skipping or sliding of the chain on the sprocket and traction wheels, the hoists are rejected.
1.20. When dynamically testing electric hoists, the operation of the brakes must be checked separately. To check the brakes during operations, the mechanisms must be stopped at least 3 times in each direction.
1.21. During dynamic testing of hoists, all operations must be carried out 2 times, and the action of the lower position limiter of the hook suspension must be checked.
After completion of the tests, the load limiter must be adjusted and its operation checked.
1.22. When testing hoists, spontaneous lowering of the load should not be observed. If cracks, ruptures and deformations are detected, the hoists are rejected.
1.23. It is allowed to carry out dynamic testing of electric hoists with a load exceeding 25% of their rated load capacity. In this case, it is permitted not to carry out a static test.
1.24. The date and results of the technical examination of the lifting mechanism are recorded by the person who carried out the examination in the mechanism’s passport, indicating the date of the next examination, as well as information about the repairs performed.
1.25. Before putting into operation, after major repairs and periodically, but at least once a year, the insulation resistance of the electrical equipment of the hoist must be measured with a 500 V megger. The insulation resistance must be at least 0.5 MOhm.
1.26. Electrical equipment of hoists with an insulation resistance of less than 0.5 MOhm must be dried.
2. Safety requirements before starting work.
2.1. The location of the hoist must be determined in such a way that there is sufficient space for visibility working area and maneuvering.
2.2. The mass of loads to be lifted must be determined before lifting. The load on lifting mechanisms should not exceed their lifting capacity.
2.3. For loads that have special devices (hinges, axles, frames) designed to lift the load in various positions, their slinging schemes must be developed.
2.4. The condition of hoists must be checked before each use.
2.5. Before starting work, the electrical steel must be inspected.
In this case, attention should be paid to their cleanliness, the presence of lubrication, the condition of the chains, ropes, gear teeth and sprockets, the serviceability of the cotter pins or rivets at the ends of the main axis, the reliability of the chains on the sprockets and the fastening of the rope to the drum, wear of the rolling surface of the running rollers, the distance between roller flanges and the outer edges of the monorail track, the serviceability of the electromagnetic brake of electric hoists and the degree of wear of friction pads: the condition of electric motors, electrical wiring and contacts, control devices, pantographs and limit switches, the absence of jamming of mechanisms and slippage of chains, as well as the level of noise arising during the operation of hoists .
The teeth of sprockets and gears, as well as chains, should not have cracks, burrs or dents on the surface; plate chains must be movable in all articulated joints.
2.6. If defects are detected, defective units and parts must be replaced before work begins.
3. Safety requirements during operation.
3.1. The place where lifting and moving loads is carried out must be well lit during work.
At insufficient lighting place of work, heavy snowfall, fog, as well as other cases when the person servicing the hoist cannot clearly distinguish the signals of the slinger or the load being moved, the operation of the hoist must be stopped.
3.2. The supply of electrical voltage to the lifting mechanism from an external power supply must be carried out using an input device that has a manual and remote control to relieve tension.
3.3. Cargo hooks for loads over 3 tons must be made rotating, with the exception of special-purpose hooks.
Load hooks from the mouth of which removable lifting devices may fall out during operation must be equipped with a safety lock.
3.4. Lifting a load for which slinging schemes have not been developed must be carried out in the presence and under the guidance of an employee responsible for the safe performance of work with cranes.
3.5. Loads suspended from the hook of a lifting mechanism must be securely tied with ropes so that during their movement the fall of individual parts (boards, scaffolding, pipes, etc.) is prevented and a stable position of the load is ensured during movement. Slinging of long loads should be done with a double sling, and in the case of vertical lifting - with a sling with a safety clip.
3.6. In the cargo handling area, all openings must be closed or fenced and safety warning signs posted.
3.7. When moving the load horizontally, it must first be lifted 0.5 m above objects encountered along the way.
3.8. Loads may be lowered to a pre-prepared place where they cannot fall. To make it easier to remove the slings from under the load at the place where it is installed, strong spacers must be placed under it.
3.9. Lower loads onto floors, supports and platforms without preliminary calculation of the strength of the structure and overload them permissible loads prohibited.
3.10. Leaving the load suspended, as well as lifting and moving people using lifting mechanisms not intended for lifting them is prohibited. In the event of a malfunction of the mechanism, when it is impossible to lower the load, the area under the suspended load must be fenced off and posters posted " Dangerous area", "The passage is closed."
3.11. Working with disabled or faulty safety devices and brakes is prohibited.
It is prohibited to simultaneously lift or lower two loads located in close proximity to each other.
3.12. Before lifting, the load must be raised to a height of no more than 300 mm to check the correctness of the sling, the uniform tension of the slings, the stability of the lifting mechanism and the reliability of the brake; only after this the load should be raised to the required height; to correct the sling, the load must be lowered.
3.13. Lifting the load must be done smoothly, without jerking or swinging.
3.14. All rubbing parts of hoists must be lubricated at least once a month.
4. Safety requirements upon completion of work.
4.1. Tidy up after finishing work workplace, turn off all electric motors of mechanisms involved in loading and unloading operations,
remove all devices, slings, auxiliary ropes and put in order the rest of the equipment and tools.
4.2. Report completion of work to the work supervisor.
4.3. Put your overalls in order, remove dust and dirt, and take a shower.
5. Safety requirements in emergency situations.
5.1. In the event of an accident or emergency situation take measures to prevent and eliminate the danger.
5.2. Immediately report to your immediate supervisor any accident that occurs at work, signs of illness, as well as a situation that poses a threat to the life and health of people.
5.3. In case of defeat electric shock it is necessary to immediately release the victim from the action of the current, observing electrical safety requirements, provide pre-medical assistance and call a medical service worker, and notify management.
5.4.If a fire occurs, notify fire department call 01, the work manager and begin extinguishing.
5.5. In the event of an accident, it is necessary to provide first aid to the victim, report the incident to management and, if necessary, call an ambulance.
Below are safety precautions when operating an electric hoist. Full instructions operation manual can be viewed.
General requirements on safety
No matter , what in relation The relevant sections of the Instructions include instructions for safe operation , The following specific requirements must be observed :
- The load must not be lifted or moved above service personnel or other persons.
- The operation of the brakes and limit switch should be checked every day before starting work.
- Lifted loads must not be left unattended.
- The rated load capacity must not be exceeded.
- Do not lift the load at an angle or drag it along the ground.
- It is necessary to check the condition of the load rope and, if necessary, replace it in a timely manner. When replacing, you should pay attention to the strong fastening of its two ends.
- After replacing the cable, as well as after repairing and re-installing the electric hoist, it is necessary to check the phase coincidence and the adjustment of the limit switch at the upper and lower extreme positions of the load hook (clause 4.4).
- When the maximum permissible axial stroke of the electric motor rotor is reached during operation, it is necessary to adjust the brake (clause 5.4).
- When performing maintenance or repair operations on the electric hoist, you should pay attention to the following:release the electric hoist from the load; WithUsing the mains switch, turn off the power supply and prevent it from being turned on by unauthorized persons or accidentally turned on.
- The load hook should be checked for cracks, deformations, and the safety latch is in good working order.
- Carriers should be checked bolted connections to prevent self-unscrewing.
- It is necessary to check the reliability of the connection: the protective conductor of the power cable to the protective busbar of the electrical panel; both ends of the protective conductors of transformer and electric motor cables.
- When using electric hoists with a movement mechanism, buffers should be installed at both ends of the monorail track (clause 4.8).
- In all cases where the command switch is removed, the external metal screws securing it to the enclosure must be re-coated with insulating material.
- The limit switch cannot be used as an operating switch.
- Do not attempt to lift firmly secured loads from the ground (for example, ruses frozen to the ground).
- Extreme positions when lifting and horizontally moving a load can only be used if there is a working limit switch.
Requirements for service personnel
To control the electric hoist, certain workers are assigned to be responsible for this mechanism, and mechanics and electricians are appointed to service and repair them. All specified persons must undergo proper training in accordance with the “Rules for the Design and Safe Operation of Load-Lifting Cranes” and receive the appropriate certificate. The results of certifications and knowledge testing are documented in a protocol and entered into the knowledge testing journal.
Workers of basic professions are allowed to control an electric hoist from the floor or from a stationary console and hang a load on the hook of an electric hoist after appropriate instruction and testing of skills in the manner established at the enterprise.
Repeated testing of individuals' knowledge service personnel(crane operators, electricians, mechanics, slingers) is carried out at least once every 12 months.
Workers of basic professions who service hoists and hook loads to the hook must undergo repeated training at least once every 12 months.
For proper maintenance of load-lifting cranes, the owner is obliged to provide crane operators, mechanics, electricians and slingers with instructions defining their rights, responsibilities and procedures for safe work, taking into account the type of electric hoists, specific operating conditions, maintenance and repair of electric hoists and the requirements contained in the “Rules for the construction and safety of operation of load-lifting cranes."
Work performance and safety precautions
Workers operating the hoist should be located on the side of the open part of the drum. The work area should be well lit and have free passage for maintenance personnel.
The hoist mechanisms are put into operation by pressing the corresponding button on the push-button station; to stop, the pressed button is released.
Ropes, chains and other lifting devices must have the proper load-carrying capacity, have appropriate stamps and tags, and fully meet the requirements of Gosgortekhnadzor. Ropes and chains should be selected in such a length that the angle between the branches does not exceed 90°; an increase in this angle can be allowed only in exceptional cases when the lifting height of the hook does not allow the use of longer shackles and when this excludes the possibility of moving the chucks along the load.
The load must be tied so that the lifting devices do not slip off it. Locating ropes and chains must be applied without knots or loops; Be sure to place pads under sharp ribs to protect ropes and chains from damage. Small loads must be lifted and moved in containers specially designed for this purpose.
A load moved horizontally must be lifted 0.5 m above objects encountered along the way.
When moving the hoist, the swing of the load should be eliminated; when the hoist stops at the moment when the load rope has a maximum deviation from the vertical, it is recommended to briefly turn on the hoist so that its movement coincides with the direction of the load deflection.
To turn long and bulky loads while lifting or moving them, special guys (hooks) of appropriate length must be used.
The load being moved must only be lowered onto a designated place where it cannot fall, tip over or slide. At the place where the load is installed, pads of appropriate strength must first be laid so that the mooring ropes or chains can be easily removed from under the load.
The load must be placed on and removed from the platform and trolley without disturbing the balance.
When lifting a load, it must first be raised to a height of no more than 200-300 mm to check the correctness of the sling and the reliability of the brakes.
Pulse operation should be avoided (very often alternating activations). During operation, it is necessary to monitor the serviceability of both brakes, which must operate simultaneously. After completion or during a break in work, the electric hoist must be unloaded, the switch feeding the hoist must be turned off and locked.
PROHIBITED:
- Paint the surfaces on which the rollers move, the rolling surfaces of the rollers and the articulated connection of the lifting mechanism with the moving mechanisms, since paint interferes with good adhesion of the rollers to the monorail and increases the grounding resistance of the electric hoist through the monorail.
- During work, be under a load between the load and the wall of the house, column, machine, stack, etc.
- Lift a load whose weight exceeds the maximum lifting capacity of the hoist. When using electric hoists for lifting and transporting molten metal, liquid slag Weight Limit the load should not exceed 75% of the maximum load capacity and the requirements of the “Rules for the design and safe operation of load-lifting cranes” must be met.
- Exceed operating hours.
- Simultaneously press buttons that turn on opposite movements of mechanisms, suddenly switch mechanisms to reverse.
- Use limit switches as working bodies to automatically stop mechanisms, bring the hoist to the end stops installed on the monorail.
- Use a hoist to tear off foundations or loads that are covered with earth, frozen to the ground, laid down by other loads or reinforced with bolts; release mooring ropes or chains caught in the load. Lift a load if the rope deviates from the vertical, lift loads suspended on the tip of a hook and in an unstable position, lift a load in a container filled above the sides; move loads in places where falling loads could cause an explosion, fire or other dangerous consequences.
- Unwind a weakened rope on hoists without a rope handler when the suspension is in a non-suspended state; level suspended or moved loads with the weight of people.
- Operate the electric hoist when open closet electrical equipment.
- Install end stops against the cart rollers.
- Work with faulty limiters.
Maintenance
The frequency of inspections and the scope of work are established by the enterprise administration, based on the specific operating conditions of the hoist. It is recommended to carry out inspections at least once a month and when carrying out them be sure to check:
- condition of the monorail track and busbars;
- grounding reliability;
- cleanliness of the hoist, presence and condition of lubricant;
- the state of insulation of the electrical supply according to the current standards for the safe operation of electrically driven mechanisms;
- condition and operation of the current collector, limit switches, magnetic starters and push-button station;
- reliability of fastening of the cargo rope and its condition;
- tightening of bolts, contact and other connections, as well as the presence and condition of stoppers (spring washers, cotter pins and other parts that provide locking);
- suspension condition and hook mobility (rotation, rolling);
- condition of gears;
- brake operation;
- condition and operation of the rope laying machine.
- The results of inspections and marks for eliminating identified faults are recorded in the periodic inspection log.
Hoist inspection responsible person must be carried out before starting work, and any malfunctions detected must be corrected immediately.
Labor costs for maintenance:
Monthly - 8 person-hours;
Annual - 18 man-hours.
Standards for working out time before the next maintenance:
Monthly - 62 mash. hours;
Annual - 740 mash. hours.
Standards for working out time until the next repair:
Current - 740 mash. hours;
Capital - 4500 mash. hours.
Note. Labor costs for maintenance and standards for working time before maintenance, current and overhaul of electric hoists are given based on work in normal conditions. production conditions loading them in average operating mode with an equivalent load of 0.5<ЗН с коэффициентом использования по времени в год 0,5, в сутки - 0,67 и в час - 0,25.
When operating an electric hoist in lighter or heavier modes, the monthly labor costs are man/hour. and standards for working out time before the next maintenance and current repairs in a machine. hours change accordingly.
1. GENERAL PROVISIONS.
1.1. Persons at least 18 years of age who have been specially trained and certified in accordance with the above Rules and who have a mark to this effect on their knowledge test certificate may be allowed to operate hoists and carry out rigging work. 1.2. Lifting mechanisms (hoists, winches) must be maintained and operated in accordance with the “Rules for the design and safe operation of load-lifting cranes” and “Rules for safe work with tools and devices.”
1.3. Hoists in use must indicate the name of the enterprise, inventory number, load capacity and the date of the next technical examination.
1.4. Repair and maintenance of electric hoists must be carried out by electrical personnel with a group not lower than III. Workers of the main professions, which by the nature of the work performed are related to the operation of hoists, must be trained in a related profession according to a special program. They must be certified by the qualification commission and the certificate contains a record of permission to perform slinging work.
1.5. The housings of electric hoists must be grounded. The body of the push-button control device of a hoist controlled from the floor must be made of insulating material or grounded by at least two conductors; a cable on which the push-button device is suspended can be used as one of the grounding conductors.
1.6. Starting devices for manual control of hoists must be suspended on a steel cable of such length that the mechanism can be controlled while being at a safe distance from the load being lifted. If the control device is located less than 0.5 m from the floor, it should be suspended on a hook attached to a cable at a height of 1-1.5 m.
1.7. Electric hoists must be equipped with limit switches to automatically stop the lifting mechanism of the load-handling member. When lifting a load with electric hoists, it is prohibited to bring the hook cage to the limit switch and use the latter for automatic stopping.
1.8. Electric hoists must be equipped with two brakes: electromagnetic and load-resistant. The braking reserve coefficient of an electromagnetic brake must be at least 1.25, and of a load-bearing brake 1.1. Electric hoists must be equipped with a load limiter and a lower position limiter for the hook suspension.
1.9. The lifting mechanism of manual hoists must be equipped with an automatic load-bearing brake. The brake must ensure smooth lowering of the load when the traction wheel rotates under the influence of traction force and automatic stopping of the load when its action ceases. 1.10. Attach hand hoists to pipelines and their hangers prohibited.
1.11. Testing of stationary hoists is carried out at the site of their installation; portable hoists for testing are suspended from a tripod or some other structure.
1.12. Hoists must undergo a full technical inspection at least once every 12 months.
1.13. An extraordinary full technical examination of lifting mechanisms should be carried out after their reconstruction, repair of the metal structures of the mechanisms with the replacement of design elements or components, major repairs or replacement of mechanisms, replacement of the hook.
1.14. The technical examination must be carried out by an engineer and technical worker who supervises lifting mechanisms at the enterprise, with the participation of the person responsible for their good condition.
1.15. Static testing of lifting mechanisms is carried out with a load 25% greater than their rated lifting capacity in order to check the strength of the mechanisms and their individual elements. In a static test, the test load is raised to a height of 100 mm and held in this position for 10 minutes.
1.16. A lifting mechanism that can withstand the static test is subjected to a dynamic test.
1.17. Dynamic testing of a lifting mechanism must be carried out with a load 10% greater than the rated lifting capacity of the mechanism in order to check the operation of its brakes.
The braking reserve coefficient, depending on the operating mode and type of mechanism drive, should be 1.5-2.5.
1.18. Dynamic tests consist of repeated (at least 6 times) raising to a height of at least 1 m and lowering the test load.
1.19. During dynamic tests, brakes, limit switches, and smooth operation of the load and traction chains are checked. In case of detection of runs, skipping or sliding of the chain on the sprocket and traction wheels, the hoists are rejected.
1.20. When dynamically testing electric hoists, the operation of the brakes must be checked separately. To check the brakes during operations, the mechanisms must be stopped at least 3 times in each direction.
1.21. During dynamic testing of hoists, all operations must be carried out 2 times, and the action of the lower position limiter of the hook suspension must be checked.
After completion of the tests, the load limiter must be adjusted and its operation checked.
1.22. When testing hoists, spontaneous lowering of the load should not be observed. If cracks, ruptures and deformations are detected, the hoists are rejected.
1.23. It is allowed to carry out dynamic testing of electric hoists with a load exceeding 25% of their rated load capacity. In this case, it is permitted not to carry out a static test.
1.24. The date and results of the technical examination of the lifting mechanism are recorded by the person who carried out the examination in the mechanism’s passport, indicating the date of the next examination, as well as information about the repairs performed.
1.25. Before putting into operation, after major repairs and periodically, but at least once a year, the insulation resistance of the electrical equipment of the hoist must be measured with a 500 V megger. The insulation resistance must be at least 0.5 MOhm.
1.26. Electrical equipment of hoists with an insulation resistance of less than 0.5 MOhm must be dried.
2. Safety requirements before starting work.
2.1. The location of the hoist must be determined so that there is sufficient space for viewing the work area and maneuvering.
2.2. The mass of loads to be lifted must be determined before lifting. The load on lifting mechanisms should not exceed their lifting capacity.
2.3. For loads that have special devices (hinges, axles, frames) designed to lift the load in various positions, their slinging schemes must be developed.
2.4. The condition of hoists must be checked before each use.
2.5. Before starting work, the electrical steel must be inspected.
In this case, attention should be paid to their cleanliness, the presence of lubrication, the condition of the chains, ropes, gear teeth and sprockets, the serviceability of the cotter pins or rivets at the ends of the main axis, the reliability of the chains on the sprockets and the fastening of the rope to the drum, wear of the rolling surface of the running rollers, the distance between roller flanges and the outer edges of the monorail track, the serviceability of the electromagnetic brake of electric hoists and the degree of wear of friction pads: the condition of electric motors, electrical wiring and contacts, control devices, pantographs and limit switches, the absence of jamming of mechanisms and slippage of chains, as well as the level of noise arising during the operation of hoists .
The teeth of sprockets and gears, as well as chains, should not have cracks, burrs or dents on the surface; plate chains must be movable in all articulated joints.
2.6. If defects are detected, defective units and parts must be replaced before work begins.
3. Safety requirements during operation.
3.1. The place where lifting and moving loads is carried out must be well lit during work.
In case of insufficient lighting of the work place, heavy snowfall, fog, as well as other cases when the person servicing the hoist cannot clearly distinguish the signals of the slinger or the load being moved, the operation of the hoist should be stopped.
3.2. The supply of electrical voltage to the lifting mechanism from an external power supply must be carried out using an input device that has manual and remote control to relieve voltage.
3.3. Cargo hooks for loads over 3 tons must be made rotating, with the exception of special-purpose hooks.
Load hooks from the mouth of which removable lifting devices may fall out during operation must be equipped with a safety lock.
3.4. Lifting a load for which slinging schemes have not been developed must be carried out in the presence and under the guidance of an employee responsible for the safe performance of work with cranes.
3.5. Loads suspended from the hook of a lifting mechanism must be securely tied with ropes so that during their movement the fall of individual parts (boards, scaffolding, pipes, etc.) is prevented and a stable position of the load is ensured during movement. Slinging of long loads should be done with a double sling, and in the case of vertical lifting - with a sling with a safety clip.
3.6. In the cargo handling area, all openings must be closed or fenced and safety warning signs posted.
3.7. When moving the load horizontally, it must first be lifted 0.5 m above objects encountered along the way.
3.8. Loads may be lowered to a pre-prepared place where they cannot fall. To make it easier to remove the slings from under the load at the place where it is installed, strong spacers must be placed under it.
3.9. It is prohibited to lower loads onto floors, supports and platforms without first calculating the strength of the structure and to overload them in excess of permissible loads.
3.10. Leaving the load suspended, as well as lifting and moving people using lifting mechanisms not intended for lifting them is prohibited. In the event of a malfunction of the mechanism, when it is impossible to lower the load, the place under the suspended load must be fenced and posters “Danger zone” and “Passage closed” must be posted.
3.11. Working with disabled or faulty safety devices and brakes is prohibited.
It is prohibited to simultaneously lift or lower two loads located in close proximity to each other.
3.12. Before lifting, the load must be raised to a height of no more than 300 mm to check the correctness of the sling, the uniform tension of the slings, the stability of the lifting mechanism and the reliability of the brake; only after this the load should be raised to the required height; to correct the sling, the load must be lowered.
3.13. Lifting the load must be done smoothly, without jerking or swinging.
3.14. All rubbing parts of hoists must be lubricated at least once a month.
4. Safety requirements upon completion of work.
4.1. After finishing work, tidy up the workplace, turn off all electric motors of the mechanisms involved in loading and unloading operations,
remove all devices, slings, auxiliary ropes and put in order the rest of the equipment and tools.
4.2. Report completion of work to the work supervisor.
4.3. Put your overalls in order, remove dust and dirt, and take a shower.
5. Safety requirements in emergency situations.
5.1. In the event of an accident or emergency situation, take measures to prevent and eliminate the danger.
5.2. Immediately report to your immediate supervisor any accident that occurs at work, signs of illness, as well as a situation that poses a threat to the life and health of people.
5.3. In the event of an electric shock, it is necessary to immediately release the victim from the action of the current, observing electrical safety requirements, provide first aid, call a medical service worker, and notify management.
5.4. If a fire occurs, notify the fire department by phone 01, the work manager and begin extinguishing.
Hoists are widely used in construction and industry for carrying out lifting and installation work. They are electrically driven devices that are powered by a motor and can lift loads weighing up to 10 tons to a certain height. Hoists are installed on single-girder overhead cranes or on a monorail track. The design of the equipment includes a movement mechanism, with the help of which the horizontal movement of the load is carried out.
Installation of the telpher must be carried out by a specialized organization or a qualified specialist with certain training. For proper installation of equipment, it is important to consider the following conditions:
- lifting capacity and lifting height of the hoist;
- speed of the moving mechanism;
- beam profile parameters;
- conditions for using the equipment;
- compliance of the electrical voltage with the manufacturer’s requirements;
- compliance of installation and connection with safety requirements.
Telphers are usually supplied assembled. Before installation, you need to make sure that the power supply voltage matches the parameters of the equipment. Many types of professional equipment operate from an industrial power supply network, but there are also models for power supply from a regular 220V network.
When choosing equipment, you should also pay attention to the beam profile numbers. The equipment passport indicates on what size tracks the equipment cart can be installed. It is not allowed to use a hoist on beams with a profile smaller than that indicated in the passport.
It is important to thoroughly inspect the equipment before installation.
- It should be free of dust, dirt and moisture, so the hoist must be thoroughly cleaned, dried and lubricated in accordance with the manufacturer’s requirements.
- It is necessary to check the serviceability of all bolted, contact connections and locking mechanisms.
- An experienced electrician should check the condition of the wires and measure the insulation resistance.
The hoist is installed on the track using bolts and fastening strips, studs and a set of washers included in the equipment kit. The hoist must be installed so that the distance between the wheel of the trolley and the rail is 4 mm on each side.
You need to make sure that nothing interferes with the movement of the cart. It is not recommended to paint the rail track for this purpose, as the paint creates resistance. The movement of the cart can also be hampered by the lubrication of the track. In addition, the path must be regularly cleaned of dust and dirt, and dried from moisture to avoid corrosion. The rail track must be clear and the slope must be at least 3%. There are special safety requirements that the rail track must meet. Below are some of them.
- The distance from the hoist to the ceiling or to the bottom point of other equipment operating above the hoist must be at least 100 mm.
- The distance from the hoist to the walls of the building or to columns and railings is at least 60 mm.
- From the bottom of the hoist to the floor or to another working platform - at least 2000 mm.
- The distance from other equipment operating near the hoist is at least 400 mm.
Telpher connection
It works from mains power, but before connecting it to the mains, you need to carry out a preliminary test.
- All individual parts of the hoist must be inspected for rust. If there is rust on the brake wheels, engine cover and brake cover, the engine may catch fire after connecting the power.
- It is necessary to check the reliable connection of the electrical unit. An ammeter is used for this.
- It is also important to check the phases by applying voltage. You need to hang the hoist and press the control buttons to check the direction of movement of the hook and trolley.
Electric hoists are connected to the power supply according to a specific scheme specified in the equipment passport.
Important!
The mains voltage must correspond to the parameters of the hoist. When choosing a power cable, you need to take into account that voltage drops should not exceed 10%. The length and cross-sectional diameter of the cable must match the power of the hoist motor.
Safety requirements
Hoists must be operated by people who have full knowledge of safety rules. In addition, specially designated people must regularly inspect the condition of the equipment.
Before first use, hoists must be tested with loads weighing 25% higher than the rated load capacity. The test should last a maximum of 10 minutes.
Warning Do not exceed the rated load capacity when working with hoists. In this case, all ropes and hooks must have the appropriate load capacity. Failure to comply with safety rules is dangerous for the lives of nearby people and for the safety of the cargo.
The equipment passport must indicate how many times the hoist can be used within an hour. This requirement must be strictly observed to avoid engine overheating. When using a hoist, the load must not be left suspended. It is also not recommended to press multiple buttons at the same time. After using the equipment, it must be disconnected from the power supply.
Equipment inspection should be carried out at least once a month. During the inspection the following should be checked:
- condition of all individual parts;
- reliability of fastenings;
- condition of the rail track;
- brake operation;
- condition of electrical wiring insulation, etc.
The results of the inspection must be recorded in the inspection log. All detected faults are subject to immediate repair or replacement.
The most important tasks when operating electrical equipment are to maintain all electrical and electromechanical components in working order. During the operation of electrical equipment, it is necessary to prevent failure of all electrical and electromechanical parts of this equipment. And conduct regular inspections of electrical equipment and periodically diagnose all components that may fail during operation. Operation of electrical equipment is a set of preparation and use of products for their intended purpose, maintenance, storage and transportation. Main Operational Tasks
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"Inspection of electrical equipment"
Continuously operating power equipment requires systematic systematic inspection by qualified personnel. Inspections are carried out on schedule and in accordance with instructions approved by those responsible for the operation of electrical equipment. During inspections of switchgears, all comments are recorded in a log of defects and malfunctions and brought to the attention of energy company managers, who take appropriate measures to eliminate identified violations as soon as possible. Regular inspections of switchgears without shutting down the equipment are carried out at the following times: at facilities with a permanent attendant - once a day and at least once a month in the dark to check for the presence of discharges.
"Electrical equipment repair"
The main responsibilities of employees of energy enterprises servicing electrical facilities are: ensuring uninterrupted power supply to consumers, reliable operation
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Moving parts and parts of electrical equipment “device contacts, mechanism parts” are subject to mechanical wear under the influence of friction or as a result of corrosion.
“System of planned preventive maintenance of electrical equipment” The preventive maintenance system, depending on the operating modes of electrical equipment and the conditions of its operation, establishes the rotation, frequency and volume of maintenance and repairs of electrical equipment, taking into account the uninterrupted operation of the enterprise and the safe conduct of work. Scheduled preventive maintenance includes maintenance work, inter-repair maintenance and current and major repairs of electrical equipment. Carrying out repairs of electrical equipment provided for by the PPR system ensures a reduction in the costs of its maintenance, reduces the number and time of downtime, the number of accidents, increases the reliability of operation and the quality of repairs. The organization of repair and maintenance of equipment at an enterprise can be carried out centrally or decentralized. The centralized system is characterized by the fact that the repair of electrical equipment is carried out by specialized repair services, and the maintenance and minor repairs of electrical equipment in operation are performed by personnel subordinate to the corresponding production unit “service, area”. With a decentralized system, there are no specialized repair services and all repair work, such as care, minor repairs and maintenance of equipment, is carried out by personnel of workshops, services, and teams of the immediate production site.
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During planned repairs, it is necessary to pay great attention to operating personnel who have group 3 access to electrical installations. When repairing an electric motor, you need to de-energize it and make sure that the electrical equipment is not energized. Visually inspect this engine to see if there is any damage, chips or other defects leading to engine failure. When disassembling the engine, we pay special attention to the integrity of the bearings and lubrication. Bearing lubrication should be 75%, only in this case can the engine be used
4. Types of repairs, their essence:
Maintenance– this is a planned repair, which ensures the normal operation of electrical equipment until the next repair by replacing or restoring worn-out parts of equipment, purchased products, as well as by carrying out preventive measures, adjusting mechanisms, and eliminating individual faults.
During routine repairs of electrical machines, the following work is performed;
Checking the degree of heating of the housing and bearings, the uniformity of the air gap between the stator and the rotor, the absence of abnormal noise in the operation of the electric motor;
Cleaning and blowing of the electric motor without disassembling it, tightening contact connections at terminal boards and connecting wires, stripping rings and commutators, adjusting and fastening the brush holder traverse, restoring insulation at the output ends, electric brushes;
Change and top up oil in bearings.
If necessary, produce:
Complete disassembly of the electric motor with elimination of damage to individual parts of the winding without replacing it;
Washing of components and parts of the electric motor;
Replacement of faulty slot wedges and insulating bushings, washing, impregnation and drying of the electric motor winding, coating the winding with topcoat varnish, checking the fan mounting and its repair, grooving the rotor shaft journals and repairing the squirrel cage (if necessary), changing flange gaskets;
Major renovation- this is a type of repair of an asynchronous motor with a short-circuit rotor in which the motor is completely disassembled, its parts or assemblies are partially or comprehensively replaced, the repaired parts and the unit as a whole are checked, the stator windings are completely replaced, and tested under load. Before a major overhaul of the electrical equipment of a 16v20 screw-cutting lathe, a work content sheet is drawn up and a set of necessary spare parts, equipment, and purchased products is prepared.
During a major overhaul, the following operations are performed: complete or partial replacement of the winding; straightening, wiping journals or replacing the rotor shaft; rotor balancing; replacement of fan and flanges; complete soldering of cockerels; cleaning, assembling and painting the electric motor and testing it under load.
5. The procedure for removing electrical equipment for repair:
When bringing electrical equipment 16v20 out for repair, it is necessary to carry out organizational and technical measures. Organizational measures include: Filling out the necessary documentation, drawing up an application, issuing work orders, drawing up a defective list, training personnel.
Technical activities:
Disconnecting equipment from the network, taking measures to prevent “spontaneous” and erroneous supply of voltage to the workplace.
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Hanging prohibiting posters: On the drives “drive handles” of manually controlled switching devices, “switches, circuit breakers, automatic machines”, in order to avoid the supply of voltage to the workplace, posters “Do not turn on! People are working” must be hung. - on fences. On the valves that block the access of air to the pneumatic drives of the disconnectors, a poster “Do not open! People are working” is posted. Fencing the workplace, hanging posters: “Grounded” posters must be posted in electrical installations; if turned on incorrectly, voltage may be applied to the grounded section of the electrical installation. For temporary fencing of live parts that remain energized, shields, screens, and screens made of insulating materials can be used. Temporary fences must be marked with the words “Stop! Voltage” or posted with appropriate posters. There are three forms of operation and repair of electrical equipment:
1) Centralized; 2) decentralized; 3) mixed. 1. Centralized - a form that can be used in most industrial enterprises. In this form, maintenance between repairs and all types of repairs of electrical equipment are carried out by a single repair unit for the entire enterprise: a repair team, a repair area or a repair shop, which is part of the service of the chief power engineer. The centralized form has a significant advantage over other forms of repair organization, since it allows you to concentrate specialized repair and testing equipment, specialized repair personnel, a stock of backup electrical equipment, spare parts and materials in the repair department, and carry out repairs in accordance with advanced technology using high-speed repair methods.
2. Decentralized - the form is used in enterprises with simple electrical equipment that does not require specialized repair and testing equipment for repair. With this form, maintenance and repair personnel are included in the staff of the main workshop. Repair of electrical equipment is carried out at workplaces or a repair shop located on the territory of the main workshop.
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Possible malfunctions of the electrical equipment of the Model T hoist and ways to eliminate them:
| Item no. | Malfunction | Cause | Remedy |
| I | The equipment does not turn on | 1) The fuse of the starting-protective transformer has blown 2) The power fuse of the electric hoist has blown 3) A break in the control circuit 4) The contactor coil has blown or there is a break in it 5) Turning on and blocking the limit switch | 1.1 Replace with a new one 2.1 Replace with a new one 3.1 Check the electrical circuit and repair the open circuit 4.1 Replace with a new one 5.1 Check the limit switch and restore its normal position |
| II | When the control button is pressed and the equipment is turned on, the electric motor of the lifting mechanism does not rotate in both directions | 1) Cone brake sticking 2) Mechanical jamming in the electric hoist or motor | 1.1 Remove the ventilation grille and press the shaft several times with the electric hoist turned off without a load 2.1 Disassemble and repair the damage |
| III | When turned on, the fuses blow and the motor does not rotate. | 1) Breakdown on the body 2) Breakdown between phases | 1.1 Check with a megohmmeter 2.1 Check phase-to-phase insulation |
| IV | The electric motor hums and does not rotate with the load | 1) The electric motor operates in two phases 2) The operating voltage is lower than specified in the regulations for electric hoist motors 3) The second brake of the electric hoist does not engage | 1.1 Check the supply voltage 2.1 Check the serviceability of the contact systems of the contactors. If necessary, replace the contact bridges or contact springs 3.1 Check the serviceability of the stator winding of the electric motor |
| V | The electric motor is overheating | 1) The rated load is exceeded 2) The voltage is asymmetrical 3) The voltage is higher than permissible 4) The operating mode is exceeded | 1.1 Observe the prescribed overload norms 2.1 Turn off the electric hoist until voltage symmetry is restored 3.1 Observe the established norms 4.1 Observe the prescribed operating mode |
| VI | When the command control panel is turned off, the electric hoist continues to operate | 1) Welded contactors of contactors 2) Sticking of the magnetic system 3) Welded contacts in the limit switch | 1.1 Replace the contact bridges with new ones 2.1 Check the counteracting springs and clean the end surfaces of the magnetic wire 3.1 Replace with new ones |
| VII | The limit switch does not operate during operation of the electric hoist and the hook hits the casing | 1) The power cable phases are connected incorrectly 2) The limit rings on the switching rod are loose | 1.1 Exchange the two phases of the power cable 2.1 Adjust and tighten the restrictor rings |
| VIII | During operation, the electric hoist makes an uncharacteristic noise | Bearings are worn out | Replace with new ones |
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7. Drawing up a defective statement:
A defect statement is a document required when setting out certain shortcomings, defects and defects found in certain material assets. This document is necessary for quality control on the part of the buyer or on the part of the seller. There is no unified form of the defective statement, and any enterprise can draw up this document on its own letterhead.
A defect report is a document that also records the malfunctions of the equipment being repaired.
The purpose of drawing up a defective statement is:
1. Reducing the repair time for electrical equipment of the hoist;
2. Improving the quality of repairs.
In practice, two types of defective statements are considered:
Preliminary
Refined
1) A preliminary statement is the name of the work and costs, the unit of measurement, the quantity of “scope of work”.
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2) An updated statement is a statement that specifies any electrical elements that will be needed in the process of repairing electrical equipment at the enterprise.
Before disassembling electrical equipment, a preliminary defective list is drawn up, and when disassembling electrical equipment, a revised defective list is drawn up.
A preliminary defective list is drawn up based on an external inspection of electrical equipment before it is taken out for repair.
An updated defect list is compiled during the process of disassembling the electrical equipment of the hoist.
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The technological map (TC) should answer the questions:
· What operations need to be performed
· In what sequence are the operations performed?
How often should operations be performed (if the operation is repeated more than once)
How long does it take to complete each operation?
The result of each operation
What tools and materials are needed to perform the operation.
· Technological maps are developed in the case of:
· High complexity of operations performed;
· The presence of controversial elements in operations, ambiguities;
· If it is necessary to determine the labor costs for operating the facility.
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9. Control and testing of EO, after repair:
Testing of electrical equipment must be carried out in compliance with the requirements of safety regulations and PTE.
Measuring the insulation characteristics of electrical equipment under operating voltage is permitted provided that devices are used that ensure safety of work and protection of the normally grounded terminal of the controlled object from the appearance of dangerous voltage on it in the event of a breakdown in connection with the ground.
Before testing the insulation of electrical equipment, the outer surface of the insulation must be cleaned of dust and dirt, except in cases where the tests are carried out using a method that does not require disconnecting the electrical equipment.
Testing the insulation of the windings of rotating machines with an increased applied voltage of 50 Hz should be carried out in turn for each electrically independent circuit or parallel branch (in the latter case, in the presence of complete insulation between the branches).
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The test voltage must rise smoothly at a speed that allows visual inspection by measuring instruments, and upon reaching the set value, it must be maintained unchanged throughout the entire test period. After the required exposure, the voltage gradually decreases to a value of no more than one-third of the test value and is turned off.
The test duration means the time of application of the full test voltage established by the standards.
10. The procedure for accepting electrical equipment into operation after repair:
Upon acceptance, you must perform the following operations:
Visual inspection; check the stator winding (for integrity, for short circuit between phases; for short circuit of windings to the housing, for turn short circuit.)
The presence of axial and radial play, which must correspond to the standard values.
Connect the electric motor to the power supply to check the engine in idle mode. At the same time, pay attention to extraneous noise, vibration and measure the no-load current.
Acceptance of electric motors with voltages above 1000 volts, power transformers, high-voltage switchgears after major and medium repairs is carried out by a commission chaired by the head of the electrical department or his deputy with an entry in the log of the removal of electrical equipment for repair and commissioning after repair.
Acceptance of current and major repairs of electric motors with voltage up to 1000 volts.
Acceptance of electrical equipment from a contract repair organization is carried out by the foreman of the electric motor repair area according to the act
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The foreman of the electric motor repair area makes entries in the electrical equipment passports about the work performed, indicating the defects in the list.
Acceptance certificates with attached technical documentation and a list of defects must be stored in electrical equipment passports.
Electrical equipment, electrical networks, networks, and grounding that are put into operation after repair are tested in accordance with the volumes and standards specified in the rules for the technical operation of consumer electrical installations. Based on the test results, protocols are drawn up.
After preliminary acceptance from repair, electrical equipment is tested under load within the time period specified by the manufacturer, but not less than 24 hours. If there are no defects in operation during this period, the commission accepts the electrical equipment into operation and installs
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After repair, the electric motor is tested on a test bench in the workshop with an inspection report issued in the form. After checking, if the test results are positive, the electric motors are transferred to the technical workshop with installation on the frame of a pump (other similar) by the repair service of the electrical workshop in the presence of working lifting mechanisms and free passages for transporting the electric motor. In the absence of lifting mechanisms or their malfunction above a given electric motor, installation of a pumping (other similar) unit on the frame is carried out jointly with the technological service of the workshop on whose balance sheet this electric motor is located. Alignment of the electric motor with the driven equipment is carried out by the repair service of the technological workshop.
11. Use of modern devices, tools and technology in the operation and repair of electrical equipment:
The following are widely used as digital measuring instruments:
1) Ammeter - a device for measuring current in amperes.
The scale of ammeters is calibrated in microamps, milliamps, amperes or kiloamps in accordance with the measurement limits of the device.
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2) Current clamp - a device for measuring alternating current without breaking the circuit in which the current is measured.
The principle of operation of current clamps is based on the fact that current flowing in a wire creates a magnetic field around itself. If this field is variable, then, according to the law of electromagnetic induction, an emf appears in another conductor enclosing the current-carrying wire, which, under certain conditions, is proportional to the measured current.
3) Voltmeter - a direct reading measuring device for determining voltage or EMF in electrical circuits. Connected in parallel to the load or source of electrical energy.
4) A multimeter is a combined electrical measuring device that combines several functions. The minimum set includes a voltmeter, ammeter and ohmmeter. Sometimes a multimeter is performed in the form
current clamps. There are digital and analog multimeters.
A multimeter can be a lightweight, portable device used for basic measurements and troubleshooting, or a complex, stationary instrument with many capabilities.
The typical error of digital multimeters when measuring resistance, DC voltage and current is less than ±(0.2% +1 least significant unit). When measuring AC voltage and current in
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12. Compliance with the requirements of safety regulations and fire safety during operation and repair of electrical equipment:
Safety regulations (HS):
Compliance with safety rules is mandatory without any reasoning or amendments.
TB rules are: unconditional and conditional; mandatory and recommendatory. Types and schedule of instruction:
1. TB training and general briefing;
2. Briefing before starting work;
3. On-the-job training.
4. Checking the instructions is always mandatory.
5. In case of violation of safety regulations, safety requirements take priority over work requirements
At the entrance to the production premises there must be a sign indicating its explosion or fire hazard class.
Persons responsible for the condition of electrical installations (chief power engineer, head of the electrical department, appropriately qualified engineer and technical worker appointed by order of the head of the enterprise or workshop) are obliged to:
a) ensure the organization and timely conduct of preventive inspections and scheduled preventative repairs of electrical equipment, equipment and electrical networks, as well as the timely elimination of violations of PTE and PTB that could lead to fires and fires;
b) monitor the correct selection and use of cables, electrical wires, motors, lamps and other electrical equipment, depending on the fire and explosion hazard class of the premises and environmental conditions;
c) systematically monitor the condition of protection devices against short circuits, overloads, internal and atmospheric overvoltages, as well as other emergency operating modes;
d) monitor the serviceability of special installations and means designed to eliminate fires in electrical installations and cable rooms;
e) organize a system of training and instruction for duty personnel on fire safety issues during operation
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f) participate in the investigation of cases of fires and fires from electrical installations, develop and implement measures to prevent them.
The electrician on duty (replacement electrician) is obliged to carry out scheduled preventive inspections of electrical equipment, check the presence and serviceability of protection devices and take immediate measures to eliminate violations that can lead to fires and fires. The results of inspections of electrical installations, detected faults and measures taken should be recorded in the operational log.
Checking the insulation of cables, wires, reliability of connections, protective grounding, operating mode of electric motors should be carried out by electricians of the enterprise, both by external inspection and with the help of instruments. Measurement of the insulation resistance of wires must be carried out within the time limits established by the PTE and PTB.
All electrical installations must be protected by protection devices against short-circuit currents and other emergency modes that can lead to fires and fires.
13. Conclusions on the project:
In the process of working on my course project, I studied the types and essence of repairs, safety and fire safety rules. I studied the electrical equipment of a screw-cutting lathe and its components. I also paid special attention to the choice of diagnostic devices and the principle of their operation in the given values. The most effective, in my opinion, are digital diagnostic instruments, such as: ammeter, voltmeter, megohmmeter, multimeter and frequency meter. The work examines modern technologies for repair work on electrical equipment of turning machines.
14. Literature:
1. Modern technologies in engine production, edited by A.G. Bratukhina, G.K. Yazova, B.E. Karaseva. Mechanical engineering, 1997 410s.
2. A.A. Garkavy, “Production of engine parts.”
3. Crane electrical equipment: Directory Yu.V. Alekseev, A.P. Theological. Energy, 1979
4. Electric crane drive: Handbook by A.G. Yaure, E.M. Pevzner. Energoatomizdat, 1988.
5. Lipkin B.Yu. Elect
