Many bridge cranes, gantry cranes, tower cranes, and port lifting equipment that have been in service for many years in the factory area can continue to be used with steel structures, but the electronic control system is aging, safety protection is lacking, and the level of automation is backward. The input cost of direct replacement of the whole machine is extremely high, and the technical transformation and upgrading of lifting equipment, using a lower budget to make up for safety shortcomings and realize intelligent upgrading, has become the preferred solution for most enterprises.
Before implementing the transformation work, enterprises often face a lot of questions: how to prepare the technical transformation and upgrading plan of lifting equipment? What are the requirements for the technical transformation and upgrading specifications of lifting equipment? How to distinguish between lifting equipment renovation and major maintenance? Inform the process of the qualifications required for crane transformation, what procedures to go through, and how to perform the transformation. This article combines the regulatory requirements of special equipment and first-line engineering experience to comprehensively answer related questions and provide a reference for the upgrading of lifting equipment in the factory.
1. Definition of lifting equipment transformation｜ Distinguish between transformation and major maintenance
If you want to carry out projects in compliance, you must first clearly understand the definition of lifting equipment transformation and clarify the boundaries between crane transformation and major maintenance. Many companies can easily confuse the two, resulting in omissions in the handling of procedures.
According to the definition of relevant lifting machinery regulations, the transformation of lifting equipment is the construction behavior that changes the original main force structure, main configuration, and rated parameters of lifting machinery, resulting in changes in equipment performance and technical indicators. The typical range includes changing the rated lifting weight, lifting height, span, and working speed, replacing the entire electronic control system, adding a complete set of intelligent safety monitoring system, and changing the main beam support structure.
Major repairs will not change the original rated parameters and main structure of the equipment, but only repair and replace parts of the same specifications to restore the original performance of the equipment. The core difference between the two: the transformation will change the original technical parameters of the equipment, and major repairs will only restore the equipment to its original state. The notification process and inspection requirements corresponding to the two types of work are different, and it is necessary to define them in the early planning stage to avoid obstacles to subsequent acceptance.
2. Specifications for the technical transformation and upgrading of lifting equipment, and how to write the transformation plan
For any upgrade project, the specifications for the technical transformation and upgrading of lifting equipment must be strictly complied with. All construction content cannot exceed the scope permitted by regulations. After the transformation is completed, the performance indicators must meet the current safety standards.
A qualified lifting equipment technical transformation and upgrading plan, that is, how to write the lifting equipment transformation plan that everyone is concerned about, the complete content should contain multiple sections. First, specify the basic information of the original lifting equipment, existing defects and transformation goals; secondly, specify the content of the transformation construction, the selection of equipment models, and the construction technology; at the same time, mark safety and security measures, construction schedule arrangements, and acceptance standards. If it involves the installation of monitoring systems, anti-collision devices, and supporting facilities for wire rope flaw detection, the technical parameters must also be clarified in the plan.
The preparation of technical transformation and upgrading plans for lifting equipment cannot simply apply templates, and it needs to be adjusted in a targeted manner based on the service life of the equipment, on-site working conditions, and the requirements of special inspection agencies. After the plan is finalized, it needs to be submitted to the supervision and special equipment inspection agencies for pre-review simultaneously to confirm the compliance of the plan before it can enter the field to carry out the implementation of the crane renovation construction plan.
3. The qualifications required for the transformation of lifting equipment, and the requirements for the transformation shall be notified
Many factories are unclear when looking for cooperative units: there are clear statutory requirements for the qualifications required for crane transformation, and non-qualified units implement the transformation, and the results of the transformation will not be recognized, and they will also face safety supervision penalties.
Units undertaking lifting equipment transformation projects must hold the corresponding type of lifting machineryInstallation, renovation, and maintenance permits, The qualification covers the corresponding equipment type. Unqualified maintenance and insurance positions can only carry out routine maintenance, and technical transformation and upgrading projects of lifting equipment are not allowed. Before an enterprise signs a contract, it must verify the validity period and scope of the other party's qualification certificate.
After confirming the construction unit, the notification process for the transformation of lifting equipment must also be implemented. Before the official start of construction, the construction unit shall submit a written notice to the safety supervision department of special equipment where the equipment belongs, which is what the industry often refers to as a notice of major repairs to the installation and transformation of lifting machinery. Unauthorized construction without fulfilling the notice is a typical violation of the law, and it is impossible to apply for supervision and inspection after the renovation is completed.
4, the technical transformation and upgrading of lifting equipment, the direction of common transformation
Combined with a large number of landing projects, the technological transformation and upgrading of lifting equipment is mainly divided into three major directions, and enterprises can choose from a combination as needed.
The first category is the upgrade of the security protection system. In view of the lack of safety devices and protection failures of old equipment, a lifting weight limiter, anti-collision protection device for lifting vehicles, travel limit, wind speed monitoring device, and crane monitoring system have been installed to supplement the necessary safety configuration for the annual inspection of special equipment and eliminate major safety hazards.
The second category is the transformation of the electrical control system. The electronic control of the old contactor is upgraded to a frequency conversion control system to reduce the impact load of the equipment, reduce the wear of parts, and optimize the smoothness of start and stop; at the same time, replace the aging cables and operation consoles to reduce the risk of electrical short circuits and motor burning.
The third category is intelligent digital upgrading. Install an intelligent operation and maintenance system for crane condition monitoring and remote monitoring terminal to realize operation data collection, fault early warning, and full data traceability, and adapt to the construction needs of smart factories and unattended workshops.
5. Key points of crane renovation and construction and control of the whole process
After perfecting the technical transformation and upgrading plan of lifting equipment, the crane transformation and construction plan needs to be strictly implemented in the landing stage and on-site safety control needs to be done.
The operation warning area is delineated before construction, and the power failure is locked and listed to prevent accidental power transmission from causing safety accidents. During the transformation process, all replacement parts must be made of regular products that meet the national standard and have a certificate of conformity, and the use of non-standard inferior parts is prohibited. It involves key processes such as steel structure welding and circuit wiring. Licensed technicians are arranged to operate and construction video records are kept simultaneously.
After all the construction of the transformation is completed, it cannot be directly put into use. Need to apply to the special equipment inspection agencyRenovation supervision and inspection, On-site verification of construction quality and equipment performance by a third-party organization. After passing the inspection, get the inspection report, complete all the archival materials, and archive and preserve the major repair materials of the entire lifting machinery installation and transformation, so that the equipment can be legally put into operation. Conditions.
6. What procedures do you need to go through for the transformation of lifting equipment? The complete process is sorted out
Sort out the key issues of many corporate consulting: what procedures do you need to go through for crane transformation, and the complete compliance process is as follows：
- Site survey to distinguish whether it is a lifting equipment renovation or a major maintenance；
- Prepare a technical transformation and upgrading plan for lifting equipment, and review and finalize the draft by multiple parties；
- Screen renovation construction units with corresponding qualifications and sign construction contracts；
- Submit a notice of the transformation of lifting equipment to the market regulatory department before starting work；
- Construction is carried out on site in accordance with the crane renovation construction plan；
- After the construction is over, apply for special equipment supervision and inspection；
- Pass the inspection and update the registration certificate for the use of lifting equipment；
- All plans, notification forms, construction records, and inspection reports are uniformly archived and kept.
The entire process is interlocking, and any missing link will cause the equipment to fail the normal annual inspection and even be ordered to stop using it.
7, summary
The technological transformation and upgrading of lifting equipment is the best way to improve the quality and efficiency of old lifting equipment, make up for safety shortcomings, and control investment costs. The technical transformation and upgrading specifications of lifting equipment must be followed throughout the project promotion process, the definition of lifting equipment transformation must be clarified, and crane transformation and major maintenance must be distinguished.
Before the enterprise implements the transformation, standardize the preparation of the lifting equipment technical transformation and upgrading plan, verify the qualifications required for the crane transformation, complete the lifting equipment transformation plan on time, organize the construction in strict accordance with the crane transformation construction plan, and implement a full set of inspection and registration procedures.
Compliance with the completion of the upgrade and transformation can not only effectively extend the service life of lifting equipment and reduce the risk of safety accidents, but also successfully pass the regular inspection of special equipment and on-site inspections by safety supervisors at all levels, helping enterprises to achieve safe, efficient and intelligent long-term operation of lifting equipment.
