Part 7: Safety Operating Procedures, High-Risk Hazard Identification, and Emergency Response Protocols for Electric Hoists
Although electric hoists are classified as light-duty lifting equipment, they fall under the legal category of "special equipment." Operations involving overhead lifting, heavy load handling, and mechanical transmission entail safety risks such as falling objects, crushing injuries, mechanical trauma, equipment overturning, and electric shock. Operating without certification, violating operational rules, and issuing unsafe commands are the primary causes of lifting-related accidents. In accordance with the GB 6067.1-2010 safety standard and actual site conditions, a standardized operational system covering the pre-operation, in-operation, and post-operation phases has been established. This system outlines key points for identifying high-risk hazards and protocols for emergency response to sudden malfunctions, thereby comprehensively ensuring the safety of personnel and equipment.
Pre-operation safety preparation serves as the first line of defense in risk prevention and control. All operators must hold a valid special equipment operation certificate and be thoroughly familiar with equipment specifications, operating procedures, potential hazards, and emergency protocols; operating without certification, independent operation by apprentices, or unauthorized substitution of personnel is strictly prohibited. Operators must wear appropriate personal protective equipment (PPE); loose clothing, jewelry, and unbound long hair are strictly forbidden to prevent entanglement in transmission mechanisms. A comprehensive equipment inspection must be conducted to verify the integrity of mechanical structures, transmission components, safety devices, and electrical circuits. Particular attention must be paid to testing braking systems, limit switches, hook safety latches, and overload protection functions to ensure all safety components are responsive and effective. The weight of the load must be strictly verified; overloading, off-center loading, and oblique pulling or lifting are strictly prohibited. The rated load of the electric hoist includes the weight of lifting tackle and ropes; a safety margin must be maintained, and operation beyond specified parameters is forbidden. The work area must be cleared of unauthorized personnel, a safety perimeter established, and obstacles within the operating radius removed to eliminate risks associated with simultaneous, conflicting operations (cross-operations).
Standardized operation during the lifting process is the core element of safety management. Operators must adhere to the principles of "vertical lifting, smooth starting and stopping, low-speed positioning, and no lingering under the load" throughout the operation. Sudden starts, drops, stops, or turns are prohibited when operating the equipment; avoiding violent load swaying and instantaneous impact forces helps minimize structural fatigue and lifting risks. When lifting a heavy load, the lift must be vertical; operations must pause after the load clears the ground by 100mm to 150mm to check the balance, the security of the rigging, and the stability of the braking system. Only after confirming there is no tilting, slipping, or abnormal noise should the load be lifted, lowered, or traversed at a steady speed. Operators must remain focused throughout the process; leaving the post, chatting, or using mobile phones is strictly prohibited. Loads must not be left suspended for extended periods, and unattended lifting operations are forbidden. During equipment travel and positioning, operators must actively avoid personnel, other equipment, and structural obstacles to prevent collisions or crushing accidents.
Operations require the precise identification of five major high-risk hazards: overloading, oblique pulling or lifting, limit switch failure, operating with equipment defects, and personnel entering the work zone. Oblique pulling/lifting subjects the load to horizontal forces and causes uneven wire rope wear, machine tilting, and unbalanced track loading, easily leading to derailment or falling-load accidents. Overloading exceeds the equipment's safety limits, potentially causing structural failure, brake failure, or total equipment destruction. Limit switch failure can result in over-travel, wire rope snapping, and load drops. Operating with defects exacerbates potential faults, leading to cascading damage and safety accidents. If sudden anomalies occur—such as abnormal noise, vibration, hook slippage, jamming, or loss of control—the load must be immediately and smoothly lowered to the ground, the main power cut off, and the machine stopped for inspection; forced operation with existing faults is strictly prohibited.
Emergency responses to sudden malfunctions must be standardized and efficient. In the event of a sudden power outage, immediately press the emergency stop button and cut the main power; do not attempt to dismantle the equipment—wait for power restoration or professional maintenance. If the equipment loses partial control or the load sways, lower it smoothly to the ground at low speed; avoid sudden stops or harsh braking. In the event of minor hook slippage, remain calm, lower the load to safe ground at a steady speed, and stop the machine to inspect the braking system. If a hazard involving personnel or equipment arises, immediately cut the power, evacuate personnel, and report the incident to management. Upon completion of the work, return the hoist to a safe position in the center of the track, remove the rigging, turn off the power, clean the site, and complete the operation records. Enterprises must conduct safety training and emergency drills on a regular basis, strengthen the risk identification and emergency response capabilities of operational personnel, and establish a closed-loop safety management and control system.
