Krude Heavy Industry’s Overhead Crane Safety Monitoring System has obtained SIL 3 certification, helping 12 companies complete their safety standard registration.
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Krude Heavy Industry’s Overhead Crane Safety Monitoring System has obtained SIL 3 certification, helping 12 companies complete their safety standard registration.
Zhengzhou, June 15, 2026——The overhead crane safety monitoring and management system independently developed by Krude Heavy Industry recently passed third-party functional safety certification, achieving a Safety Integrity Level (SIL) of 3, and received a report confirming full compliance with the GB/T 28264-2017 standard, “Safety Monitoring and Management Systems for Lifting Machinery.” To date, the system has helped 12 enterprises in the metallurgy, chemical, and port industries complete the installation, acceptance, and safety certification filing of their safety monitoring systems.
I. The Technical Value of SIL 3 Certification
SIL 3 is the third safety integrity level defined in the IEC 61508 and GB/T 20438 standards, requiring that the system continue to operate safely under single-fault conditions, with a safety failure probability of less than 10⁻⁷ per hour. The Krude Heavy Industry Safety Monitoring System is developed based on the Siemens S7-1500F safety PLC platform, with hardware configurations including the 1515F-2 PN safety-rated CPU, the F-DI 16x24V safety digital input module, and the F-DQ 8x24V/2A safety digital output module; all links employ a dual-channel redundant design.
The system covers all seven safety monitoring functions required by GB/T 28264-2017: load capacity limit, hoisting height limit, travel limit, travel speed monitoring, wind resistance and anti-slip protection, interlock protection, and fault self-diagnosis. Among these, the emergency stop safety function achieves SIL 3/PLe level—dual-channel emergency stop buttons are connected via the F-DI module, and a safety stop is triggered if either channel is disconnected, cutting off the main contactor and the inverter’s STO within 200 ms. Limit switch protection also achieves SIL 3 level, utilizing a dual-channel configuration of mechanical limit switches and proximity switches. Overspeed protection and load limiting meet the SIL 2/PLd level, achieved through dual-channel speed monitoring via encoders and comparison logic using load cells.
II. One-Stop Service from Hardware to Acceptance
Krude Heavy Industry provides end-to-end services ranging from conceptual design, hardware selection, on-site installation, and PLC programming and debugging to the preparation of regulatory filing documentation. The system comes standard with a safety PLC control cabinet. All safety input signals (emergency stop, limit switches, door locks, light curtains, and LiDAR obstacle avoidance) are pre-wired to the F-DI module, and the F-LADDER safety logic program is tested prior to shipment. On-site installation requires only sensor wiring and integrated testing before the system is ready for use.
During the filing process, Krude Heavy Industry provides clients with complete templates for GB/T 28264 test reports, HARA hazard analysis reports, and SIL certificates, significantly shortening the safety standard filing cycle for enterprises. According to statistics from 12 completed projects, the average cycle from contract signing to successful acceptance is 18 days, comprising 6 days for electrical installation, 5 days for integrated commissioning and testing, and 7 days for preparing filing documentation. This represents a time savings of approximately 60% compared to when companies organize the procurement and integration of solutions on their own.
III. Typical Application Cases
Among the 12 companies where the project has been completed, the installations span four industries: steel and metallurgy (6 companies), chemicals (3 companies), ports (2 companies), and power generation (1 company). The crane capacities range from 16 metric tons to 160 metric tons, with a total of 78 safety monitoring systems installed. After installing the Krude Heavy Industry safety monitoring system on a group of 32-metric-ton metallurgical overhead cranes at a certain steel enterprise, the system not only successfully passed the safety standard acceptance inspection conducted by the local Special Equipment Inspection Institute but also achieved integration of safety monitoring data with the enterprise’s MES system. Crane operation data can now be centrally managed through Krude Heavy Industry’s digital remote monitoring platform (seeDigital Remote Monitoring Solution for Overhead Cranes), managers can check the security status and fault logs at any time via their mobile phones.
IV. Market Strategy
The Krude Heavy Industry Safety Monitoring and Management System is currently compatible with both newly installed overhead cranes and retrofits of existing cranes. For newly installed overhead cranes, the safety PLC control cabinet can be integrated before the crane leaves the factory. For retrofitted cranes, an external installation solution is used—a safety monitoring cabinet is added next to the existing electrical control cabinet and operates independently without affecting the original control system. The system also includes interfaces for intelligent functions such as anti-sway control and AI vision inspection (seeOverhead Crane Anti-Sway Control Solution), leaving room for future smart upgrades.
