PPr welding equipment. Scheduling scheduled preventive maintenance (PPR)

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How to draw up an electrical equipment maintenance schedule?

How to draw up an annual maintenance schedule for electrical equipment? I will try to answer this question in detail in today's post.

It's not a secret for anyone that the main document according to which the repair of electrical equipment is carried out is the annual schedule of preventive maintenance of electrical equipment, on the basis of which the need for repair personnel, in materials, spare parts, and components is determined. It includes each unit subject to overhaul and current repair of electrical equipment.

To draw up an annual preventive maintenance schedule (PPR schedule) of electrical equipment, we need standards for the frequency of equipment repair. These data can be found in the manufacturer's passport data for electrical equipment, if the plant specifically regulates this, or use the reference book "System of maintenance and repair of power equipment". I am using the reference book of 2008, therefore, further I will refer to this source.

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So. There is a certain amount of power equipment on your farm. All this equipment must be included in the PPR schedule. But first, a little general information about what the annual PPR schedule is.

Column 1 indicates the name of the equipment, as a rule, concise and understandable information about the equipment, for example, name and type, capacity, manufacturer, etc. Column 2 - number according to the scheme (inventory number). I tend to use numbers from electrical one-line diagrams or from technological ones. Columns 3-5 indicate the resource standards between major repairs and current ones. Columns 6-10 indicate the dates of the last major and current repairs. In columns 11-22, each of which corresponds to one month, the type of planned repair is indicated by a symbol: K - capital, T - current. Columns 23 and 24, respectively, record the annual downtime of equipment in repair and the annual fund of working time. Now that we have considered the general provisions on the PPR schedule, we will consider a specific example. Suppose that in our electrical facilities, in building 541, we have: 1) a three-phase two-winding oil transformer (T-1 according to the scheme) 6 / 0.4 kV, 1000 kVA; 2) pump electric motor, asynchronous (designation according to the scheme Н-1), Рн = 125 kW; Step 1. We enter our equipment into the empty form of the PPR schedule.

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Step 2. At this stage, we determine the resource standards between repairs and downtime. a) For our transformer: open the reference book page 205 and in the table "Standards for the frequency, duration and labor intensity of repairing transformers and complete substations" we find a description of the equipment that fits our transformer. For our capacity of 1000 kVA, we select the values ​​of the frequency of repairs and downtime during major and current repairs, and write them down in our schedule.

b) For an electric motor according to the same scheme - page 151 Table 7.1 (see figure).

The found standards in the tables are transferred to our PPR schedule

January 2005 "href =" / text / category / yanvarmz_2005_g_ / "rel =" bookmark "> January 2005, current - January 2008. For the H-1 pump engine, capital - September 2009, current - March 2010. Submit this data into a graph.

January 2011 "href =" / text / category / yanvarmz_2011_g_ / "rel =" bookmark "> January 2011, it is for this year that we draw up a schedule, therefore, in column 8 (January) for the T-1 transformer we enter“ T".

September 2015 "href =" / text / category / sentyabrmz_2015_g_ / "rel =" bookmark "> September 2015. The current one is held 2 times a year (every 6 months) and, according to the last current repair, we plan for March and September 2011 An important note: if the electrical equipment is newly installed, then all types of repair, as a rule, "dance" from the date of putting the equipment into operation. Our schedule takes the following form:

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An important note: at some enterprises, power engineers in their annual PPR schedules, instead of the last two graphs of annual downtime and annual fund, indicate only one column - “Labor intensity, person * hour”. This labor intensity is calculated by the number of pieces of equipment and the labor intensity norms of one repair. This scheme is convenient when working with contractors performing repair work. Do not forget that the dates of repairs must be coordinated with the mechanical service and, if necessary, the instrumentation and control department, as well as with other structural divisions directly related to the repair and maintenance of related equipment. If you have any questions about drawing up an annual PPR schedule, ask questions, I will try, if possible, to answer them in detail.

Planned preventive repair is the easiest and safest way to plan your repairs.

The main conditions that ensure a planned preventive relationship regarding the repair of equipment are as follows:

The main need for electrical equipment for repair is satisfied due to scheduled repairs performed after a specific number of hours worked by it, due to which a periodically repeating cycle is formed;

Each scheduled preventive repair of electrical installations is carried out to the extent necessary to eliminate all existing defects, as well as to ensure the natural operation of the equipment until the next scheduled repair. The term of scheduled repairs is determined accordingly with the established periods;

The organization of scheduled preventive maintenance and control is based on the usual scope of work, the implementation of which ensures the efficient condition of the equipment;

The normal scope of work is determined by the established optimal periods between scheduled periodic repairs;

Between scheduled periods, electrical equipment undergoes scheduled inspections and checks, which are a means of prevention.

The frequency and alternation of scheduled equipment repair depends on the purpose of the equipment, its design and repair features, dimensions and operating conditions. Preparation for scheduled repair is based on clarification of defects, selection of spare parts and spare parts that will need to be replaced during repair. An algorithm for carrying out this repair is specially created, which ensures uninterrupted operation during the repair. Such an approach to preparation makes it possible to carry out a complete repair of equipment without disrupting the usual work of production.

Well-designed preventive repairs provide for:

Planning;

Preparation of electrical equipment for scheduled repairs;

Carrying out scheduled repairs;

Carrying out activities related to scheduled maintenance and repair.

The system of preventive maintenance of equipment includes a couple of stages:

1. Stage between overhauls

It is carried out without disrupting the operation of the equipment. Includes: systematic cleaning; systematic lubrication; systematic examination; systematic adjustment of the operation of electrical equipment; replacement of parts that have a short service life; elimination of small malfunctions.

In other words, this is prevention, which includes daily inspection and maintenance, while it must be properly organized in order to maximize the life of the equipment, to preserve quality work, reduce the cost of scheduled repairs.

The main work performed at the overhaul stage:

Tracking the status of equipment;

Conduct by employees of the rules of appropriate use;

Daily cleaning and lubrication;

Timely elimination of minor breakdowns and adjustment of mechanisms.

2. Current stage

Preventive maintenance of electrical equipment is most often carried out without disassembling the equipment, only its work stops. It includes the elimination of breakdowns that occurred during the period of work. At the current stage, measurements and tests are carried out, with the help of which equipment flaws are identified at an early stage.

The decision on the suitability of electrical equipment is made by the repairers. This decree is based on a comparison of the test findings during routine maintenance. In addition to scheduled repairs, to eliminate defects in the equipment, work is performed outside the plan. They are carried out after the exhaustion of the entire resource of the equipment.

3. Stage middle

It is carried out for the complete or partial restoration of old equipment. Includes disassembly of assemblies intended for viewing, cleaning mechanisms and eliminating identified defects, replacing some quickly wearing parts. The middle stage is carried out no more than 1 time per year.

The system at the middle stage of scheduled preventive maintenance of equipment includes the installation of the cycle, volume and sequence of work in accordance with the normative and technical documentation. The middle stage affects the maintenance of the equipment in good condition.

4. Overhaul

It is carried out by opening electrical equipment, its full check with inspection of all details. Includes tests, measurements, elimination of identified malfunctions, as a result of which the modernization of electrical equipment is carried out. As a result of a major overhaul, a complete restoration takes place technical parameters devices.

Overhaul is possible only after the overhaul stage. To carry it out, you must do the following:

Draw up work production schedules;

Spend preliminary inspection and verification;

Prepare documents;

Prepare tools and necessary replacement parts;

Carry out fire-fighting measures.

Overhaul includes:

Replacement or restoration of worn-out mechanisms;

Modernization of any mechanisms;

Performing preventive checks and measurements;

Carrying out work related to the elimination of minor damage.

Malfunctions discovered during the equipment check are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.

Each separate species equipment has its own frequency of scheduled preventive maintenance, which is regulated by the Technical Operation Rules. All activities are reflected in the documentation, strict records are kept of the availability of equipment, as well as its condition. According to the approved annual plan, a nomenclature plan is created, which reflects the implementation of capital and current repairs. Before starting current or major repairs, it is necessary to clarify the date of installation of electrical equipment for repair.

Schedule of the preventive maintenance year- this is the basis for drawing up a budget plan for the year, developed 2 times a year. The sum of the year of the plan-estimate is divided by months and quarters, it all depends on the period of the overhaul.

Today, for the system of scheduled preventive maintenance of equipment, computer and microprocessor technology (structures, stands, installations for diagnostics and tests) is most often used, which affects the prevention of equipment wear, lower repair costs, and also contributes to an increase in operational efficiency.

For the repair of complex equipment (computers, power equipment), proprietary service is increasingly used, which is carried out by special divisions of the manufacturer. Currently, the processing enterprises operate a system of scheduled preventive maintenance of equipment (TSHR), which is a progressive form of organization of repair work. PPR is a set of organizational and technical measures aimed at maintaining equipment in working order and preventing its emergency exit from operation. Each machine, after working out a certain number of hours, stops and undergoes preventive inspection or repair, the frequency of which is determined by the design features and operating conditions of the machines. The PPR system at RUE MZIV provides for the following types of services: 1.

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Table 3.3 Works regulated by the Regulations on PPR for mechanical and electrothermal equipment Name of equipment Types of maintenance and repairs Frequency, months. The number of TO, TP and K in the repair cycle during the service life before decommissioning The structure of the repair cycle Amortization period, years Electric boilers, grills, braziers, autoclaves TO 1 100 5TO… TP-10 TP 6 18 5TO-TP… k 60 1 ... 5TO-IP-K Electric stoves, cabinets, sko TO 1 100 5TO-TP ... 10 breeds, bain-marie TP 6 20 ... 5TO-TP Electric boilers TO 1 50 5TO-TP ... 5 TP 6 8 ... 5TO-TP-k 30 1 5TO-TR-K Electric steam boilers TO 1 100 5TO-TP… 10 pairs of TR 6 17 5TO-TR-K 36 2 Potato-cleaning machines TO 1 80 5TO-TP ...

Equipment PPR system

In some industries, I happened to see how they remove an old, unusable bearing and put another old bearing on the assembly, of course, such an attitude to the financing of production will also cause a corresponding return on production.

• The quality of repairs by personnel, with poor-quality performance, breakdowns will be more frequent. In this case, it will be necessary to schedule repairs and equipment maintenance more often.
• Repair planning quality, qualifications of equipment repair organizers. The organizers of equipment repairs in production include a mechanic, and on large production lines, even a completely department of the chief mechanic.

Drawing up a schedule for scheduled preventive maintenance of equipment

It consists in replacing individual worn-out parts, eliminating defects, performing lubrication and fastening operations, etc. Overhaul is a repair carried out to restore the resource of a product with the replacement or restoration of any of its parts. Major and current repairs can be planned and unplanned.

Attention

Planned repairs are being carried out on schedule. Unscheduled repairs are carried out in order to eliminate the consequences of sudden failures and breakdowns. In most cases, commercial equipment undergoes scheduled overhaul. Planned overhaul is not provided for equipment that does not have mechanical wear (for example, thermal) during operation.

• Major repairs.
PPR of equipment, it is also scheduled preventive maintenance Today we will consider the weekly repair of equipment (PPR or MOT). It is called weekly symbolically, in fact, depending on the specifics of the equipment, repairs can be organized both more often, for example, several times a week (which is very rare), or much less often, for example, once every two weeks. Or maybe once a month (such repairs are much more common).

PPr graph of technological equipment in food production sample

Here you need to partially disassemble the mechanism, replace and restore worn parts. It is performed without removing the mechanism from the foundation. 5. Overhaul, consisting in replacing worn out parts and assemblies, checking and adjusting machines and restoring them in accordance with technical conditions.

Overhaul involves complete disassembly of the equipment with removal, if necessary, from the foundation. Inspections, current and major repairs are carried out by special repair personnel with the involvement of service staff. At the heart of the preparation of the PM plan are the standards and structure of the repair cycle.

The repair cycle is the operating time of the machine from the beginning of its commissioning to the first major overhaul. It depends on the durability of the parts and the operating conditions of the equipment.
These data can be found in the manufacturer's passport data, if the plant specifically regulates this, or use the reference book "Maintenance and repair system". There is a certain amount of equipment. All this equipment must be included in the PPR schedule. Column 1 indicates the name of the equipment, as a rule, concise and understandable information about the equipment.
In column 2 - the number of equipment In column 3-4 - the resource standards between major repairs and current ones are indicated. (See Appendix 2) Columns 5-6 - the labor intensity of one repair (see Table 2 Appendix 3) based on the list of defects. In columns 7-8 - the dates of the last major and current repairs are indicated (conditionally, we take the month of January of the current year) In columns 9-20, each of which corresponds to one month, the symbol indicates the type of planned repair: K - major, T - current.

Info

For the efficient operation of equipment at RUE MZIV, a clear organization of its material and technical maintenance is necessary. A large number of this is assigned to the organization of equipment repair. The essence of the repair is to preserve and restore the performance of equipment and mechanisms by replacing or restoring worn parts and adjusting mechanisms.

Important

Annually more than 10-12% of equipment undergoes major overhaul, 20-30% - medium and 90-100% - small. The cost of repair and maintenance of equipment is more than 10% of the cost of production. Over the entire service life of the machine, the cost of repairing it is several times higher than its original cost.

Reliability is the property of equipment to remain operational for a certain operating time, that is, work without failure for a given period of time. Durability reflects such a property of the equipment as maintaining operability until major overhaul or decommissioning. Maintainability is the ability of equipment to prevent, detect, and eliminate failures and malfunctions.