Schedules of preventive maintenance of production equipment. Drawing up a schedule for preventive maintenance of equipment. Instructions for filling out the annual schedule for maintenance and repairs of equipment of the division

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

It's no secret that the main document by 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, materials, spare parts, and components is determined. It includes each unit subject to major and current repairs of electrical equipment.

For compiling annual schedule preventive maintenance (PPR schedule) of electrical equipment, we will need standards for the frequency of equipment repairs. These data can be found in the manufacturer's passport data for electrical equipment, if the plant specifically regulates this, or use the "System Maintenance and repair power equipment". I use A.I. FMD in 2008, therefore, I will refer to this source further.

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So. Your household has a certain amount of power equipment. All this equipment must be included in the PPR schedule. But first, some general information about the annual PPR schedule.

Column 1 indicates the name of the equipment, as a rule, brief and understandable information about the equipment, for example, name and type, power, manufacturer, etc. Column 2 - number according to the scheme (inventory number). I often use numbers from electrical single-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 symbol indicates: K - capital, T - current. In columns 23 and 24, respectively, the annual downtime of equipment in repair and the annual fund of working hours are recorded. Now that we have considered general provisions about the PPR schedule, consider a specific example. Let's assume 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 motor, asynchronous (designation according to the scheme H-1), Рн=125 kW;

Step 1. We enter our equipment into the empty form of the PPR schedule.

Step 2 At this stage, we determine the resource standards between repairs and downtime:

a) For our transformer: we open the reference book p. 205 and in the table "Standards for the frequency, duration and complexity of repair of transformers and complete substations" we find a description of the equipment that fits our transformer. For our power 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).

We transfer the found standards in the tables to our PPR schedule

Step 3 For the selected electrical equipment, we need to determine the number and type of repairs in the coming year. To do this, we need to determine the dates of the last repairs - major and current. Suppose we are making a schedule for 2011. The equipment is operational, the dates of repairs are known to us. For T-1, a major overhaul was carried out in January 2005, the current one - in January 2008. For the pump engine N-1, the capital one is September 2009, the current one is March 2010. We enter this data into the chart.

We determine when and what types of repairs are due for the T-1 transformer in 2011. As we know there are 8640 hours in a year. We take the found resource standard between major repairs for the T-1 transformer 103680 h and divide it by the number of hours in a year 8640 h. We calculate 103680/8640 = 12 years. Thus, the next overhaul should be carried out 12 years after the last overhaul, and since. the last one was in January 2005, which means that the next one is planned for January 2017. For current repairs, the same principle of operation: 25920/8640=3 years. The last maintenance was carried out in January 2008, thus. 2008+3=2011. The next current repair is in January 2011, it is for this year that we draw up a schedule, therefore, in column 8 (January) we enter “T” for the T-1 transformer.

For the electric motor we get; major repairs are carried out every 6 years and are planned for September 2015. The current one is held 2 times a year (every 6 months) and, according to the latest current repairs, we plan for March and September 2011. Important note: if the electrical equipment is newly mounted, then all types of repairs, as a rule, "dance" from the date the equipment was put into operation.

Our chart looks like this:

Step 4 We determine the annual downtime for repairs. For a transformer, it will be equal to 8 hours, because. in 2011, we planned one current repair, and in the resource norms for current repairs, the denominator is 8 hours. For the N-1 electric motor in 2011 there will be two current repairs, the downtime rate in the current repair is 10 hours. Multiply 10 hours by 2 and get an annual downtime equal to 20 hours. In the column of the annual working time fund, we indicate the number of hours that this equipment will be in operation, minus downtime for repairs. We get the final form of our graph.

An important note: at some enterprises, power engineers in their annual PPR schedules, instead of the last two columns of annual downtime and the annual fund, indicate only one column - “Labor intensity, man * hour”. This labor intensity is calculated according to the number of pieces of equipment and the norms of labor intensity 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 service, as well as with other structural divisions directly related to the repair and maintenance of related equipment.

If you have any questions about the preparation of the annual PPR schedule, ask questions, I will try, if possible, to answer them in detail.

2. The system of preventive maintenance of equipment

The planned preventive form of organizing the repair of technological equipment throughout the world is recognized as the most effective and has found the greatest distribution. The development of a system of planned preventive maintenance of equipment began in the USSR in 1923. At present, various versions of the PPR system are the basis for organizing maintenance and repair of equipment at enterprises in most industries in the field of material production and service.

Equipment preventive maintenance system is a set of planned organizational and technical measures for the care, supervision of equipment, its maintenance and repair. The purpose of these measures is to prevent progressively increasing wear, prevent accidents and maintain equipment in constant readiness for operation. The PPR system involves the implementation of preventive maintenance and scheduled repairs of equipment after a certain number of hours of its operation, while the alternation and frequency of activities are determined by the characteristics of the equipment and its operating conditions.

PPR system includes

Maintenance

and scheduled maintenance of equipment.

Maintenance- this is a complex of operations to maintain the operability of equipment when used for its intended purpose, during storage and transportation. Maintenance includes

ongoing overhaul maintenance

and periodic preventive maintenance operations.

Current overhaul maintenance consists in daily monitoring of the condition of the equipment and compliance with the rules of its operation, timely regulation of mechanisms and elimination of minor malfunctions that arise. These works are carried out by the main workers and on-duty maintenance personnel (mechanics, oilers, electricians), as a rule, without equipment downtime. Periodic preventive maintenance operations are regulated and carried out by maintenance personnel according to a predetermined schedule without equipment downtime. These operations include

inspections carried out to identify defects that must be eliminated immediately or during the next scheduled repair;

flushing and oil change provided for equipment with a centralized and crankcase lubrication system;

accuracy checks performed by department personnel technical control and chief mechanic.

Scheduled repairs includes

Maintenance

and overhaul.

Maintenance is carried out during the operation of the equipment in order to ensure its operability until the next scheduled repair (the next current or overhaul). The current repair consists in the replacement or restoration of individual parts (parts, assembly units) of the equipment and the adjustment of its mechanisms. Overhaul is carried out in order to restore the full or close to full resource of the equipment (accuracy, power, performance). Overhaul, as a rule, requires repair work in stationary conditions and the use of special technological equipment. Therefore, it is usually required to remove the equipment from the foundation at the site of operation and transport it to a specialized unit where a major overhaul is carried out. During a major overhaul, a complete disassembly of the equipment is carried out with a check of all its parts, replacement and restoration of worn parts, alignment of coordinates, etc.

The repair and maintenance system, depending on the nature and operating conditions of the equipment, can function in various organizational forms:

in the form of a post-inspection system,

periodic repair systems

or standard repair systems.

Post-examination system involves carrying out, according to a predetermined schedule, inspections of equipment, during which its condition is established and a list of defects is compiled. Based on the inspection data, the timing and content of the upcoming repairs are determined. This system is applicable to some types of equipment operating under stable conditions.

Periodic Repair System involves planning the timing and volumes repair work of all types on the basis of a developed regulatory framework. The actual scope of work is adjusted relative to the standard according to the results of the inspection. This system is most common in mechanical engineering.

Standard repair system involves planning the scope and scope of repairs based on precisely established standards and strict adherence to repair plans, regardless of the actual condition of the equipment. This system applies to equipment whose unscheduled stop is unacceptable or dangerous (for example, lifting and transport devices).

The effectiveness of the PPR system is largely determined by the development of its regulatory framework and the accuracy of the established standards. The standards of the PPR system of an enterprise are differentiated by groups of equipment. Basic repair standards are

repair cycles and their structure,

the complexity and material intensity of repair work,

inventories for repair needs.

Repair cycle- this is the period of time from the moment the equipment is put into operation until the first overhaul or between two consecutive overhauls. The repair cycle is the smallest recurring period of operation of the equipment, during which all types of maintenance and repair are carried out in the established sequence in accordance with the structure of the repair cycle. The structure of the repair cycle establishes the list, quantity and sequence of equipment repairs during the repair cycle. For example, a repair cycle structure might include the following repair sequence:

K - T 1 - T 2 - T 3 - TO,

where T 1 , T 2 and T 3 - respectively, the first, second and third current repairs;

TO- overhaul (only one overhaul is included in the repair cycle).

The content of the work performed within the framework of each of the current repairs is regulated and may differ significantly from others present in the repair cycle. The structure of the repair cycle may include a small ( M) and average ( WITH) repair: for example, T 2 = C; T 1 = T 3 = M.

Similarly, the structure of the maintenance cycle can be presented, which establishes the list, quantity and sequence of work on overhaul maintenance (replacement inspection, partial inspection, replenishment of lubricant, replacement of lubricant, preventive adjustment, etc.). It is possible to include maintenance work ( THEN) into the structure of the repair cycle, for example:

WHO 1 - T 1 - THEN 2 - T 2 - THEN 3 - T 3 - THEN 4 - TO.

The repair cycle is measured by the operating time of the equipment, downtime in repair is not included in the cycle. The duration of the repair cycle is determined by the service life of the main mechanisms and parts, the replacement or repair of which can be carried out during the complete disassembly of the equipment. Wear of the main parts depends on many factors, the main ones being

type of production, on which the intensity of equipment use depends;

physical and mechanical properties of the processed material, on which the intensity of wear of equipment and its parts depends;

operating conditions, such as high humidity, dust and gas contamination;

equipment accuracy class, which determines the level of requirements for monitoring the technical condition of equipment;

Repair cycle duration T is determined in worked machine hours by calculation according to empirical dependencies, taking into account the influence of many factors, including those listed above:

where T n- normative repair cycle, hours (for example, for certain metal-cutting machines T n= 16,800 hours);

ß P , ß m , ß at , ß T , ß R- coefficients taking into account, respectively, the type of production, the type of material being processed, the operating conditions, the accuracy and dimensions of the equipment.

The values ​​of the coefficients and the standard duration of the repair cycle are determined on the basis of a generalization and analysis of the actual data of the enterprise or are taken according to reference data.

overhaul period T mr and maintenance intervals T then expressed as the number of hours worked:

, (104)

, (105)

where n T and n THEN- respectively, the number of current repairs and maintenance work in one repair cycle.

The duration of the repair cycle, the overhaul period and the frequency of maintenance can be expressed in years or months, if the shift of the equipment is known. Proper maintenance of equipment during its operation, carrying out organizational and technical measures that extend the service life of parts and parts of equipment, contribute to a change in the actual duration of the repair cycle and overhaul periods compared to the normative ones. The service life of wear parts and parts of equipment is shorter than the overhaul period. Therefore, it is advisable to replace them as they wear out during the overhaul period. At the same time, the complexity of repairs is reduced, the amount of work on overhaul maintenance increases.

The labor intensity and material intensity of repair and maintenance of equipment depend on its design features. The more complex the equipment, the larger its dimensions and the higher the accuracy of processing, the higher the complexity of its repair and maintenance, the higher the labor intensity and material consumption of these works. On the basis of the complexity of the repair, the equipment is divided into categories of repair complexity. The complexity of repair work separately for the mechanical and electrical parts of the equipment is determined through the labor intensity of a unit of repair complexity.

Category of repair complexity (TO) is the degree of difficulty in repairing equipment. The category of repair complexity of equipment is determined by the number of repair complexity units assigned to this group of equipment by comparing it with the accepted standard - conditional equipment. At domestic engineering enterprises, the repair complexity of conditional equipment is traditionally taken as a unit of repair complexity of the mechanical part, the complexity of the overhaul of which is 50 hours, for the unit of repair complexity of its electrical part - 12.5 hours (1/11 of the labor intensity of the overhaul of a 1K62 screw-cutting lathe, which was assigned the 11th category of repair complexity).

repair unit (R. e.) is the labor intensity of the corresponding type of equipment repair of the first category of repair complexity. The labor intensity standards for one repair unit are set according to the types of repair work (flushing, inspection, inspection, maintenance and overhaul) separately for locksmith, machine and other work. The labor intensity of each type of repair work is determined by multiplying the time norms for this type of work for one repair unit by the number of repair units of the complexity category of repair of the corresponding equipment.

The total labor intensity of repair work (Q) in the planning period is calculated by the formula:

q K , q T and q THEN- norms of labor intensity of capital and current repairs, maintenance per one repair unit, hours;

n TO , n T , n THEN- the number of major and current repairs, maintenance work in the planned period.

The main document by 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, materials, spare parts, and components is determined. It includes each unit subject to major and current repairs of electrical equipment.

To draw up an annual preventive maintenance schedule (PPR schedule) for electrical equipment, we need standards for the frequency of equipment repairs. 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 for maintenance and repair of power equipment". Let's use the reference book of A.I. FMD 2008.

Let's take a concrete example. Let's assume that in our electrical facilities, in building 541, we have:

1. Three-phase two-winding oil transformer 6/0.4 kV,

2. Pump motor, asynchronous Рн=125 kW;

Step 1. We enter our equipment into the empty form of the table “Initial data for drawing up a PPR schedule”.

Step 2 At this stage, we determine the resource standards between repairs and downtime.

a) For our transformer: we open the reference book p.205 and in the table "Standards for the frequency, duration and complexity of repair of transformers and complete substations" we find a description of the equipment that fits our transformer. For our power of 1000 kVA, we select the values ​​​​of the frequency of repairs and downtime during major and current repairs, and write them down in the table "Initial data for drawing up a PPR schedule."

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

We transfer the found standards in the tables to the table “Initial data for drawing up a PPR schedule”.

Table. - Initial data for drawing up a PPR schedule

Regular inspections of electrical equipment (without turning them off) are carried out once a month. The duration and complexity of maintenance of electrical equipment should be 10% of the current repair.

In order to determine how long the repair will last in months, it is necessary to divide the number of hours of the frequency of repairs for equipment by the number of hours per month. We make a calculation for the T-1 transformer: 103680/720 = 144 months.

Step 3 After the table “Initial data for drawing up a PPR schedule”, it is necessary to calculate the number of repairs between inspections and draw up a structure for the repair cycle for each type of equipment.

Step 4

For the selected electrical equipment, we need to determine the number and type of repairs in the coming year. To do this, we need to determine the dates of the last repairs - major and current. Suppose we are making a schedule for 2014. The equipment is operational, the dates of repairs are known to us. For the T-1 transformer, the overhaul was carried out in January 2008, the current one - in January 2011. For the N-1 electric motor, the capital one is September 2012, the current one is March 2013.

We determine when and what types of repairs are due for the T-1 transformer in 2014. As we know there are 8640 hours in a year. We take the found resource standard between major repairs for the T-1 transformer 103680 hours and divide it by the number of hours in a year 8640 hours. We calculate 103680/8640 = 12 years. Thus, the next overhaul should be carried out 12 years after the last overhaul, and since. the last one was in January 2008, so the next one is planned for January 2020.

For current repairs, the same principle of operation: 25920/8640=3 years. The last current repair was carried out in January 2011, thus. 2011+3=2014. The next current repair is in January 2014, it is for this year that we draw up a schedule, therefore, in column 8 (January) for the T-1 transformer, enter “T”.

For the electric motor, we get: a major overhaul is carried out every 6 years and is planned for September 2018. The current one is held 2 times a year (every 6 months) and, according to the latest current repairs, we plan for March and September 2014.

Important note: if the electrical equipment is newly mounted, then all types of repairs, as a rule, "dance" from the date the equipment was put into operation.

Step 5 We determine the annual downtime of current repairs. For a transformer, it will be equal to 8 hours, because. in 2014, we planned one current repair, and in terms of resource for current repairs - 8 hours. For the N-1 electric motor in 2014 there will be two current repairs, the downtime rate in the current repair is 10 hours. Multiply 10 hours by 2 and get an annual downtime equal to 20 hours .

Step 6 Determine the annual labor intensity of repairs.

For a transformer, it will be equal to 62 people / hour. in 2014, we planned one current repair, and in terms of resource for current repairs - 62 people per hour. For the N-1 electric motor in 2014 there will be two current repairs, the labor intensity rate in the current repair is 20 people per hour. We multiply 20 people / hour by 2 and get the annual labor intensity - 40 people / hour.

Our chart looks like this:

Step 7 Based on the structure of the repair cycle for each equipment, we put down the number of inspections between repairs and determine the annual downtime for maintenance.

For one transformer, downtime will be equal to 0.8 hours, according to the structure of the repair cycle, the number of inspections between repairs is 35TO. In 2014, we planned one current repair, so the number of inspections will be only 11, the annual maintenance downtime rate will be 8.8 (11 times 0.8).

For the N-1 electric motor, downtime will be equal to 0.1 hours, according to the structure of the repair cycle, the number of inspections between repairs is 5TO. In 2014, we planned two current repairs, so the number of inspections will be 10, the annual maintenance downtime rate will be 1.0 (10 times 0.1).

The labor intensity is calculated by the number of pieces of equipment and the norms of labor intensity of one repair. For a transformer, it will be equal to 68.2 people / hour (we multiply 6.2 people / hour by 11TO).

For the N-1 electric motor in 2014, it will be equal to 20 people / hour (2 people / hour multiplied by 10 TO).

We get the final form of our graph.

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 service, as well as with other structural units that are directly related to the repair and maintenance of related equipment.

Table 6.1., column 9, line "Total".

Table 6.6., PPR schedule, column 19, line "Total".

Table 6.1., column 4, line "Total".

successful entrepreneurial activity, especially in the manufacturing sectors of the real sector of the economy, is directly related to the accuracy of fulfilling contractual obligations. Their implementation is influenced by many internal and external factors and conditions. In this case, a well-designed plan for the repair and maintenance of equipment can play an important role.

The model of cause-and-effect relationships that affect the fulfillment of contractual obligations is shown in fig. one.

Rice. 1. Causal relationships in case of violation of contractual obligations

As can be seen from the presented diagram, a malfunction and / or emergency failure of the equipment causes the occurrence of defects and additional costs associated with its elimination, downtime of the workflow, and the need for unscheduled repairs.

To prevent such a development of events, the repair service of the enterprise is called upon, whose tasks are:

• ensuring constant operational readiness of existing equipment;
• lengthening the overhaul period of equipment operation;
• reducing the cost of repairing machinery and equipment.

The functions of the repair service of the enterprise are as follows:

All these functions and related activities are aimed at ensuring the required level of equipment reliability under specified operating conditions at minimal cost for its maintenance and repair.

An important component of the organization of equipment repair is the preparatory work - the preparation of defective statements and specifications for repairs.

Note!

When planning the repair and maintenance of equipment, it is necessary to use such a specific repair indicator as a “repair unit”, which characterizes the standard labor and / or time costs for equipment repair. Accordingly, any repair of equipment is estimated in repair units, and labor costs for the implementation of preventive operations to maintain equipment in working condition are also estimated in repair units.

The downtime of equipment during repair and maintenance work is affected by:

• complexity of the problem;
• the repair method used;
• the composition of the repair team involved in the repair;
• technology used for repair work, etc.

Since at a particular enterprise these conditions change quite rarely, when planning repair work, it becomes possible to use pre-developed norms and standards.

Repair work is divided according to the level of complexity of their implementation (in Fig. 2 they are presented in ascending order).

Rice. 2. Types of repair work by the level of complexity of their implementation

Overhaul and medium repairs of equipment are regulated by established overhaul cycles, and the entire set of repairs performed is a single preventive maintenance system(PPR).

Note!

The PPR system also establishes the standards for work on overhaul maintenance. The volume of these works cannot be precisely regulated, therefore the number of repair workers at the enterprise is most often determined by the standards of service.

In addition to scheduled repairs, the enterprises also carry out emergency and recovery repairs as needed. As the name implies, such repairs are unscheduled and most often urgent, strongly affecting the rhythm and organization of the main production process. If possible, it is necessary to avoid, or rather, prevent the occurrence of emergency breakdowns and, accordingly, the need for such repairs.

When drawing up a repair plan, it is necessary to determine:

• types and terms of repair, their duration, labor intensity and necessary support for each machine;
• the total volume of repair work by shops and enterprise, with a monthly breakdown;
• the necessary number of repair workers, a complete set of specialized repair teams and workers engaged in equipment maintenance, as well as an appropriate fund wages;
• the quantity and cost of the necessary materials with reference to the repair schedule;
• temporary fund of planned downtime of equipment under repair;
• the cost of repairs.

The repair work schedule is drawn up in the form of a Gantt chart (Fig. 3).

Rice. 3. Workshop equipment repair schedule

On each piece of equipment, a schedule and structure of the overhaul cycle are posted, which indicate the timing and type of repairs performed specifically for this piece of equipment. Naturally, the general and individual schedules must match.

For your information

As shows comparative analysis, it is often much more profitable for an enterprise to use repair services provided by third-party enterprises than to maintain its own repair service. However, in any case, the enterprise must have an employee responsible for analyzing the technical condition of the equipment, drawing up schedules for its repair and for timely placing orders for repairs with the relevant counterparties.

A planned preventive maintenance plan is being developed in without fail must be consistent with production plans, sales plans, as well as planned stocks finished products in the company's warehouse.

With intense planned tasks, maintenance and adjustment of equipment can be performed in the evening and at night.

In order to evenly load the repair personnel throughout the year, the repair schedule is adjusted so that the amount of work in standard hours by month is approximately the same. To do this, part of the repair work from the month with a significant excess of the volume in standard hours is transferred to months with an underload of workers compared to the available monthly fund of time.

Repair time can be reduced by using the nodal repair method. At the same time, the company creates a stock of ready-to-install or repaired units. If the corresponding unit fails, it is simply replaced with a similar repaired one, and the damaged unit is sent for repair.

When evaluating and analyzing the work of the repair service, the following technical and economic indicators are used:

• planned and actual downtime of equipment under repair per one repair unit;
• the turnover of the fleet of spare parts, equal to the ratio of the cost of used spare parts to the average balance of them in the pantries. This indicator should be as large as possible;
• planned standards for the stock of repair units, parts and accessories. Such a standard should ensure the implementation of scheduled and unscheduled repairs for the period of ordering and delivery of the relevant parts;
• the number of accidents, breakdowns and unscheduled repairs per piece of equipment, which characterizes the effectiveness of the PPR system.

Note!

There is a certain dependence between the given technical and economic indicators. Reducing the downtime of equipment in repair per one repair unit leads to an increase in the number of repair units of installed equipment per one repair worker, since the same amount of repair work can be performed by a smaller number of workers with a reduction in time for it. This helps to reduce the cost of repairing one repair unit.

When performing repair work, it is desirable to create specialized repair sites, and with a large amount of the same type of work, specialized repair services, although it is also possible to use integrated repair teams assigned either to the types of equipment being repaired or to certain production units of the enterprise. In the latter case, the responsibility of repair workers for the condition of the equipment increases, but the maximum labor productivity, minimum downtime and repair costs are not always ensured.

Today, scheduled preventive maintenance is the simplest, but at the same time reliable method of carrying out work. With regard to the resumption of the operation of the equipment, the list of basic conditions that ensure it includes the following:

The units have already worked out a specific number of hours and a new periodic work cycle is coming, which must necessarily precede the scheduled preventive maintenance.

The normal level of repair work is clearly indicated by determining the optimal periods between scheduled periodic maintenance.

Organization of approved works. Control over them is based on the standard scope of work. Their responsible implementation ensures the further full functioning of the existing units.

Scheduled preventive maintenance of electrical installation equipment is carried out to the extent necessary to effectively eliminate all existing defects. It is also carried out to ensure the natural course of operation of the equipment until the subsequent repair. Typically, a scheduled preventive maintenance schedule is drawn up taking into account established periods.

In the intervals between the planned repair work, the electrical equipment is also subject to pre-scheduled inspections and a number of checks, which, in fact, are preventive.

Repair work of electrical equipment

Alternation, periodicity of scheduled repairs of units depend both on their purpose and on their design features, operating conditions, dimensions. The basis of preparation for this work is the clarification of defects, the selection of spare parts and spare parts, which will subsequently need to be replaced. An algorithm for performing this type of manipulation is specially developed, due to which uninterrupted operation of equipment (machines) during repair is possible. Proper preparation of such an action plan makes it possible to carry out a full resumption of the functioning of all devices without disturbing the usual operating mode of production.

Organization of the process

Competent planned preventive maintenance provides for the following sequence:

1. Planning.

2. Preparation of units for repair.

3. Carrying out repair work.

4. Implementation of activities related to repair and scheduled maintenance.

The considered system of scheduled preventive maintenance of equipment has stages: overhaul, current. They can be considered in more detail.

Interrepair stage

The overhaul stage allows repairing the equipment without disrupting the production process. It includes systematic cleaning, lubrication, inspection, adjustment of units. This also includes the elimination of minor faults, the replacement of parts with a short service life. In other words, this is prevention, which is not complete without daily examination and care. It must be properly organized in order to maximize the life of existing equipment.

A serious approach to this issue can significantly reduce the cost of future repairs and contribute to a better and more efficient implementation of the tasks set by the enterprise. The main work that is carried out during the overhaul stage is daily lubrication and cleaning of the units, compliance by all employees with the rules for using devices, monitoring the current state of the equipment, adjusting mechanisms and timely elimination of minor breakdowns.

current stage

This stage of planned preventive repair of electrical equipment often does not involve disassembly of devices, but it includes the rapid elimination and elimination of all breakdowns that have arisen during the operation period. In this case, only the units stop. During the current phase, tests and measurements are carried out, thanks to which equipment defects are detected even at an early stage, and this is very important.

The decision on whether electrical equipment is suitable is made by repair specialists. This is within their purview. They base the issued decision on a comparison of the available conclusions obtained during the tests during the implementation of the planned current repair work.

The elimination of defects in the functioning of the units can be carried out not only during scheduled repairs, but also outside of it. This usually happens after the resource of the equipment has completely exhausted itself.

Carrying out scheduled preventive maintenance: medium stage

Allows you to partially or completely restore the units that have already served their purpose. The stage includes disassembly of the necessary units for viewing them, elimination of identified defects, cleaning of mechanisms and replacement of some rapidly wearing spare parts and parts. It is held annually.

The system of scheduled preventive maintenance at the middle stage includes setting the volume, cyclicity and sequence of the works indicated here in strict accordance with all regulatory and technical documents. Thanks to this, the normal operation of the equipment occurs.

Overhaul and its prerequisites

It is carried out after opening the equipment, its full check with the study of the presence of defects in all parts. V this stage includes measurements, tests, elimination of identified faults, due to which the modernization of units is necessary. Here there is a 100% restoration of the technical parameters of the devices in question.

When is the overhaul of electrical equipment carried out?

Such manipulations are possible only after the completion of the overhaul stage. The following conditions must also be met:

A work schedule has been drawn up.

Conducted preliminary checks and inspections.

All necessary documents have been prepared.

Replacement parts and tools provided.

Fire fighting measures have been taken.

What does a major overhaul include?

The process of repairing electrical equipment in this case consists of:

1. Replacement / restoration of worn out mechanisms.

2. Upgrading devices that require it.

3. Perform measurements and preventive checks.

4. Implementation of work to eliminate minor damage.

Malfunctions and defects that are discovered during the inspection of equipment (machines) are eliminated during the subsequent repair. Breakdowns classified as emergency are repaired immediately. Equipment of different types has its own frequency of activities related to repair work, which is regulated by the rules of technical operation. All manipulations carried out are reflected in the documentation, the strictest records of the availability of units and their condition are kept.

According to the approved plan for the year, a nomenclature plan is created, which records the current / major repairs. Before proceeding with them, the date of stopping the electrical equipment (machines) for repair must be specified.

The scheduled preventive maintenance schedule is the official basis for drawing up a budget plan for the year, developed twice during the specified period. The total amount of the plan-estimate is distributed by months, quarters, taking into account the period of capital repair work.

Peculiarities

To date, the preventive maintenance system provides for the use of microprocessor and computer technology (rigs, structures, test and diagnostic facilities). This prevents equipment wear and tear and reduces refurbishment costs. Also, all this contributes to an increase in operational efficiency, and consequently, the profits of enterprises.

Scheduled preventive maintenance: drawing up a schedule for the year

Consider how the schedule for the year is drawn up. Scheduled preventive maintenance of buildings or electrical equipment is a full-fledged complex of organizational and technical measures closely related to supervision and maintenance. It applies to all types of repairs and is carried out periodically according to a previously drawn up plan. This helps to prevent premature partial or complete wear of equipment, accidents. All fire protection systems are in constant readiness.

Scheduled preventive maintenance is organized according to a system that includes such types of maintenance as:

Weekly technical fix.

Monthly maintenance work.

Annual pre-scheduled preventive maintenance.

The developed regulation on preventive maintenance is approved by the sectoral ministries, as well as departments. The document is obligatory for execution by the enterprises of the industry.

Scheduled preventive maintenance is always carried out in strict accordance with the existing annual work schedule, which includes each mechanism subject to current or major repairs. When compiling this schedule, the standards for the frequency of equipment maintenance are used. They are taken from the passport data of the units prepared by the manufacturer. All available mechanisms, devices are included in the schedule, which indicates brief information about them: quantity, resource standards, labor intensity of one current or major repair. It also records information about the last ongoing current and major repairs.

Additional Information

The regulation on scheduled preventive maintenance contains information on intra-shift maintenance (supervision, care) and preventive inspection of existing equipment. It is usually assigned to operational and duty personnel. It also contains information about the implementation of the planned work.

The benefits of preventive maintenance systems include:

Fixing downtime of units, equipment, machines.

Control over the duration of overhaul periods of operation of devices.

Forecasting the cost of repairing equipment, mechanisms, units.

Accounting for the number of personnel involved in the activity, which depends on the repair complexity.

Analysis of the causes of equipment failure.

Disadvantages of preventive maintenance systems:

The complexity of calculating labor costs.

Lack of convenient and suitable tools for planning (implementing) repair activities.

The complexity of taking into account the parameter/indicator.

The complexity of the operational adjustment of the planned work.

Each preventive maintenance system has an accident-free model of operation/repair of units, but in case of accidents or as a result of wear and tear, unscheduled work can also be carried out related to the full resumption of the operation of the units.

The frequency of stopping the operation of equipment for major or current repairs is determined by the service life of wear mechanisms, parts, assemblies. And their duration is determined by the time that is necessary to perform the most time-consuming manipulations.

Lifting machines (aggregates), in addition to routine inspection, are also subject to technical examination. It is carried out by specialists responsible for the supervision of this equipment.