How to make a schedule for equipment inspection. What is scheduled preventative maintenance?

DEVELOPING A PREVENTIVE MAINTENANCE SCHEDULE (PPR)

In order to ensure reliable operation of equipment and prevent malfunctions and wear, enterprises periodically carry out scheduled preventive maintenance of equipment (PPR). It allows you to carry out a number of works aimed at restoring equipment and replacing parts, which ensures economical and continuous operation of the equipment.

The rotation and frequency of scheduled preventive maintenance (PPR) of equipment is determined by the purpose of the equipment, its design and repair features, dimensions and operating conditions.

Equipment is stopped for scheduled maintenance while it is still in working order. This (planned) principle of bringing equipment out for repairs allows necessary preparation to stopping the equipment - both from the service center specialists and from production staff customer. Preparation for scheduled preventive maintenance of equipment consists of identifying equipment defects, selecting and ordering spare parts and parts that should be replaced during repairs.

This preparation allows for the full scope of repair work to be carried out without disturbing normal operation enterprises.

Competent implementation of PPR presupposes:

· planning preventive maintenance of equipment;
· preparation of equipment for scheduled maintenance;
· carrying out scheduled preventive maintenance of equipment;
· Carrying out activities related to scheduled preventative repairs and maintenance of equipment.

Scheduled equipment repairs include the following steps:

1. Between-repair phase of maintenance.

The between-repair stage of equipment maintenance is carried out mainly without stopping the operation of the equipment itself.

The between-repair stage of equipment maintenance consists of:

· systematic cleaning of equipment;
· systematic lubrication of equipment;
systematic inspection of equipment;
· systematic adjustment of equipment operation;
· replacement of parts with a short service life;
· elimination of minor faults and defects.

The maintenance period between repairs is prevention in other words. The maintenance period between repairs includes daily inspection and maintenance of equipment and must be properly organized in order to:

· radically extend the period of operation of the equipment;
· save excellent quality work;
· reduce and speed up costs associated with scheduled repairs.

The maintenance period between repairs consists of:

· tracking the condition of the equipment;
· implementation of rules of proper operation by workers;
· daily cleaning and lubrication;
· timely elimination of minor breakdowns and regulation of mechanisms.

The maintenance period between repairs is carried out without stopping the production process. This maintenance stage is carried out during breaks in equipment operation.

2. Current stage of scheduled maintenance.

The current stage of preventive maintenance is often carried out without opening the equipment, temporarily stopping the operation of the equipment. The current stage of scheduled preventive maintenance consists of eliminating breakdowns that appear during operation and consists of inspection, lubrication of parts, and cleaning of equipment.

The current stage of scheduled preventive maintenance precedes the overhaul. At the current stage of preventive maintenance, important tests and measurements are carried out, leading to the identification of equipment defects at an early stage of their occurrence. Having assembled the equipment at the current stage of scheduled maintenance, it is adjusted and tested.

A decision on the suitability of equipment for further operation is made by repairmen, based on a comparison of test results at the current stage of scheduled maintenance with existing standards and the results of past tests. Testing of equipment that cannot be transported is carried out using electrical mobile laboratories.

In addition to scheduled preventive maintenance, work outside the plan is carried out to eliminate any defects in the operation of equipment. These works are carried out after the entire working life of the equipment has been exhausted. Also, to eliminate the consequences of accidents, emergency repairs are carried out, which require immediate shutdown of the equipment.

3. Middle stage of scheduled maintenance

The middle stage of scheduled preventive maintenance is intended for partial or complete restoration of used equipment.

The middle stage of scheduled maintenance is to disassemble equipment components to inspect, clean parts and eliminate identified defects, change parts and assemblies that wear out quickly and that do not ensure proper use of the equipment until the next major overhaul. The middle stage of scheduled maintenance is carried out no more than once a year.

The middle stage of scheduled preventative maintenance includes repairs in which normative and technical documentation establishes the cyclicity, volume and sequence of repair work, regardless of the technical condition in which the equipment is located.

The middle stage of preventive maintenance ensures that the operation of the equipment is maintained normally and there is little chance that the equipment will fail.

4. Major renovation

Overhaul of equipment is carried out by opening the equipment, checking the equipment with a meticulous inspection of the “internals”, testing, measurements, eliminating identified breakdowns, as a result of which the equipment is modernized. Major repairs ensure the restoration of the original technical characteristics equipment.

Major repairs of equipment are carried out only after the overhaul period. To implement it, the following steps are necessary:

· drawing up work schedules;
· carrying out preliminary inspection and verification;
· preparation of documentation;
· preparation of tools, spare parts;
· implementation of fire prevention and safety measures.

Overhaul of equipment consists of:

· replacement or restoration of worn parts;
· modernization of any parts;
· performing preventive measurements and checks;
· Carrying out work to eliminate minor damage.

Defects that are discovered during equipment inspection are eliminated during subsequent major overhaul of the equipment. Breakdowns that are emergency in nature are eliminated immediately.

A specific type of equipment has its own frequency of scheduled preventive maintenance, which is regulated by the rules of technical operation.

Activities under the PPR system are reflected in the relevant documentation, with strict consideration of the availability of equipment, its condition and movement. The list of documents includes:

· Technical certificate for each mechanism or its duplicate.
· Equipment registration card (appendix to the technical passport).
· Annual cyclical equipment repair schedule.
· Annual plan and estimate for equipment overhaul.
· Monthly plan-report for equipment repairs.
· Acceptance certificate for major repairs.
· Shift log of technological equipment malfunctions.
· Extract from the annual PPR schedule.

Based on the approved annual PPR schedule, a nomenclature plan is drawn up for major and current repairs, broken down by months and quarters. Before starting a major or current repairs It is necessary to clarify the date of equipment delivery for repair.

Annual PPR schedule and tables of initial data are the basis for drawing up an annual budget plan, which is developed twice a year. The annual amount of the estimate plan is divided into quarters and months depending on the period of major repairs according to the PPR schedule for a given year.

Based on the report plan, the accounting department is provided with a report on the costs incurred for major repairs, and the manager is provided with a report on the implementation of the nomenclature repair plan according to the annual PPR schedule.

Currently, computer and microprocessor technology (installations, stands, devices for diagnostics and testing of electrical equipment) are increasingly used for scheduled preventive maintenance (PPR), which influence the prevention of equipment wear and reduction of equipment repair time, reduction of repair costs, as well as helps improve the operating efficiency of electrical equipment.

5. FORMS OF REPAIR DOCUMENTATION

5.1. The repair documentation of this Handbook is maximally unified with the documentation of industry “Systems” Maintenance and repair of power equipment." The maintenance of the following forms of repair documentation is provided (forms 1-19):

a shift log of identified defects and work to eliminate them; repair log; list of defects; cost estimate;

deed of delivery to major renovation;

certificate of release from major repairs;

annual preventive maintenance schedule;

monthly plan-schedule-report of PPR or monthly repair report;

statement of annual repair costs;

act for changing the calendar period of repairs;

shutdown schedule;

log of installation and removal of plugs;

act of acceptance of work after shutdown repairs;

passport of power equipment;

nomenclature of the main equipment of the workshop;

range of auxiliary equipment;

work permit for repair work;

permission to carry out excavation work on the territory.

5.2. Changes and additions to previously existing forms of repair documentation were made based on the results of testing " Uniform provisions on scheduled preventive maintenance of equipment industrial enterprises Russia" (Order of the Ministry of Industry and Science of Russia dated May 29, 2003 05.900 114–108).

5.3. The main document by which equipment repairs are carried out is the annual repair schedule (Form 7), on the basis of which the need for repair personnel, materials, spare parts, and purchased components is determined. It includes each unit of equipment subject to major repairs. The basis for drawing up the annual schedule is the standards for the frequency of equipment repairs given in this Handbook.

5.4. In order to coordinate the timing of repairs of power equipment with technological equipment, the annual schedule is agreed upon with the plant's OGM. If it is necessary to use the services of the chief instrument technician, the planned repair periods are agreed upon with the OCP. The timing of repairs of major equipment that limits the implementation of the production program is agreed upon with the planning department of the enterprise.

5.5. In columns 11–22 of the annual schedule (form 7), each of which corresponds to one month, symbol in the form of a fraction it is indicated: in the numerator - the planned type of repair (K - capital, T - current), in the denominator - the duration of downtime in hours. Notes on the actual completion of repairs in these columns are made by coloring the planned numbers with a colored pencil.

In columns 23 and 24, respectively, the annual equipment downtime for repairs and the annual working time fund are recorded.

5.6. The operational document for equipment repair is a monthly plan-schedule-report, approved by the chief power engineer of the enterprise for each energy department and section (Form 8). It is allowed to maintain a monthly repair report (Form 8A) instead of a monthly plan-schedule-report.

5.7. In this case, monthly repair planning is carried out in accordance with the annual repair schedule.

5.8. In columns 7-37 (Form 8), each of which corresponds to one day of the month, the symbol in the form of a fraction indicates: in the numerator - the type of repair (K - capital, T - current), in the denominator - its duration (current - in hours , capital – in days).

5.9. A note on the actual completion of repairs is made after their completion by a specially appointed responsible person in the OGE, in production workshops - by the workshop foreman.

5.10. The logbook for the installation and removal of plugs (Form 14) is kept by the deputy head of the energy department (head of department, installation, shift supervisor).

5.11. Explanations on the procedure for maintaining other repair documentation are given above in the relevant sections.

5.12. The repair documentation forms given in this section are typical. Depending on the specifics of accounting for repairs carried out in the repair services of enterprises, preventive measures, not regulated by this Handbook (repair inspections, checks, tests, etc.), additional columns (items) may be included in the repair documentation forms.

Form 1

Form 2

Form 3

Form 4

Form 5

Form 6

Form 7

Form 8

Form 8A

Form 9

Form 10

Form 11

Form 12

Form 13

Form 14

Distribution of personnel into groups

After selecting the form of service and the structure of the electrical service of the farm, electricians and engineers are distributed among structural units.

The required number of personnel in maintenance and repair groups or at service areas is determined by the formula.

where N x is the number of personnel in the group (at the site, people);

T i - annual labor costs for performing the first type of work in a group (at a site), person/hour;

The number of personnel in the operational (duty) group is determined.

where KD is the coefficient of shared participation of labor costs for operational (duty) maintenance in the planned costs of maintenance, repairs, and equipment

(K D =0.15…..0.25).

The number of personnel in the repair group is determined as

where N repair is the number of personnel in the repair group (persons);

T i - annual labor costs for repairs, man/hour;

F D - actual working time fund per worker, hours.

The number of personnel in the maintenance group is determined

When distributing personnel, it should be taken into account that, according to the requirements of safety regulations when operating consumer electrical installations, at least two electricians must be assigned to each site (facility), one of whom is appointed senior.

The total number of electricians in groups (in areas) of the electrical service, determined by labor costs (without major repairs), should not differ sharply from total number electricians, determined by average load.

Drawing up schedules for electrical equipment maintenance

Requirements for maintenance and repair schedules

The basis for organizing work on the operation of electrical equipment are monthly, quarterly and annual maintenance and repair schedules. When developing them, the following must be taken into account:

TR dates for electrical equipment should be combined with repair dates for the machines on which it is used;

It is advisable to repair electrical equipment used seasonally before the period of its intensive use;

The planned duration of work must correspond to the complexity category of electrical equipment;

The time for electricians to move around service facilities during the working day must be reduced as much as possible;

The entire working day of electricians should be filled with work as much as possible.

The procedure for drawing up maintenance and maintenance schedules

The schedules are drawn up in the following order:

1. A worksheet is developed, on the basis of which a monthly schedule of preventative maintenance is drawn up. The work tables (Appendix 1) provide a list of electrical equipment of individual production divisions of the economy (complex, farm, mechanical repair shops, subsidiary enterprises, etc.) indicating the timing of installation of equipment, carrying out the latest major, current and emergency repairs, maintenance . Each piece of equipment is shown on a separate line.

Maintenance planning begins with a more complex type, i.e. from major repairs, then routine repairs are planned and lastly the time for maintenance is set.

The duration of a particular type of maintenance work is determined by the frequency and date of its last implementation. If the days of repairs fall on Sundays (Saturdays) or pre-holidays, then the repairs are postponed to a later or earlier date

If the dates of maintenance, repair or repair work coincide, more than complex look repair. Calendar days for major equipment repairs are set depending on the specific conditions of the farm or the organization involved. The timing of subsequent maintenance and repairs is determined by the frequency of their implementation. If the frequency of scheduled preventative repairs or maintenance is violated, they are scheduled for the beginning of the month.

The type of repair (overhaul, current) or maintenance is indicated in the calendar day columns, respectively, with the letters KR, TR or TO. The table also marks weekends (W) and holidays (P).

2. Based on the worksheet data, a monthly PPR schedule is drawn up (Appendix 2). Using data on the labor intensity of maintenance and repairs, the labor costs of electricians are determined by day to complete the planned amount of work. Repair costs are not taken into account if this type of repair is performed by a third party.

In some cases: with territorial dispersion of units and low cost labor for maintenance (0.5-1h) and current repairs (2-8h); If there is a lack of means of transporting workers, the frequency of routine repairs and maintenance can be neglected. In this case, planning is carried out based on: a full shift workload of electricians (at least two people) and minimal violation of the deadlines for carrying out maintenance work. It is not advisable to violate the frequency of performing maintenance work on electrical equipment operating under conditions of ammonia release in damp rooms.

Schedules for subsequent months are drawn up in the same way.

3. Based on monthly schedules, quarterly and annual schedules are compiled (Appendix 2).

When compiling general schedules PPR for all departments of the economy must be ensured that there is no overlap in the timing of work at various facilities for the same services. After drawing up the schedules, they are carefully checked.

To ensure continuity technological processes Maintenance and repair of electrical equipment is carried out during technological breaks. Current repairs of electrical equipment are planned simultaneously with routine repairs of process equipment. Seasonal maintenance and repairs, as well as major repairs of electrical wiring livestock premises and grain flows are planned for the period of their downtime. This work must be completed before the start of the operating season of the production facility.

At the same time, the schedule must ensure: uniform workload of electricians throughout the day, month and year; minimal loss of time for transition and transfers between objects; compliance with the standardized frequency of preventive measures (deviations should not exceed ±35%).

How to draw up a maintenance schedule for electrical equipment?

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 no secret that the main document by which electrical equipment is repaired 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 routine repairs of electrical equipment.

To draw up an annual preventive maintenance schedule (preventive maintenance schedule) for electrical equipment, we will need standards for the frequency of equipment repairs. This 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.” I am using the 2008 reference book, so I will continue to refer to this source.

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So. Your household has a certain amount of energy equipment. All this equipment must be included in the maintenance schedule. But first a little general information, what is 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 process diagrams. Columns 3-5 indicate service life 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 the type of planned repair: K - capital, T - current. In columns 23 and 24, respectively, the annual equipment downtime for repairs and the annual working time fund are recorded. Now that we've looked at general provisions about the PPR schedule, let’s look at 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 diagram) 6/0.4 kV, 1000 kVA; 2) pump electric motor, asynchronous (designation according to scheme N-1), Рн=125 kW; Step 1. We enter our equipment into the empty PPR schedule form.

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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 p. 205 and in the table “Standards for the frequency, duration and labor intensity of repairs of transformers and complete substations” we find a description of the equipment that is suitable for 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 - p. 151 Table 7.1 (see figure).

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

January 2005." href="/text/category/yanvarmz_2005_g_/" rel="bookmark">January 2005, current - January 2008. For the N-1 pump motor, capital - September 2009, current - March 2010. We add 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 carried out 2 times a year (every 6 months) and, according to the latest current repair, we plan for March and September 2011 Important note: if the electrical equipment is newly installed, then all types of repairs, as a rule, “dance” from the date of commissioning of the equipment. Our schedule takes the following form:

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Important note: at some enterprises, power engineers in their annual schedules of PPR instead of the last two columns 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 standards for one repair. This scheme is convenient when working with contractors performing repair work. Do not forget that repair dates must be coordinated with the mechanical service and, if necessary, the instrumentation service, as well as with other structural units directly related to the repair and maintenance of related equipment. If you have any questions about drawing up the annual PPR schedule, ask questions, I will try, if possible, to answer them in detail.

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, materials, spare parts, and components is determined. It includes each unit subject to major and routine repairs of electrical equipment.

Let's look at a specific example. Let's assume that in our electrical department, in building 541, we have:

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

2. Pump electric 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: open the reference book p. 205 and in the table “Standards for the frequency, duration and labor intensity of repairs of transformers and complete substations” we find a description of the equipment that is suitable for 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 maintenance 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 labor intensity of maintenance of electrical equipment should be 10% of current repairs.

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

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

Step 4.

For the selected electrical equipment, we need to decide on 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. Let's say we are making a schedule for 2014. The equipment is operational, the dates of repairs are known to us. For the T-1 transformer, major repairs were carried out in January 2008, the current one was carried out 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 the T-1 transformer will undergo in 2014. As we know there are 8640 hours in a year. We take the found service life 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 major overhaul should be carried out 12 years after the last major overhaul, and since the last one was in January 2008, which means the next one is planned for January 2020.

For current repairs, the operating principle is the same: 25920/8640 = 3 years. The last current repair was carried out in January 2011, i.e. 2011+3=2014. The next routine 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 we enter “T”.

For the electric motor we get: major repairs are carried out every 6 years and are planned for September 2018. The current one is carried out 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 installed, then all types of repairs, as a rule, “dance” from the date of commissioning of the equipment.

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

Step 6. We determine the annual labor intensity of repairs.

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

Our graph looks like this:

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

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

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

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