In case of failure or improper performance by the seller of his duties...
Main stages of PPR equipment
Planned and preventative well-designed repairs include:
Planning;
Preparation of electrical equipment for scheduled repairs;
Carrying out scheduled repairs;
Carrying out activities related to scheduled maintenance and repairs.
The system of scheduled preventive maintenance of equipment includes a couple of stages:
1. Inter-repair phase
Performed without disrupting equipment operation. Includes: systematic cleaning; systematic lubrication; systematic examination; systematic adjustment of electrical equipment; replacement of parts that have a short service life; elimination of minor faults.
In other words, this is prevention, which includes daily inspection and care, and it must be properly organized in order to maximize the service life of the equipment, maintain high-quality work, and reduce the cost of scheduled repairs.
The main work performed during the overhaul phase:
Monitoring the condition of equipment;
Conducting employees to follow appropriate use guidelines;
Daily cleaning and lubrication;
Timely elimination of minor breakdowns and adjustment of mechanisms.
2. Current stage
Planned preventative maintenance of electrical equipment is most often carried out without disassembling the equipment, only stopping its operation. Includes the elimination of breakdowns that occurred during operation. At the current stage, measurements and tests are carried out, with the help of which equipment defects are identified at an early stage.
The decision on the suitability of electrical equipment is made by repairmen. This ruling is based on a comparison of test findings during routine maintenance. In addition to scheduled repairs, unplanned work is performed to eliminate defects in equipment operation. They are carried out after the entire resource of the equipment has been exhausted.
3. Middle stage
It is carried out for the complete or partial restoration of used equipment. Includes disassembly of components intended for viewing, cleaning mechanisms and eliminating identified defects, replacing some quickly wearing parts. The middle stage is carried out no more than once a year.
The system at the middle stage of scheduled preventive maintenance of equipment includes setting the cyclicity, volume and sequence of work in accordance with the regulatory and technical documentation. The middle stage affects the maintenance of equipment in good condition.
4. Major renovation
It is carried out by opening electrical equipment, checking it completely and inspecting all parts. Includes testing, measurements, elimination of identified faults, as a result of which electrical equipment is modernized. As a result of a major overhaul, the technical parameters of the devices are completely restored.
Major repairs are possible only after the inter-repair phase. To carry it out you must do the following:
Draw up work schedules;
Conduct preliminary inspection and verification;
Prepare documents;
Prepare tools and necessary replacement parts;
Carry out fire prevention measures.
Major repairs include:
Replacement or restoration of worn mechanisms;
Modernization of any mechanisms;
Carrying out preventative checks and measurements;
Carrying out work related to the elimination of minor damage.
Malfunctions discovered during equipment testing are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.
PPR systems and its basic concepts
The system of scheduled preventive maintenance of power equipment (hereinafter referred to as the SystemPPREO) is a set of methodological recommendations, norms and standards designed to ensure the effective organization, planning and implementation of maintenance (MOT) and repair of power equipment. The recommendations given in this System of PPR EO can be used at enterprises of any type of activity and form of ownership that use similar equipment, taking into account the specific conditions of their work.
The planned and preventive nature of the EO PPR System is implemented by: carrying out equipment repairs at a given frequency, the timing and logistics of which are planned in advance; carrying out maintenance operations and technical condition monitoring aimed at preventing equipment failures and maintaining its serviceability and performance in the intervals between repairs.
The EO PPR system was created taking into account new economic and legal conditions, and in technical terms, with maximum use of: the capabilities and advantages of the aggregate repair method; the entire range of strategies, forms and methods of maintenance and repair, including new tools and methods of technical diagnostics; modern computing technology and computer technologies for collecting, accumulating and processing information about the condition of equipment, planning repair and preventive actions and their logistics.
The operation of the PPR EO System applies to all equipment of energy and technological workshops of enterprises, regardless of the place of its use.
All equipment operated at enterprises is divided into basic and non-core. The main equipment is the equipment with the direct participation of which the main energy and technological processes of obtaining a product (final or intermediate) are carried out, and the failure of which leads to a cessation or a sharp reduction in the output of products (energy). Non-core equipment ensures the full flow of energy and technological processes and the operation of the main equipment.
Depending on the production significance and functions performed in energy and technological processes, equipment of the same type and name can be classified as either primary or non-core.
The EO PPR system provides that the equipment’s need for repair and preventive actions is satisfied by a combination of various types of maintenance and scheduled equipment repairs, differing in frequency and scope of work. Depending on the production significance of the equipment, the impact of its failures on personnel safety and the stability of energy technological processes, repair actions are implemented in the form of regulated repairs, repairs based on operating hours, repairs based on technical condition, or a combination of them.
Table 5 - number of repairs in 12 months
Table 6 - Planned balance of working time for the year
Payroll ratio
- 1. For discontinuous production =1.8
- 2. For continuous production =1.6
5. FORMS OF REPAIR DOCUMENTATION
5.1. The repair documentation of this Handbook is maximally unified with the documentation of the industry “Systems for 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;
certificate of delivery for major repairs;
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 approbation of the “Unified Regulations on Scheduled Preventive Maintenance of Equipment of Industrial Enterprises in 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, the symbol in the form of a fraction indicates: 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). Instead of a monthly plan-schedule-report, it is allowed to maintain a monthly repair report (Form 8A).
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 the 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 ongoing repair and maintenance activities that are not regulated by this Handbook (repair inspections, inspections, tests, etc.) in the repair services of enterprises, 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
For the repair of complex equipment (computers, power equipment), proprietary service is increasingly being used, which is carried out by special departments of the manufacturer. Currently, processing enterprises operate a system of planned preventive maintenance of equipment (PSM), which is a progressive form of organizing repair work. PPR is a set of organizational and technical measures aimed at maintaining equipment in working condition and preventing its emergency decommissioning. Each machine, after working a certain number of hours, is stopped and subjected to 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.
Blanker.ru
Table 3.3 Works regulated by the Regulations on preventive maintenance for mechanical and electrothermal equipment Name of equipment Types of maintenance and repairs Frequency, months. Number of maintenance, repair and repair cycles during the service life until write-off Structure of the repair cycle Depreciation period, years Electric boilers, grills, braziers, autoclaves TO 1 100 5TO…TR- 10 TR 6 18 5TO-TR… to 60 1 …5TO-IP-K Electric stoves, cabinets, speed TO 1 100 5TO-TR… 10 water, food warmers TR 6 20 …5TO-TR Electric boilers TO 1 50 5TO-TR… 5 TR 6 8 …5TO-TR- k 30 1 5TO-TR-K Electric steamers TO 1 100 5TO-TR… 10 paratha TR 6 17 5TO-TR-K k 36 2 Potato peelers TO 1 80 5TO-TR…
PPR equipment 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 towards financing production will cause a corresponding return on production.
- The quality of repairs carried out by personnel; if carried out poorly, breakdowns will occur more often. In this case, it will be necessary to schedule repairs and maintenance of equipment more often.
- Quality of repair planning, qualification of equipment repair organizers. The organizers of equipment repairs in production include mechanics, and on large production lines even the entire department of the chief mechanic.
Drawing up a schedule for preventive maintenance of equipment
It consists of replacing individual worn parts, eliminating defects, performing lubrication and fastening operations, etc. Overhaul is a repair performed to restore the service life of a product with the replacement or restoration of any of its parts. Major and current repairs can be planned or unplanned.
Attention
Planned repairs are carried out according to schedule. Unscheduled repairs are carried out in order to eliminate the consequences of sudden failures and breakdowns. Trade equipment in most cases undergoes a planned overhaul. Planned overhaul is not provided for equipment that does not experience mechanical wear during operation (for example, thermal).
All of the above work is designed to maintain the performance of machines and devices until the next scheduled repair.
The preventive maintenance system includes the following types of technical repairs and maintenance: weekly maintenance, monthly routine maintenance, annual scheduled maintenance. Annual scheduled maintenance is carried out in accordance with the annual equipment maintenance schedule. Drawing up a maintenance schedule An annual schedule of preventive maintenance, on the basis of which the need for repair personnel, materials, spare parts, and components is determined. It includes every unit subject to major and current repairs.
To draw up an annual schedule of preventive maintenance (PPR schedule), we will need standards for the frequency of equipment repairs.
Very often, such repairs are called equipment maintenance (scheduled preventive maintenance) or equipment maintenance (equipment maintenance).
- Major repairs. Equipment maintenance, also known as scheduled preventive maintenance Today we will look at weekly equipment repairs (preventive maintenance or maintenance). It is called weekly symbolically; in fact, depending on the specifics of the equipment, repairs can be organized either more often, for example, several times a week (which is very rare), or much less frequently, for example, once every two weeks. Or maybe once a month (such repairs are much more common).
Sample schedule for process equipment in food production
Here you need to partially disassemble the mechanism, replace and restore worn parts. It is performed without removing the mechanism from the foundation. 5. Major repairs, consisting of replacing worn parts and assemblies, checking and adjusting machines and restoring them in accordance with technical specifications.
Carrying out a major overhaul involves complete disassembly of the equipment, removing it from the foundation if necessary. Inspections, current and major repairs are performed by special repair personnel with the assistance of maintenance staff. The basis for drawing up a maintenance plan is the standards and structure of the repair cycle.
The repair cycle is the operating time of the machine from the start of its commissioning until the first major overhaul. It depends on the durability of the parts and operating conditions of the equipment.
This data can be found in the manufacturer’s passport data, if the plant specifically regulates this, or use the “Maintenance and Repair System” reference book. There is some equipment available. All this equipment must be included in the maintenance schedule. Column 1 indicates the name of the equipment, as a rule, brief and understandable information about the equipment.
Column 2 - quantity of equipment. Column 3-4 - indicates service life standards between major repairs and current ones. (See Appendix 2) Columns 5-6 - 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 (we conventionally accept 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 logistics and technical maintenance is necessary. A large amount is devoted to organizing equipment repairs. The essence of repair is to preserve and restore the functionality of equipment and mechanisms by replacing or restoring worn parts and adjusting mechanisms.
Important
Every year, more than 10-12% of equipment undergoes major repairs, 20-30% - medium and 90-100% - minor. The costs of repairs and maintenance of equipment account for 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.
The main task of the repair facility is to maintain equipment in technically sound condition, which ensures its uninterrupted operation.
Number of equipment units 7 2 Number of equipment repairs (inspections) in the structure of the repair cycle · capital 1 1 · average 1 2 · current 2 3 · inspections 20 48 Category of equipment repair complexity 1.5 1.22 Duration of equipment repairs, shifts · capital 1 30 · average 0.6 18 · current 0.2 8 · inspections 0.1 1 Duration of the repair cycle, months. 18 48 Labor intensity of repairs (inspections) · capital 35.0 35.0 · average 23.5 23.5 · current 6.1 6.1 · inspections 0.85 0.85 Between-repairs maintenance rate per worker per shift (per based on the “Regulations on the system of planned preventive maintenance of equipment): for wine bottling equipment - 100 and other technological equipment 150 conventional repair units. Annual working time fund for one worker is 1860 hours, the production rate fulfillment rate is 0.95, equipment shifts are 1, 5.
Equipment that does not meet at least one of the requirements established by the operational documentation, standards (GOSTs), and technical specifications (TU) is considered faulty. Malfunctions include a decrease in the productivity and efficiency of machines, loss of accuracy, deviations in technological processes (above permissible limits). The reliability of equipment is determined by reliability, durability, maintainability and storage.
Reliability is the ability of equipment to remain operational for a certain period of time, i.e., operation without failure for a given period of time. Durability reflects such a property of equipment as maintaining operability until major repairs or write-off. Maintainability is the adaptability of equipment to prevent, detect and eliminate failures and malfunctions.
PPR system is a set of planned organizational and technical measures for the care, supervision, maintenance and repair of equipment. The measures are preventive in nature, i.e. After each piece of equipment has worked for a certain amount of time, preventive inspections and scheduled repairs are carried out: small, medium, major.
The alternation and frequency of repairs is determined by the purpose of the equipment, its design and repair features and operating conditions.
The equipment maintenance work includes the following work:
Between overhauls;
Periodic inspections;
Periodic scheduled repairs:
Average;
Capital.
Between overhauls- this is the daily care and supervision of equipment, making adjustments and repairs during its operation without disrupting the production process. It is performed during breaks in the operation of equipment (during non-working shifts, at the junction of shifts, etc.) by the shop repair service personnel on duty.
Periodic inspections— inspections, washings, accuracy tests and other preventive operations carried out according to plan after a certain number of hours worked by the equipment.
Periodic scheduled repairs
Small repairs- detailed inspection, change and replacement of worn parts, identification of parts requiring replacement during the next scheduled repair (medium, major) and drawing up a defective list for it (repair), checking for accuracy, testing.
Medium renovation— detailed inspection, disassembly of individual components, replacement of worn parts, checking for accuracy before disassembly and after repair.
Major renovation— complete disassembly of equipment and components, detailed inspection, washing, wiping, replacement and restoration of parts, checking for technological accuracy of processing, restoration of power, performance according to standards and specifications.
PPR is carried out according to a schedule developed on the basis of PPR standards:
Duration of the repair cycle;
Duration of overhaul and inspection cycles;
Duration of repairs;
Labor and material intensity of repair work.
Repair cycle— this is the period of operation of the equipment from the beginning of its commissioning until the first major overhaul or the period of operation between two major overhauls.
The structure of the repair cycle is the order of alternating repairs and inspections, depending on the type of equipment, the degree of its load, age, design features and operating conditions. For example, for aggregate finishing machines the structure of the repair cycle is as follows
K-O-O-M 1 -O-O-M 2 -O-O-S 1 -O-O-M 3 -O-O-M 4 -O-O-S 2 -O-O-M 5 -O-O-M 6 -O-O-K,
where K is a major overhaul (or commissioning of equipment);
C - medium repair;
M - minor repairs;
O - inspection;
1, 2, 3, ..., 6 — serial number of repairs in the cycle.
Repair cycle duration— the period of time between two major overhauls.
Repair complexity category (RCC) assigned to each piece of equipment. As repair unit 1/11 of the labor intensity of a major overhaul of a 16K20 screw-cutting lathe, which belongs to the eleventh complexity group, was accepted.
For a unit of repair complexity, standards in hours for repairs by type of work are calculated:
Locksmiths;
Machine tools;
Others (painting, welding, etc.).
Workover workover of special technological equipment (a р.c) is determined by the labor intensity of repair work:
where t is the standard time for performing each plumbing operation, in standard hours;
t r.e.sles - time standard for one repair unit of equipment overhaul, in standard hours;
m - a typical list of plumbing works (indicating the percentage of replacement of worn-out critical parts) performed during major repairs.
For most equipment in mechanical engineering and instrument making, the time standard for one repair unit is equal to:
23 hours for the mechanical part of the equipment;
11 hours for the electrical part.
Quantity:
Price: 35
Discount: %?
We have a discount system
take more - pay less
when ordering from 50 pcs. - 5% discount
when ordering from 100 pcs. - 10% discount
when ordering from 300 pcs. - 15% discount
when ordering from 500 pcs. - 20% discount
when ordering from 1000 pcs. - 25% discount
Sum:
including VAT 20%
X
You ordered a thin magazine again.
Perhaps you need a magazine with more pages and other features.
Please use calculator
