PZ No. 4. Calculation of equipment maintenance schedule.

Task number 1. The operating time of the pump between overhauls is 8640 hours, the average - 2160 hours, the current ones - 720 hours. The actual number of days of work per year is 360. The number of work shifts is 3, the duration of the shift is 8 hours. By the beginning of the year, the equipment had run after overhaul 7320 hours, average - 840 hours, current - 120 hours. Make a schedule for the shutdown of the pump for the year.

Decision.

To schedule a pump shutdown for a year:

1. Number of working days in a month: 360 / 12 = 30 days

2. Month of shutdown for repairs:

Capital (8640 - 7320) / 3 * 8 * 30 = 1.8 months, we accept February.

Current (2160 - 840) / 3 * 8 * 30 = 1.8 months, we accept February

RTO (720 - 120) / 3 * 8 * 30 \u003d 0.8 months, we accept January.

3. We determine after how many months it is necessary to make subsequent repairs:

Capital 8640 / 3 * 8 * 30 = 12 months, we accept 12 months, i.e. next year;

Current 2160 / 720 = 3 months, we accept in 3 months, those in February, May, August, November.

PTO 720 / 720 = 1 month, accepted after 1 month, i.e. every month except February, May, August and November.

4. We draw up a pump PPR schedule:

Month: Jan. Feb. March Apr may june july aug. sept. oct. Nov. dec

Type TO TO TO TO T TO TO TO T TO TO T TO

repair

Task 2. There are 20 dryers in the PVC resin production workshop. The actual operating time of one dryer per year is 6480 hours, the duration of the overhaul cycle is 8640 hours, from overhaul to current repairs is 4320 hours, between maintenance and repair is 864 hours. The calendar operating time of the equipment per year is 8640 hours. Determine the number of major, current repairs and maintenance of dryers per year.

Methodical instructions.

The required number of repairs per year for each type and type of equipment is determined by the formula:

n rem. = Ood.rev. * Tfact * n in. rem. / tc, where

Ood.ob. - the number of units of the same type of equipment in operation;

Tts - the duration of the overhaul cycle, hour;

Tfact - the actual operating time of the equipment, hour;

n in. rem. - the number of all repairs (major, medium, current) of the overhaul cycle.

The number of repairs of each type is determined by the formulas:

capital

n cap. = Tk / Tc

current

n cf. = Tk / Tc.t. - one

repair and maintenance services

n pto \u003d Tk / Tc.t. - ∑ (cap. + current), where

Tk is the calendar operating time of the equipment, hour.

Tc.t. - the duration of the overhaul period from overhaul to current repairs, hour;

∑ (cap. + current ..) - the amount of capital and current repairs.

Task 3. Calculate the number of compressor repairs based on the following data: the number of compressors - 8, the duration of the overhaul cycle = 8640 hours, the overhaul period between major repairs - 7130 hours, between the current ones - 2160 hours, between RTO - 720 hours. Actual number of days of operation per year - 358, number of shifts - 3, shift duration - 8 hours.

Methodical instructions.

To complete the task, use the formulas for calculation given in the guidelines for task 2.

Task 4. Draw up a schedule for the shutdown of equipment according to the data below:

Indicators	Option 1	Option 2	Option 3
Equipment	Compressor	Dryer	Autoclave
Working time between repair hours, hours
Capital	7130	14700	8238
Current	2160	2880	2880
RTO
Actual number of days worked per year
Number of shifts
Duration working days, hours
Continued mileage rev. after rem. by the beginning of the year,
Capital	5310	12200	7310
current			1950
RTO

Methodical instructions.

To complete the task, use the formulas for the calculation given in the guidelines for task 1.

Task 5. Determine the downtime of equipment in repair according to the data below:

Indicators	Pump	Distillation column	Bake
Labor intensity of repair, man-hour
number
riggers
locksmiths
welders
Working hours
Number of shifts

Guidelines

The downtime is equal to the quotient of the division: the numerator is the complexity of the repair, the denominator is the product of the number of repairmen times the working day and the rate of completion of the norm.

SCHEDULE PREVENTIVE REPAIR (PPR)

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

The alternation 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.

The equipment is stopped for scheduled preventive maintenance while it is still in working condition. This (scheduled) principle of taking equipment out for repair makes it possible to make the necessary preparations for stopping the equipment - both on the part of the service center specialists and on the part of the customer's production personnel. Preparation for scheduled preventive maintenance of equipment consists in clarifying equipment defects, selecting and ordering spare parts and parts that should be replaced during repairs.

Such preparation allows carrying out the full scope of repair work without disturbing the normal operation of the enterprise.

Competently conducting PPR involves:

• planning of scheduled preventive maintenance of equipment;
• preparation of equipment for scheduled preventive maintenance;
• Carrying out scheduled preventive maintenance of equipment;
• Carrying out activities related to preventive maintenance and equipment maintenance.

Scheduled maintenance of equipment includes the following steps:

1. Interrepair maintenance phase.

The overhaul stage of equipment maintenance is carried out mainly without stopping the operation of the equipment itself.

The overhaul 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 overhaul stage of maintenance is prevention in other words. The TBO includes daily inspection and maintenance of the equipment and should be properly organized to:

• drastically extend the period of operation of the equipment;
• Maintain excellent quality of work
• Reduce and accelerate the costs associated with scheduled repairs.

The overhaul phase of maintenance consists of:

• Tracking the state of the equipment;
• · implementation by the workers of the rules of proper exploitation;
• Daily cleaning and lubrication
• Timely elimination of minor breakdowns and regulation of mechanisms.

The overhaul stage of maintenance is carried out without stopping the production process. This stage of maintenance is carried out during breaks in the operation of the equipment.

2. The current stage of scheduled preventive 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 preventive maintenance consists in the elimination of breakdowns that occur 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 preventive maintenance, it is adjusted and tested.

The decision on the suitability of equipment for further work is issued by repairmen, based on a comparison of test results at the current stage of scheduled preventive maintenance with existing standards, 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, to eliminate any flaws in the operation of the equipment, work is carried out outside the plan. These works are carried out after the exhaustion of the entire working resource of the equipment. Also, to eliminate the consequences of accidents, emergency repair is carried out, which requires the immediate cessation of equipment operation.

3. Middle stage of preventive maintenance

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

The middle stage of preventive maintenance is to dismantle the equipment components to review, clean parts and eliminate identified flaws, change parts and components that wear out quickly and which do not provide proper use of the equipment until the next overhaul. The middle stage of scheduled preventive maintenance is carried out no more than once a year.

The middle stage of scheduled preventive maintenance includes repairs, in which the normative and technical documentation establishes the cyclicity, volume and sequence of repair work, even 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, there is little chance that the equipment will fail.

4. Overhaul

Overhaul of equipment is carried out by opening the equipment, checking the equipment with a meticulous inspection of the “insides”, testing, measuring, eliminating the identified breakdowns, as a result of which the equipment is being modernized. Overhaul ensures the restoration of the original technical characteristics of the equipment.

Overhaul of equipment is carried out only after the overhaul period. For its implementation, the following steps are required:

• drawing up work schedules;
• Carrying out a preliminary inspection and verification;
• preparation of documentation;
• Preparation of tools, spare parts;
• Implementation of fire prevention and safety measures.

Major overhaul of equipment consists of:

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

Flaws that are discovered during the inspection of the equipment are eliminated during the subsequent overhaul of the equipment. Breakdowns that are of an emergency 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.

Measures for 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 passport for each mechanism or its duplicate.
• · Equipment accounting card (appendix to the technical passport).
• · Annual cyclic plan-schedule of equipment repair.
• · Annual cost estimate for equipment overhaul.
• · Monthly plan-report of equipment repair.
• · Acceptance certificate for major repairs.
• · Replaceable log of process equipment malfunctions.
• · Extract from the annual PPR schedule.

On the basis of the approved annual plan-schedule of the PPR, a nomenclature plan is drawn up for the production of capital and current repairs, broken down by months and quarters. Before starting a major or current repair, it is necessary to clarify the date of putting the equipment for repair.

The annual PPR schedule and tables of initial data are the basis for the preparation of the annual budget plan, which is developed twice a year. The annual amount of the plan-estimate is divided into quarters and months, depending on the period of the overhaul according to the PPR schedule of the given year.

On the basis of 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.

At present, for scheduled preventive maintenance (PPR), computer and microprocessor technology tools (installations, stands, devices for diagnostics and testing of electrical equipment) are increasingly being used, which affect the prevention of equipment wear and tear of equipment repair, reduction of repair costs, as well as helps to increase the efficiency of electrical equipment operation.

5. FORMS OF REPAIR DOCUMENTATION

5.1. The repair documentation of this Handbook is maximally unified with the documentation of the industry-specific "Systems for the maintenance and repair of power equipment". It is planned to maintain the following forms of repair documentation (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;

an act for issuance from a major overhaul;

annual schedule of preventive maintenance;

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

statement of annual costs for repairs;

an act to change the calendar period of repair;

shutdown schedule;

log of installation and removal of plugs;

act of acceptance of works after stop repair;

power equipment passport;

nomenclature of the main equipment of the workshop;

nomenclature of auxiliary equipment;

work permit for repair work;

permission to carry out earthworks in the territory.

5.2. Changes and additions to the previously existing forms of repair documentation were made based on the results of approbation of the “Unified Regulation on Scheduled Preventive Repairs of Equipment of Industrial Enterprises of 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 is repaired 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 piece of equipment subject to overhaul. 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 link the terms of repair of power equipment with technological equipment, the annual schedule is coordinated with the OGM of the enterprise. If it is necessary to use the services of the chief instrument operator, the planned repair time is agreed with the OCP. The terms of repair of the main equipment, limiting the implementation of the production program, are agreed 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. Marks on the actual implementation of repairs in these columns are made by painting over the planned numbers with a colored pencil.

In columns 23 and 24, respectively, the annual downtime of equipment in repair and the annual fund of working hours are recorded.

5.6. The operational document for the repair of equipment is a monthly plan-schedule-report approved by the chief power engineer of the enterprise for each power shop 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 planning of repairs is carried out according to 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 implementation of repairs is made after they are completed by a specially appointed responsible person in the OGE, in production workshops - by the workshop foreman.

5.10. The record book for installing and removing plugs (form 14) is maintained by the deputy head of the power department (head of the department, installation, shift supervisor).

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

5.12. The forms of repair documentation given in this section are typical. Depending on the specifics of accounting for repair and preventive measures that are not regulated by this Handbook (repair inspections, inspections, tests, etc.), established in the repair services of enterprises, additional columns (paragraphs) 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

Scheduled preventive maintenance is the simplest and most reliable way to schedule repairs.

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

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

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

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

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

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

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

Well-planned preventive maintenance includes:

Planning;

Preparation of electrical equipment for planned repairs;

Carrying out scheduled repairs;

Carrying out activities related to scheduled maintenance and repair.

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

1. Stage overhaul

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

In other words, this is preventive maintenance, which includes daily inspection and maintenance, and at the same time, it must be properly organized in order to maximize the life of the equipment, maintain high-quality work, and reduce the cost of scheduled repairs.

The main work performed at the overhaul stage:

Tracking the state of equipment;

Enforcement by employees of the rules of appropriate use;

Daily cleaning and lubrication;

Timely elimination of minor breakdowns and adjustment of mechanisms.

2. Current stage

Scheduled preventive maintenance of electrical equipment is most often carried out without dismantling the equipment, only its operation stops. Includes the elimination of breakdowns that occurred during the period of work. At the current stage, measurements and tests are carried out, with the help of which flaws in equipment are detected at an early stage.

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

3. Stage middle

It is carried out for the full or partial restoration of obsolete equipment. Includes disassembly of units, designed to view, clean the mechanisms and eliminate the identified defects, replace some wear 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 cycle, volume and sequence of work in accordance with the regulatory and technical documentation. The middle stage affects the maintenance of the equipment in good condition.

4. Overhaul

It is carried out by opening electrical equipment, its full check with inspection of all details. It includes tests, measurements, elimination of identified faults, as a result of which the modernization of electrical equipment is carried out. As a result of the overhaul, the technical parameters of the devices are completely restored.

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

Draw up work schedules;

Carry out preliminary inspection and verification;

Prepare documents;

Prepare tools and necessary replacement parts;

Carry out fire fighting measures.

Major overhaul includes:

Replacement or restoration of worn mechanisms;

Modernization of any mechanisms;

Perform preventive checks and measurements;

Carrying out minor repairs.

Malfunctions found during equipment checks are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.

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

Planned preventive maintenance year- this is the basis that serves to draw up a budget plan for the year, developed 2 times a year. The sum of the year of the budget plan is divided into months and quarters, it all depends on the period of the overhaul.

To date, for the system of preventive maintenance of equipment, computer and microprocessor technology (structures, stands, installations for diagnostics and testing) are most often used, which affects the prevention of equipment wear, lower repair costs, and also helps to increase operational efficiency.

The totality of all types of work on the supervision, care, maintenance and repair of the machine park in order to minimize its wear and tear and more productive use is combined into a single system of preventive maintenance.

It is based on three types of repair:

• current;
• average;
• capital.

• Current- minor repairs, associated with the elimination of individual defects that have manifested themselves during operation.
• Average- more extensive, with the replacement of individual parts.
• Capital- speaks for itself. The process is costly, labor intensive and time consuming. Associated with the repair of engines, the replacement of major parts and assemblies.

This system is formed on the basis of standards:

• repair categories of complexity;
• cyclical repairs, their structure;
• a stock of parts to replace failed ones;
• duration of operational periods;
• laboriousness.

Sequence of individual repairs:

KR-TO-TO-MP1-TO-MP2-TO-SR-TO-TO-MP3-TO-KR (KR - overhaul, etc.).

When determining the cycle, the features of production, the repair base, the skills of repair workers, etc. are taken into account.

Approval of the required number of works during the repair, their volume

How much and what needs to be done at a particular point in time, in order to prevent critical wear of the machine park, can be established during operation.

1. The conditions under which one or another unit of the machine park operates.
2. Design features of the machine park, and hence the complexity of the work.
3. The level of performance of previous work during the repair and the quality of service.
4. Number of hours worked since the last repair.
5. Availability of skills and skill level of workers, productivity.

These are the basic factors on which the system of all repairs is built. As a result of changes in some factors, the scope of work may change and be adjusted. They can be more or less, depending on their influence, which is different. The changes don't have to be significant.
The deterioration of the conditions in which the machine equipment operates, which entailed an increase in the volume of repair work, is considered an abnormal phenomenon. This can happen due to non-compliance with proper supervision of the correct operation and normal maintenance of machine equipment, a decrease in the quality of industrial training and periodic instructing of workers. This is unacceptable and urgent action is needed.

Fundamental provisions of the PPR.

1. During the normal, unchanged operation of the enterprise, the value of the amount of repair work can change solely as a result of a change in the amount of time the equipment operates without repair.
2. Subject to the schedule of repairs in accordance with the hours worked by each machine, in order to ensure normal operation of the enterprise without emergency, an increase in the volume of repair work, as a rule, is not required.
3. With the mandatory planned withdrawal of machine tools for repair work, after the established time worked by them, critical wear of individual parts of the equipment is excluded, as a result of which an increase in the volume of repair work may follow. On the contrary, it becomes optimally constant (with optimal intervals between repairs).
4. With optimal overhaul intervals, the required amount of repair work is reduced without compromising the technical condition of all machine equipment.
5. The need for repair of all equipment can be ensured by compliance with all PPR cycles.

For non-emergency operation of any enterprise, a PPR schedule is built, which covers all available equipment. This schedule is approved and strictly observed during the operation of the equipment. Funds are being allocated to ensure that all necessary work is completed in a timely manner.

With the correct organization of repair and preventive maintenance, changes can occur only as a result of changes in production plans, the transition to the manufacture of other products and other factors associated with changes in the load on equipment or changes in technological processes.

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