Main stages 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 disturbing the operation of the equipment. 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 and preserve quality work, reduce costs for planned repairs.
The main work performed during the overhaul phase:
Monitoring the condition of equipment;
Enforcement of appropriate use policies by employees;
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 current repairs. 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
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 major repairs, full recovery technical parameters devices.
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 for scheduled preventive maintenance of power equipment (hereinafter referred to as the SystemPPREO) is a complex methodological recommendations, norms and regulations designed to ensure effective organization, planning and carrying out 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 computer technology and computer technologies for collecting, accumulating and processing information about the condition of equipment, planning repair and preventive actions and their logistical support.
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 the energy and technological processes equipment of the same type and name can be classified as both primary and non-main.
The EO PPR system provides that the equipment’s need for repair and preventive actions is satisfied by a combination various types Maintenance and scheduled repairs of equipment, 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;
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 carrying out repair work;
production permit earthworks in the territory.
5.2. Changes and additions to previously existing forms of repair documentation were made based on the results of testing the “Unified Regulations 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. Repair timeframes for major equipment limiting completion production program, are 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 OGE, in production workshops- 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 ongoing repair and maintenance activities that are not regulated by this Handbook (repair inspections, checks, 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
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 the equipment was put into operation. Our schedule takes the following form:
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Important note: at some enterprises, power engineers in their annual production schedules, instead of the last two columns of annual downtime and annual capital, indicate only one column - “Labor intensity, man*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 system of scheduled preventive maintenance or the PPR system, as this method of organizing repairs is usually called for short, is a fairly common method that originated and became widespread in countries former USSR. The peculiarity of the “popularity” of this type of organization of the repair economy was that it fit quite neatly into the planned form of economic management of that time.
Now let's figure out what PPR (scheduled preventive maintenance) is.
System of planned preventive maintenance (PPR) of equipment– a system of technical and organizational measures aimed at maintaining and (or) restoring operational properties technological equipment and devices in general and (or) individual pieces of equipment, structural units and elements.
Enterprises use different varieties systems of planned preventive maintenance (PPR). The main similarity in their organization is that the regulation of repair work, their frequency, duration, and costs for this work is planned. However, various indicators serve as indicators for determining the timing of planned repairs.
Classification of PPR
I would highlight several types of scheduled maintenance systems, which have the following classification:
regulated PPR (scheduled preventive maintenance)
- PPR by calendar periods
- PPR by calendar periods with adjustment of the scope of work
- PPR according to operating time
- PPR with regulated control
- PPR by operating modes
PPR (scheduled preventive maintenance) according to condition:
- PPR for permissible level parameter
- PPR according to the permissible level of the parameter with adjustment of the diagnostic plan
- PPR based on the permissible level of a parameter with its prediction
- PPR with reliability level control
- PPR with reliability level forecast
In practice, a system of regulated scheduled preventive maintenance (PPR) is widespread. This can be explained by greater simplicity compared to the condition-based PPR system. In the regulated PPR, the reference is made to calendar dates and the fact that the equipment operates throughout the entire shift without stopping is simplified. In this case, the structure of the repair cycle is more symmetrical and has fewer phase shifts. In the case of organizing a PPR system according to any acceptable indicator parameter, it is necessary to take into account a large number of these indicators specific to each class and type of equipment.
Advantages of using a preventive maintenance system or scheduled maintenance of equipment
The system of planned preventive maintenance of equipment (PPR) has a large number of advantages that determine its widespread use in industry. As the main ones, I would highlight the following advantages of the system:
- monitoring the duration of equipment operation between repair periods
- regulation of equipment downtime for repairs
- forecasting the costs of repairing equipment, components and mechanisms
- analysis of the causes of equipment failure
- calculation of the number of repair personnel depending on the repair complexity of the equipment
Disadvantages of the preventive maintenance system or scheduled maintenance of equipment
Along with the visible advantages, there are also a number of disadvantages of the PPR system. Let me make a reservation in advance that they are mainly applicable to enterprises in the CIS countries.
- absence convenient tools planning repair work
- complexity of labor cost calculations
- the complexity of taking into account the indicator parameter
- difficulty in quickly adjusting planned repairs
The above disadvantages of the PPR system relate to certain specifics of the fleet of technological equipment installed at CIS enterprises. First of all, this is a high degree of equipment wear. Equipment wear often reaches 80 - 95%. This significantly deforms the system of planned preventative repairs, forcing specialists to adjust maintenance schedules and carry out a large number of unplanned (emergency) repairs, significantly exceeding the normal volume of repair work. Also, when using the method of organizing the PPR system according to operating hours (after a certain time of operation of the equipment), the labor intensity of the system increases. In this case, it is necessary to organize a record of actually worked machine hours, which, together with a large fleet of equipment (hundreds and thousands of units), makes this work impossible.
Structure of repair work in the equipment maintenance system (scheduled preventive maintenance)
The structure of repair work in the equipment maintenance system is determined by the requirements of GOST 18322-78 and GOST 28.001-78
Despite the fact that the PPR system assumes a trouble-free model of operation and repair of equipment, in practice it is necessary to take into account unscheduled repairs. Their cause is most often an unsatisfactory technical condition or an accident due to poor quality
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 is 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 use the A.I. reference book. FMD 2008, therefore, further I will refer to this source.
Download the reference book A.I. Foot and mouth disease
So. Your household has a certain amount of energy equipment. All this equipment must be included in the maintenance schedule. But first, some general information about what the annual PPR schedule is.
Column 1 indicates the name of the equipment, as a rule, brief and clear 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: 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 have examined the 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.
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 - 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 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 2011. The equipment is operational, we know the dates of repairs. For T-1, a major overhaul was carried out in January 2005, the current one in January 2008. For the N-1 pump motor, the major 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 the T-1 transformer will undergo in 2011. 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 2005, which means the next one is planned for January 2017. For current repairs, the operating principle is the same: 25920/8640 = 3 years. The last current repair was carried out in January 2008, so 2008+3=2011. The next routine repair is in 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”.
For the electric motor we get; major repairs are carried out every 6 years and are planned for September 2015. 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 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 graph 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 routine repair, and in the resource standards for routine repairs the denominator is 8 hours. For the N-1 electric motor, there will be two routine repairs in 2011; the standard downtime for routine repairs is 10 hours. We multiply 10 hours by 2 and get annual downtime equal to 20 hours. In the annual working time column, we indicate the number of hours that this equipment will be in operation minus downtime for repairs. We get the final look of our graph.
Important note: at some enterprises, power engineers in their annual production schedules, instead of the last two columns of annual downtime and annual capital, indicate only one column - “Labor intensity, man*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.