PPR plan of the electrical equipment of the hostel building sample. What is scheduled preventive maintenance

The system of planned preventive repairs or the PPR system, as it is customary to call this method of organizing repairs for short, is a fairly common method that originated and became widespread in the countries of the former USSR. The peculiarity of such a "popularity" of this type of organization of the repair economy was that it fit rather harmoniously into the planned form of economic management of that time.

Now let's look at what PPR (planned preventive maintenance) is.

System of planned preventive maintenance (PPR) of equipment- a system of technical and organizational measures aimed at maintaining and (or) restoring the operational properties of process equipment and devices as a whole and (or) individual pieces of equipment, structural units and elements.

Enterprises use various types of scheduled preventive maintenance (PPR) systems. The main similarity in their organization is that the regulation of repair work, their frequency, duration, costs for these works is planned. However, various indicators serve as indicators for determining the timing of scheduled repairs.

PPR classification

I would single out several varieties of the preventive maintenance system, which have the following classification:

regulated PPR (scheduled preventive maintenance)

• PPR by calendar periods
• PPR for calendar periods with adjustment of the scope of work
• PPR for operating time
• PPR with regulated control
• PPR by operating modes

PPR (scheduled preventive maintenance) according to the state:

• PPR according to the permissible level of the parameter
• PPR according to the permissible level of the parameter with the adjustment of the diagnostic plan
• PPR on the admissible level of the parameter with its prediction
• PPR with control of the level of reliability
• PPR with a forecast of the level of reliability

In practice, the system of regulated preventive maintenance (PPR) is widespread. This can be explained by greater simplicity, compared with the state-based PPR system. In the regulated PPR, the binding goes to calendar dates and it is simply accepted that the equipment operates throughout the entire shift without stopping. 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 some acceptable parameter-indicator, it is necessary to take into account a large number of these indicators specific to each class and type of equipment.

Benefits of using a PPR system or preventive 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 single out the following advantages of the system:

• control over the duration of overhaul periods of equipment operation
• regulation of equipment downtime for repairs
• forecasting the cost 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 PPR system or preventive maintenance of equipment

Along with the visible advantages, there are a number of disadvantages of the PPR system. I will make a reservation in advance that they are mainly applicable to enterprises of the CIS countries.

• lack of convenient tools for planning repairs
• complexity of labor costs calculations
• the complexity of taking into account the parameter-indicator
• the complexity of the operational adjustment of the planned repairs

The above shortcomings of the PPR system relate to certain specifics of the technological equipment park installed at CIS enterprises. First of all, this is a large degree of equipment wear. Often equipment wear reaches 80 - 95%. This significantly deforms the system of preventive maintenance, forcing specialists to adjust the PPR schedules and carry out a large number of unscheduled (emergency) repairs, significantly exceeding the normal amount of repair work. Also, when using the method of organizing the PPR system by operating time (after a certain time of equipment operation), the labor intensity of the system increases. In this case, it is necessary to organize accounting of actually worked machine hours, which, together with a large fleet of equipment (hundreds and thousands of units), makes this work impossible.

The structure of repair work in the PPR system of equipment (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 an accident-free model for the 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

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

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

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

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

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

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

Repair work of electrical equipment

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

Organization of the process

Competent planned preventive maintenance provides for the following sequence:

1. Planning.

2. Preparation of units for repair.

3. Carrying out repair work.

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

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

Interrepair stage

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

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

current stage

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

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

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

Carrying out scheduled preventive maintenance: medium stage

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

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

Overhaul and its preconditions

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

When is the overhaul of electrical equipment carried out?

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

A work schedule has been drawn up.

Conducted preliminary checks and inspections.

All necessary documents have been prepared.

Replacement parts and tools provided.

Fire fighting measures have been taken.

What does a major overhaul include?

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

1. Replacement / restoration of worn out mechanisms.

2. Upgrading devices that require it.

3. Perform measurements and preventive checks.

4. Implementation of work to eliminate minor damage.

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

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

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

Peculiarities

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

Scheduled preventive maintenance: drawing up a schedule for the year

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

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

Weekly technical fix.

Monthly maintenance work.

Annual pre-scheduled preventive maintenance.

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

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

Additional Information

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

The benefits of preventive maintenance systems include:

Fixing downtime of units, equipment, machines.

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

Forecasting the cost of repairing equipment, mechanisms, units.

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

Analysis of the causes of equipment failure.

Disadvantages of preventive maintenance systems:

The complexity of calculating labor costs.

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

The complexity of taking into account the parameter/indicator.

The complexity of the operational adjustment of the planned work.

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

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

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

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

It's no secret that the main document for the repair of electrical equipment is the annual schedule of preventive maintenance of electrical equipment, on the basis of which the need for repair personnel, materials, spare parts, components is determined. It includes each unit subject to major and current repairs of electrical equipment.

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

Download A.I. foot and mouth disease

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

Column 1 indicates the name of the equipment, as a rule, brief and understandable information about the equipment, for example, name and type, power, manufacturer, etc. Column 2 - number according to the scheme (inventory number). I often use numbers from electrical single-line diagrams or from technological ones. Columns 3-5 indicate the resource standards between major repairs and current ones. Columns 6-10 indicate the dates of the last major and current repairs. In columns 11-22, each of which corresponds to one month, the symbol indicates the type of planned repair: K - capital, T - current. In columns 23 and 24, respectively, the annual downtime of equipment in repair and the annual fund of working hours are recorded. Now that we have considered the general provisions on the PPR schedule, let's consider a specific example. Let's assume that in our electrical facilities, in building 541, we have: 1) a three-phase two-winding oil transformer (T-1 according to the scheme) 6 / 0.4 kV, 1000 kVA; 2) pump motor, asynchronous (designation according to the scheme H-1), Рн=125 kW; Step 1. We enter our equipment into the empty form of the PPR schedule.

Step 2 At this stage, we determine the resource standards between repairs and downtime. a) For our transformer: we open the reference book p. 205 and in the table "Standards for the frequency, duration and complexity of repair of transformers and complete substations" we find a description of the equipment that fits our transformer . For our power of 1000 kVA, we select the values ​​​​of the frequency of repairs and downtime during major and current repairs, and write them down in our schedule.

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

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

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

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

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

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

An important note: at some enterprises, power engineers in their annual PPR schedules, instead of the last two columns of annual downtime and the annual fund, indicate only one column - “Labor intensity, man * hour”. This labor intensity is calculated according to the number of pieces of equipment and the norms of labor intensity of one repair. This scheme is convenient when working with contractors performing repair work. Do not forget that the dates of repairs must be coordinated with the mechanical service and, if necessary, the instrumentation and control service, as well as with other structural units that are directly related to the repair and maintenance of related equipment. If you have any questions about the preparation of the annual PPR schedule, ask questions, I will try, if possible, to answer them in detail.

When organizing planning and scheduling, network scheduling is used.

Network planning and management includes 3 main stages:

1. A network schedule is being developed that reflects the entire range of works, their relationship in a certain technological sequence to be completed to achieve the first goal;

2. The network schedule is being optimized, i.e. choice of the received variant;

3. Operational management and control over the progress of work. The order of building a network diagram:

a list of works is compiled;

a list of events is compiled;

a rational technological sequence and interconnection of works is determined;

the need for material and labor resources for each work is determined;

set duration of work.

4.2 Drawing up a card-determinant of work for the network diagram.

Drawing up a job identification card is the first step in network planning. The identification card is compiled according to the following data:

norms for the duration of installation and deadlines for completion of work;

project for the production of electrical work and technological maps;

valid maps and prices for electrical work;

data on the duration of certain types of work based on practical experience.

The Department of the Chief Power Engineer works in close cooperation with the departments:

capital construction;

chief mechanic;

marketing department;

planning and economic.

Repair personnel calculation

Chrem \u003d Labor ppr / Ffak

Chrem=1986/1435=1.3=1 person

For safety reasons we accept 2 people

Staff on duty - around the clock

Changes per day

1st shift from 7 am to 4 pm

II shift from 16-23 hours

III shift from 23-7 hours

IV shift - day off

5. Operation of electrical equipment.

5.1 Preventive maintenance system.

The PPR system is a set of technical and organizational measures for the care, maintenance and repair of equipment, carried out in a planned manner and of a preventive nature.

This system is called planned because all activities are carried out according to a plan (schedule) within a predetermined time frame.

It is called preventive because, in addition to repair work, it includes preventive measures that prevent accidents and breakdowns. Such activities include:

daily care;

equipment supervision;

overhaul maintenance - checking for accuracy;

• wash and oil change.

PPR system

overhaul

service

flushing