PPR schedule of technological equipment. Drawing up an annual schedule of scheduled preventive maintenance of equipment

The main stages of PPR equipment

Well-planned preventive maintenance includes:

Planning;

Preparation of electrical equipment for planned repairs;

Carrying out scheduled repairs;

Carrying out activities related to the planned 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, it 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, save quality work, 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 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 a look at all the details. It includes tests, measurements, elimination of identified faults, as a result of which the modernization of electrical equipment is carried out. Full restoration as a result of a major overhaul technical parameters devices.

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.

PPR systems and its basic concepts

The system of preventive maintenance of power equipment (hereinafter referred to as System PPREO) is a complex guidelines, norms and standards designed to ensure effective organization, planning and carrying out maintenance (TO) and repair of power equipment. The recommendations given in this PPR EO System 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 PPR EO 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 monitoring the technical condition aimed at preventing equipment failures and maintaining its serviceability and performance in the intervals between repairs.

The PPR EO system was created taking into account the new economic and legal conditions, and in technical terms, with the maximum use of: the capabilities and advantages of the aggregate repair method; the whole 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 state of equipment, planning maintenance and preventive actions and their logistics.

The action of the PPR EO System applies to all equipment of energy and technological shops of enterprises, regardless of the place of its use.

All equipment operated at enterprises is divided into main and non-main. The main equipment is the equipment, with the direct participation of which the main energy and technological processes of obtaining the product (final or intermediate) are carried out, and the failure of which leads to the cessation or a sharp reduction in the output of products (energy). Non-essential equipment ensures the full flow of energy and technological processes and operation of the main equipment.

Depending on the production significance and the functions performed in the energy and technological processes, equipment of the same type and name can be classified as both main and non-main.

The PPR EO system provides that the need for equipment in repair and preventive actions is satisfied by a combination of various kinds Maintenance and scheduled repairs of equipment, differing in the frequency and scope of work. Depending on the production significance of the equipment, the impact of its failures on the safety of personnel and the stability of energy technological processes, repair actions are implemented in the form of regulated repair, repair by operating time, repair by technical condition, or in the form of a combination of them.

Table 5 - number of repairs in 12 months

Table 6 - Planned balance of working hours for the year

Payroll ratio

• 1. For interrupted production = 1.8
• 2. For continuous production = 1.6

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.

Solution.

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 the calculation given in guidelines to task 2.

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

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:

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 and the working day and the coefficient of fulfillment of the norm.

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 in single system scheduled preventive maintenance.

It is based on three types of repair:

• current;
• middle;
• capital.

• Current- minor repairs, associated with the elimination of individual defects that have manifested themselves during operation.
• Middle- 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. Runlevel previous works when carrying out repairs 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 tools operate, 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 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, to ensure normal without emergency work enterprises, 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.

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

MAYBE YOU WILL BE INTERESTED

Purpose: to learn how to calculate the frequency of scheduled maintenance and repair work. Draw up an annual plan - a schedule for the maintenance of equipment.

Working process:

1. Select the equipment number according to the option (see Appendix 1)
2. We enter our equipment into the empty form of the PPR schedule.
3. At this stage, we determine the resource standards between repairs and downtime:
4. We look at Appendix No. 1 “Standards for the frequency, duration and complexity of repairs”, select the values ​​\u200b\u200bof the frequency of repairs and downtime during major and current repairs, and write them down in your schedule.
5. For the selected equipment, we need to determine the number and type of repairs in the coming year. To do this, we need to determine the number of equipment hours worked (the calculation is conditionally carried out from January) (see Appendix 2)
6. 4. We determine the annual downtime in repairs
7. 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.
8. Draw a conclusion

Table 1 - Task

Theoretical part

Scheduled preventive maintenance (PPR) - This is a complex of organizational and technical measures for supervision, maintenance and all types of repairs, which are carried out periodically according to a predetermined plan.

Thanks to this, premature wear of equipment is prevented, accidents are eliminated and prevented, fire protection systems are maintained in constant operational readiness.

The preventive maintenance system includes the following types technical repair and service:

weekly maintenance,

monthly maintenance,

annual scheduled preventive maintenance,

Annual scheduled preventive maintenance is carried out in accordance with the annual equipment maintenance schedule.

Drawing up a PPR schedule

The annual preventive maintenance schedule, 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 current repairs.

To draw up an annual preventive maintenance schedule (PPR schedule), we need standards for the frequency of equipment repairs. These 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. All this equipment must be included in the PPR schedule.

Column 1 indicates the name of the equipment, as a rule, brief and understandable information about the equipment.

In column 2 - the number of equipment

In column 3-4 - indicate the resource standards between major repairs and current ones. (See Appendix 2)

Columns 5-6 - the complexity 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 conditionally accept the month of January of the current year)

In columns 9-20 each of which corresponds to one month, symbol indicate the type of planned repair: K - capital, T - current.

In columns 21 and 22, respectively, the annual downtime of equipment in repair and the annual fund of working hours are recorded.

The annual plan-schedule of scheduled preventive maintenance of equipment can be downloaded here.

Attachment 1

STANDARDS OF PERIODICITY, DURATION AND LABOR-INCESSION OF MAINTENANCE AND REPAIR

Annex 2

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 order. This (scheduled) principle of taking equipment out for repair makes it possible to make the necessary preparations for shutting down equipment - both on the part of specialists service center, and from the side production staff customer. 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 appear during operation and consists of inspection, lubrication of parts, and cleaning of equipment.

The current stage of scheduled preventive maintenance precedes the overhaul. At the current stage of preventive maintenance, important tests and measurements are carried out, leading to the identification of equipment defects at an early stage of their occurrence. Having assembled the equipment at the current stage of 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 regulatory and technical documentation establishes the cyclicality, volume and sequence of repair work, even regardless of the technical condition of the equipment.

The middle phase 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. The overhaul ensures the restoration of the original specifications 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 violations of work technological equipment.
• · 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. Annual amount The budget plan 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.