Preventative maintenance schedule. How to draw up a maintenance schedule for electrical equipment

The PPR system is based on the following basic principles:

 preventive work must be carried out strictly according to pre-drawn calendar schedules;

 when justifying the frequency of preventive maintenance, it is necessary to take into account environmental conditions, temporary operating modes of equipment, the degree of responsibility of technological processes, etc.;

 the volume and labor intensity of the preventive work performed are provided on an average basis (enlarged) and in each specific case are specified depending on the technical condition of the equipment;

 the design of the equipment must comply with environmental conditions and operating modes, based on the requirements of regulatory documents.

Scheduled preventative maintenance is a set of works aimed at maintaining and restoring the performance of equipment. Depending on the nature and degree of wear of the equipment, on the volume, content and complexity of preventive maintenance, it includes between-repair maintenance, current, average and major renovation s.

Inter-repair maintenance is preventive in nature. It consists of regular cleaning and lubrication of equipment, inspection and testing of the operation of its mechanisms, replacement of parts with a short service life, and elimination of minor faults. These works, as a rule, are performed without stopping the equipment during its current operation.

Current repairs are a complex repair work carried out between two next major overhauls and consisting of the replacement or restoration of individual parts. Current repairs are carried out without completely disassembling the equipment, but it requires a short-term shutdown and removal of the equipment from operation with stress relief. During routine repairs of equipment, external inspection, cleaning, lubrication, checking the operation of mechanisms, repairing broken and worn parts are carried out, for example, inspecting and cleaning a generator without removing the rotor, varnishing the frontal parts, wiping insulators, inspecting and cleaning the inputs of transformers and switches without changing them. etc.

Thus, routine repairs are performed to ensure or restore the operability of electrical equipment by eliminating failures and malfunctions that arise during its operation. During routine repairs, the necessary measurements and tests are carried out to identify equipment defects at an early stage of their development. Based on measurements and tests, the scope of the upcoming major overhaul is determined. Current repairs are usually carried out at least once every 1–2 years.

During a medium repair, individual components are disassembled for inspection, cleaning of parts and elimination of detected faults, repair or replacement of wear parts or components that do not ensure normal operation of the equipment until the next major overhaul. Average repairs are carried out at intervals of no more than once a year.

During a major overhaul, equipment is opened and inspected with a thorough internal inspection and measurements technical parameters and eliminating detected faults. Major repairs are carried out at the end of the overhaul period established for each type of equipment. During final repairs, all worn parts are replaced or restored, and individual elements and components of equipment are modernized. These works require disassembly of units, complete external and internal repairs with checking the condition of components and parts, a significant number of highly qualified workers, long-term shutdown of electrical equipment, a large amount of testing and complex devices. The main electrical equipment undergoes major overhauls within a certain period of time.

Unlike current repairs, medium and capital repairs are aimed at restoring partially or completely used up mechanical and switching life of equipment.

Upon completion of the repair, equipment assembly, adjustment and testing are carried out. After preliminary acceptance from repair, the main equipment of power plants and substations is checked in operation under load for 24 hours.

A conclusion about the suitability of equipment for operation is made based on a comparison of test results with current standards, the results of previous tests, as well as measurements obtained on the same type of equipment. Non-transportable equipment is tested in mobile electrical laboratories.

In addition to scheduled preventative repairs, in the practice of power supply systems, unplanned repairs take place: emergency repairs and unscheduled ones. The task of emergency repair is to eliminate the consequences of an accident or eliminate damage that requires immediate shutdown of equipment. In emergency circumstances (fire, insulation failure, etc.), the equipment is stopped for repairs without the permission of the dispatcher.

The timing of major repairs of the main equipment of power facilities is as follows:

Unscheduled repairs are agreed upon with the system dispatcher and submitted with a corresponding application. They are carried out to eliminate various malfunctions in the operation of equipment, as well as after the switching resource has expired. Thus, depending on the type, circuit breakers with voltages of 6 kV and higher are subject to unscheduled repairs after disconnecting 3–10 short circuits at the rated interruption current.

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 capital and current repairs. In columns 11-22, each of which corresponds to one month, symbol indicate 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 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.

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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.

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

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

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

Organization of approved work. Control over them is based on a standard scope of work. Their responsible implementation ensures the continued full functioning of 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 subsequent repairs. Typically, a planned preventive maintenance schedule is drawn up taking into account established periods.

During breaks between scheduled repair work, electrical equipment is also subject to pre-scheduled inspections and a number of checks, which are essentially preventive.

Repair work of electrical equipment

The alternation and frequency 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 to clarify defects, select spare parts and spare parts that will need to be replaced in the future. An algorithm for performing this type of manipulation is specially developed, making it possible to ensure uninterrupted operation of equipment (machines) during repairs. Proper preparation Such an action plan makes it possible to completely restore the functioning of all devices without disrupting the usual operating mode of production.

Organization of the process

Competent planned preventive maintenance involves the following sequence:

1. Planning.

2. Preparing units for repair.

3. Carrying out repair work.

4. Carrying out activities related to repairs and scheduled maintenance.

The system of planned preventive maintenance of equipment under consideration has stages: between repairs, current. They can be considered in more detail.

Interrepair phase

The between-repair phase allows for equipment repair work to be carried out without disrupting the production process. It includes systematic cleaning, lubrication, inspection, and adjustment of units. This also includes eliminating minor faults and replacing parts with a short service life. In other words, this is prevention, which cannot be done without daily examination and care. It must be properly organized in order to maximize the service life of existing equipment.

A serious approach to this issue can significantly reduce the costs of future repairs and contribute to better and more efficient implementation of the tasks set by the enterprise. The main work that is carried out during the overhaul phase is daily lubrication and cleaning of units, compliance by all employees with the rules for using devices, tracking current state equipment, adjustment of mechanisms and timely liquidation minor damage.

Current stage

This stage of scheduled preventive maintenance of electrical equipment often does not involve disassembling the devices, but it includes the prompt elimination and elimination of all breakdowns that arose during the period of operation. In this case, only the units stop. During the current stage, tests and measurements are carried out, thanks to which equipment defects are identified even on early stages, and this is very important.

The decision about whether electrical equipment is suitable is made by repair specialists. This is within their competence. They base their decision on a comparison of the existing conclusions obtained during tests during the implementation of planned ongoing repair work.

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

Carrying out scheduled preventative maintenance: middle stage

Allows you to partially or completely restore worn-out units. The stage includes disassembling the necessary components to view them, eliminating identified defects, cleaning mechanisms and replacing some quickly wearing parts and components. It is held annually.

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

Major repairs and its prerequisites

It is carried out after opening the equipment and thoroughly checking it, examining all parts for defects. IN this stage includes measurements, tests, elimination of identified faults that require modernization of units. Here, a 100% restoration of the technical parameters of the devices in question takes place.

When is a major overhaul of electrical equipment carried out?

This kind of manipulation is possible only after the completion of the overhaul phase. The following conditions must also be met:

A work schedule has been drawn up.

A preliminary check and inspection has been carried out.

All necessary documents have been prepared.

Replacement parts and tools provided.

Fire safety measures have been completed.

What does a major renovation include?

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

1. Replacement/restoration of worn mechanisms.

2. Upgrades of devices that require this.

3. Carrying out measurements and preventive checks.

4. Carrying out work to eliminate minor damage.

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

According to the approved plan for the year, a nomenclature plan is created, which records the implementation of current/major repairs. Before starting work, the date of shutdown of electrical equipment (machines) for repairs must be specified.

The schedule of planned preventive maintenance is the official basis for drawing up an annual budget plan, developed twice during the specified period. The total amount of the estimate plan is distributed by month and quarter, taking into account the period of capital repair work.

Peculiarities

Today, the preventive maintenance system involves the use of microprocessor and computer technology (stands, structures, testing and diagnostic installations). Thanks to this, equipment wear is prevented and restoration costs are reduced. Also, all this helps to increase operational efficiency, and consequently, the profit of enterprises.

Preventive maintenance: drawing up a schedule for the year

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

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

Weekly technical repairs.

Monthly repair work.

Annual pre-scheduled preventive maintenance.

The developed regulations on scheduled preventive maintenance are approved by line ministries, as well as departments. The document is mandatory for execution by industry enterprises.

Preventative maintenance is always carried out in strict accordance with the existing annual work schedule, which includes each mechanism subject to routine or major repairs. When drawing up this schedule, 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 and 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 latest ongoing and major repairs.

Additional Information

The regulations on preventive maintenance contain 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 planned work.

The advantages of planned preventive maintenance systems include:

Recording downtime of units, equipment, machines.

Control over the duration of the between-repair periods of operation of devices.

Forecasting the costs of repairing equipment, mechanisms, components.

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

Analysis of the causes of equipment failure.

Disadvantages of planned preventive maintenance systems:

The complexity of calculating labor costs.

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

Difficulty in taking into account the parameter/indicator.

The complexity of operational adjustment of planned work.

Each preventative maintenance system has a trouble-free model for the operation/repair of units, but in the event of accidents or as a result of wear and tear, unscheduled work may also be carried out related to the full restoration of the functioning of the devices.

The frequency of equipment shutdowns for major or routine repairs is determined by the service life of wear-out mechanisms, parts, and assemblies. And their duration is determined by the time needed to perform the most labor-intensive manipulations.

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

When organizing planning and scheduling, network scheduling is used.

Network planning and management includes 3 main stages:

1. A network diagram is developed that reflects the entire complex of works, their interrelation in a certain technological sequence that must be performed to achieve the set goal;

2. The network diagram is optimized, i.e. selecting the resulting option;

3. Operational management and control over the progress of work. The procedure for constructing a network diagram:

a list of works is compiled;

a list of events is compiled;

a rational technological sequence and interrelation of work is determined;

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

the duration of the work is established.

4.2 Drawing up a work definition card for the network diagram.

Drawing up a work definition card is the first stage of network planning. The identification card is compiled according to the following data:

standards for installation duration and completion dates;

production project electrical installation work and technological maps;

current maps and prices for electrical installation 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;

economic planning.

Calculation of repair personnel

Chrem=Labor ppr/Fak

Chrem=1986/1435=1.3=1 person

Due to safety precautions we accept 2 people

Staff on duty - 24 hours a day

Shifts per day

I shift - from 7-16 hours

II shift from 16-23 hours

III shift from 23-7 hours

IV shift - day off

5. Operation of electrical equipment.

5.1 System of preventive maintenance.

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

This system is called a planned one 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 to prevent accidents and breakdowns. Such events include:

daily care;

equipment supervision;

overhaul maintenance - checking for accuracy;

• washing and oil change.

PPR system

Between repairs

service

Flushing