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Development and approval of ppr. What is scheduled preventive maintenance

What is a preventive maintenance (PPR) system? PPR is a set of organizational, technical, economic works that allows you to ensure reliable, economical operation, and allows you to bring or bring the parameters of technical characteristics of equipment and economic indicators to design values ​​or to the characteristics of new equipment.

Approach to the problem. During operation, the equipment becomes dirty, wears out, which reduces the productivity, efficiency of this equipment; in addition, untimely maintenance, cleaning, repairs of various types lead to emergency situations (Sayano-Shushenskaya HPP), and, accordingly, economic damage, human losses, consumer problems, etc.

In addition, the rational organization of work on the maintenance of equipment (expensive, complex) also requires enormous costs (if maintenance is not carried out in a timely manner, then in the future its implementation will be even more expensive and more difficult). The equipment must always be in a state of operational readiness.

Thus, the need for repair requires the implementation of a rational, economical, good organization and an established system of PPR.

Each type of equipment has some parts that are subject to the greatest wear. PPR ensures the maintenance of equipment in working condition; solves the problems of rational organization of the repair process, reducing the time for repairs; lengthening the intervals of continuous operation between various types of repairs; reduction in the cost of repairs.

The PPR equipment system involves:

— accounting of available equipment;
- planning the range of removable parts that wear out quickly;
- establishment of their service life (service life of wear parts);
- determination of the frequency and content of repairs by equipment groups;
– development of technological processes for standard repair work; and development of instructions for carrying out these typical repairs;
- development of standards necessary for the use of the volume and cost of repair work;
- creation of stocks and spare parts of materials, storage and accounting of materials.

Equipment wears differently depending on different production conditions (type of production, operating conditions, environmental conditions).

The following factors influence wear:

— duration of equipment operation and load mode;
— quality parameters of the primary energy used;
- environmental conditions;
— the quality of the materials from which the equipment is made;
— design features;
- quality of workmanship, assembly;
— the existing PPR system;

Requirements for the PPR system:

— flexibility (efficiency, various rational methods, professional workers);
— functionality (eliminate duplication in maintenance);
- complexity;
- the possibility of carrying out work in a centralized way;
- manageability, which implies a clear relationship of all service functions, strict subordination functionality, and have a subordination scheme.

The maintenance of the equipment in working condition is ensured by:
– maintenance
Revision of the state in which the equipment is located. Everyday activities. External visual inspection. Cleaning, lubricating, wiping, etc. This is done by the person in charge of the equipment. This also includes any minor repairs. This service is ongoing.

Types of repair: current and capital.

The qualifications of the personnel conducting the inspection, revision and repair of equipment must be mandatory.
Current repairs are carried out between major repairs. Its purpose is to restore the health of the equipment, ensuring its performance for the period until its next repair.
A major overhaul is a major overhaul, it provides for large repairs, it can be complex (entirely) and nodal (individual nodes, but large). The scope of capital works includes both standard and special works. Data on typical work can be found in the reference book of Sinyagin N.N. - “The system of preventive maintenance of equipment and networks of industrial energy”.

Fundamentals of the organization of the PPR system.

The rational organization of PPR is based on 2 principles:
1 - the principle of prevention;
2 - the principle of planning.
The organization of work is based on the study of the wear of parts, and as a result of the inspection, the frequency and content of repair work is established. Depending on the degree of knowledge or analysis of wear, three forms of organization of PPR are possible.
1 - after viewing
2 - standard
3 - planned periodic.

When after the inspection form of the PPR, only the period of the inspection is planned in advance, this period is usually determined on the basis of indicative data (depending on the condition of the equipment) or the minimum service life of some parts. As a result of this, the nearest repair period and its volume are planned. And it is produced subjectively (maybe a master, maybe a worker). This form is random. There is no preparation for this work. Everything happens by chance (almost).

Standard form. It is based on standards. With the help of regulatory data, the frequency, volume, period, types of parts and assemblies are determined in accordance with wear standards, and does not depend on their condition. Preparatory work is necessary (materials, count and plan everything). It is used in critical areas of production. This system is rarely used. She's expensive.
Planned periodic form of organization of PPR. It dominates production. Inspections and repairs are foreseen here. For each type of equipment by timing. In this period of time, the reliability of the equipment must be guaranteed. Estimated volume is the actual volume, which is revealed during inspections. It turns out the amount of work in standard hours.

For the rational organization of the PPR system, it is necessary to take into account all the equipment (the entire composition, location, service life). An electronic accounting system should be established.

Organization of spare parts in warehouses.

Norms of frequency and content of repairs. A series of repetitive repairs form a repair cycle. The repair cycle is between two overhauls.

K-O-O-T-T-O-O-K.

The structures of the repair cycle are characterized by the composition and sequence of alternation of various repairs.

For the repair of complex equipment (computers, power equipment), branded maintenance is increasingly being used, which is carried out by special divisions of the manufacturer. Currently, the processing enterprises have a system of preventive maintenance of equipment (TSHR), which is a progressive form of organization of repair work. PPR is a set of organizational and technical measures aimed at maintaining equipment in working condition and preventing its emergency exit from operation. Each machine, after working out a certain number of hours, stops and undergoes routine inspection or repair, the frequency of which is determined by the design features and operating conditions of the machines. The PPR system at RUE MZIV provides for the following types of services: 1.

Blanker.ru

Table 3.3 Works regulated by the Provision on PPR for mechanical and electrothermal equipment Name of equipment Types of maintenance and repairs Periodicity, months. Number of maintenance, TR and C in the repair cycle during the service life until write-off Structure of the repair cycle Depreciation period, years Electric boilers, grills, braziers, autoclaves Maintenance 1 100 5TO…TR-10 TR 6 18 5TO-TR… to 60 1 …5TO-IP-K Electric stoves, cabinets, speed TO 1 100 5TO-TR… 10 water, food warmers TR 6 20 …5TO-TR Electric boilers TO 1 50 5TO-TR… 5 TR 6 8 …5TO-TR- to 30 1 5TO-TR-K Electric Steam Cookers TO 1 100 5TO-TR… 10 Steamers TR 6 17 5TO-TR-K to 36 2 Potato Peelers TO 1 80 5TO-TR…

PPR equipment system

In some industries, I happened to see how they remove an old unusable bearing and put another old bearing on the assembly, of course, such an attitude towards financing production will also cause a corresponding return on production.

  • The quality of repairs by personnel, with poor quality, breakdowns will be more frequent. In this case, it will be necessary to plan repairs and maintenance of equipment more often.
  • Quality of repair planning, qualification of equipment repair organizers. The organizers of equipment repairs in production include a mechanic, and on large production lines, even the entire department of the chief mechanic.

Drawing up a schedule for preventive maintenance of equipment

It consists in replacing individual worn parts, eliminating defects, performing lubrication and fastening operations, etc. Overhaul is a repair performed to restore the resource of a product with the replacement or restoration of any of its parts. Capital and current repairs can be planned and unscheduled.


Attention

Planned repairs are carried out according to the schedule. Unscheduled repairs are carried out in order to eliminate the consequences of sudden failures and breakdowns. Commercial equipment in most cases undergoes a planned overhaul. Scheduled overhaul is not provided for equipment that does not have mechanical wear during operation (for example, thermal equipment).


All these works are designed to maintain the performance of machines and devices until the next scheduled repair.
The system of scheduled preventive maintenance includes the following types of technical repairs and maintenance: weekly maintenance, monthly maintenance, annual scheduled preventive maintenance. Drawing up a schedule of preventive maintenance Annual schedule of preventive maintenance, 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.
To draw up an annual preventive maintenance schedule (PPR schedule), we need standards for the frequency of equipment repairs.
Very often, such repairs are called PPR equipment (scheduled preventive maintenance) or equipment maintenance (equipment maintenance).
  • Capital repairs.
    • Maintenance of equipment, also known as scheduled preventive maintenance Today we will look at weekly maintenance of equipment (PPR or maintenance). It is called weekly symbolically, in fact, depending on the specifics of the equipment, repairs can be organized both more often, for example, several times a week (which is very rare), and much less often, for example, once every two weeks. Or maybe even once a month (such repairs are much more common).

PPR schedule of technological equipment in food production sample

Here you need to partially disassemble the mechanism, replace and restore worn parts. It is performed without removing the mechanism from the foundation. 5. Overhaul, which consists in replacing worn parts and assemblies, checking and adjusting machines and restoring them in accordance with specifications.

Overhaul involves a complete disassembly of equipment with removal, if necessary, from the foundation. Inspections, current and major repairs are carried out by special repair personnel with the involvement of the maintenance staff. The basis for the preparation of the PPR plan is the standards and structure of the repair cycle.

The repair cycle is the operating time of the machine from the beginning of its commissioning to the first major overhaul. It depends on the durability of the parts and the operating conditions of the equipment.
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.
Column 2 - number of equipment Column 3-4 - indicate the resource standards between major repairs and current ones. (See Appendix 2) Columns 5-6 - Labor intensity of one repair (see Table 2 Appendix 3) based on the list of defects. In columns 7-8 - indicate the dates of the last major and current repairs (we conditionally accept the month of January of the current year) In columns 9-20, each of which corresponds to one month, the symbol indicates the type of planned repair: K - capital, T - current.

Info

For the efficient operation of equipment at RUE MZIV, a clear organization of its logistics is necessary. A large amount of this is given to the organization of equipment repair. The essence of repair is to preserve and restore the performance of equipment and mechanisms by replacing or restoring worn parts and adjusting mechanisms.


Important

Every year more than 10-12% of the equipment undergoes major repairs, 20-30% - medium and 90-100% - small. The cost of repair and maintenance of equipment is more than 10% of the cost of manufactured products. Over the entire life of the machine, the cost of its repair is several times higher than its original cost.


The main task of the repair facility is to keep the equipment in a technically sound condition, which ensures its uninterrupted operation.
Number of pieces of equipment 7 2 Number of repairs (inspections) of equipment in the structure of the repair cycle Capital 1 1 Medium 1 2 Current 2 3 Inspections 20 48 Equipment repair complexity category 1.5 1.22 Duration of equipment repair, shifts Capital 1 30 · average 0.6 18 · current 0.2 8 · inspections 0.1 1 Duration of the repair cycle, months. 18 48 Labor intensity of repairs (inspections) capital 35.0 35.0 average 23.5 23.5 current 6.1 6.1 inspections 0.85 0.85 on the basis of the "Regulations on the system of preventive maintenance of equipment): for equipment for bottling wines - 100 and other technological equipment 150 conditional repair units Annual fund of working hours of one worker 1860 hours, coefficient of performance of the production rate 0.95, shift work of equipment 1, 5.
Faulty equipment is considered to be equipment that does not meet at least one of the requirements established by the operational documentation, standards (GOSTs), technical specifications (TU). Malfunctions include a decrease in the productivity and efficiency of machines, loss of accuracy, deviations in technological processes (in excess of permissible limits). The reliability of the equipment is determined by the reliability, durability, maintainability and persistence.

Reliability is the property of equipment to remain operational for some operating time, i.e., work without failure for a given period of time. Durability reflects such a property of equipment as the preservation of performance before overhaul or before decommissioning. Maintainability is the ability of equipment to prevent, detect and correct failures and malfunctions.

It is known that the operation of the machine and the duration of operation are affected by maintenance carried out on time and with high quality, as well as repairs. Back in the USSR, a PPR system (planned preventive maintenance and repair) was introduced. It regulates the scope of the proposed work, the timing of their implementation, as a result of which the reasons for which machine malfunctions are possible are eliminated. Thus, planned preventive maintenance prolongs the mechanisms and improves their quality of work.

Planned preventive maintenance of machines and construction equipment

The operation of mechanisms involves the implementation of complex work, which constitute the PPR system, the purpose of which is to prevent breakdowns due to wear of parts. Special events that ensure the maintenance of each machine are necessarily planned in advance, they are prepared.

During the use of machines, scheduled preventive maintenance is carried out either monthly or according to an approved plan. Maintenance, carried out monthly, is carried out during the work shift, at its beginning or at the end. Scheduled maintenance is carried out in accordance with the requirements of the mechanism manufacturer. They also distinguish between maintenance carried out seasonally twice a year, when the machines are prepared for the winter or summer period of operation. During the storage of machines or their transportation, scheduled preventive maintenance is carried out in accordance with the documentation and requirements for compliance with the operating rules.

Engineers or crew members can independently carry out daily repairs to the machine that is assigned to them. However, if scheduled repairs are not part of their duties, then the machine is sent for maintenance centrally to the preventive maintenance departments, where specialists deal with it. Works on daily maintenance of mechanisms are not planned, as they are mandatory. During the maintenance of construction and road machines, technical diagnostics, cleaning, lubrication, inspection, regulation, refueling are carried out.

Scheduled preventive maintenance of electrical equipment

At large industrial enterprises, the current scheduled preventive maintenance is carried out by shop personnel. Only a major repair is a task that is carried out under the guidance of a skilled worker. The operational group thus formed, headed by the shift supervisor, supervises the electrical equipment in the workshops and is responsible for its minor scheduled repairs. At power plants, the inspection of tunnels, channels and mines is carried out by the personnel of the electrical department. The work is on schedule. During the inspection, the detected defects are recorded in a log, they are eliminated when the opportunity arises.

Types of scheduled preventive maintenance

As a system, planned preventive maintenance of equipment includes such types of maintenance, care and supervision of the repair and operation of mechanisms as:

  • routine preventive maintenance of equipment
  • scheduled checks and inspections
  • scheduled repairs, medium and small
  • overhaul

The repair cycle is called the period between 2 which includes several inspections and repairs of smaller ones. A minor repair is a scheduled preventive repair, in which the unit is completely disassembled. The average includes scheduled repairs, during which the mechanism is partially disassembled, individual components undergo major repairs. During a major overhaul, components and parts that are badly worn out are replaced, the unit is completely disassembled, the basic parts are repaired and adjusted.

In order to prevent damage, it is necessary to follow the maintenance instructions and the rules for operating the 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 not a secret for anyone that the main document by which the repair of electrical equipment is carried out 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 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: 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, a major overhaul was carried out in January 2005, the current one - in 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 We 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.

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 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.

PPR work execution project- this is organizational and technological documentation, containing the technology and organization of preparatory and main types of construction and installation work at the construction site, quality control and acceptance requirements, work of the final period, labor protection and safety measures in accordance with current regulatory and technical documents, as well as the standards of the Customer's organization. Does not apply to working or project documentation object, which are only the basis for the development of WEP. Prepared before the start of all construction and installation work.

PPR (deciphering the abbreviation - project for the production of works) is one of the executive documents required for the construction, reconstruction and overhaul of the facility. Its main purpose is to choose a technology for construction and installation and / or repair work that allows the most rational use of material, material, technical and labor resources while ensuring overall safety. Without this document, it is impossible to properly organize and start the workflow. With its help it is possible:

  • reduce the cost of materials and equipment;
  • ensure the safety of work;
  • reduce risks;
  • ensure compliance with the terms of construction or repair of the facility.

In 2019, when compiling the PPR, it is necessary to take into account only the changes made to the NTD (Urban Planning Code, RD guidelines, codes of rules for joint ventures, building codes and rules for SNiP, state standards GOST, etc.). The requirements remain the same as in 2018, 2017 and previous years. Of course, it would be wrong to use ready-made standard documents that are common on the Internet, since in 2018-2019 many changes were made to the NTD and the old ones were replaced. Every year a bunch of documents are updated and it becomes difficult to take on the development of a project for the production of works on our own.

The explanatory note is the main part and consists of the most important sections. It includes the entire organizational sequence of work performed and provides links to flow charts by type of work performed. Engineering support of construction, taking into account the duration, composition of the working personnel, the number of machines and mechanisms, is given in the preparatory period.

In the appendix to the PPR, work schedules are inserted that determine the technical and economic indicators of construction. The calendar schedule is drawn up in accordance with the contract for the performance of work on the facility without deviations, regardless of the duration specified in the construction organization project. Delivery schedules and requirements are divided into weeks, months or quarters depending on the construction time.

Who develops the project for the production of PPR works

The development of projects for the production of PPR works is carried out by a general contractor, or by order of a specialized organization. The developer organization should have in its staff specialists with experience working at construction sites, who know the technology of construction production. When using lifting structures, it is necessary to have attestation protocols for industrial safety for specialists. For the development of technical solutions adopted in the PPR, the Customer often requires the developer to be a member of the SRO.

The General Contractor may prescribe in the contract with the Subcontractor the obligation to develop it. In this case, based on the volumes performed by the Subcontractor, a decision is made to develop a WEP and/or separate flow charts for an already existing project for the execution of works at the facility.

Who approves the project for the production of work

The WEP is approved by the technical manager of the contractor (chief engineer, technical director, deputy director for construction, etc.) performing these works. Thus, taking all prescribed measures for execution.
The project for the production of works is submitted for approval in a fully finished form with all attachments and signatures. After signing, the seal of the organization is affixed and the project is submitted for approval to the interested parties involved in the construction (Departments of the Customer, Construction Control of the Customer, owners of engineering networks, etc.).

Who agrees on the project for the production of PPR works

The approval of the WEP is carried out by the Contractor in the following sequence:

  • Services of the Customer: department of capital construction of OKS, HSE, fire department, power engineering department, department of the chief mechanic and other representatives depending on the structure of the company;
  • OATI (for Moscow), GATI (for St. Petersburg) and similar organizations, taking into account the regulatory legal acts of the Government of the Russian Federation in the area of ​​work;
  • Owners of buildings and structures located near the projected object;
  • Organizations-owners of intersected underground and above-ground communications (water supply, communication cables, gas pipeline, heating, etc.) at their intersection;
  • Owners of used machines and mechanisms;
  • In some cases, representatives of Rostekhnadzor.

To agree on the project for the production of work, it includes a separate sheet with columns: position, full name, signature and comments. Based on the signatures on the title page, the signature of the technical managers of the coordinating persons is put.

Who signs the project for the production of works

The signing of the PPR is carried out by specialists who have developed individual sections. On the table of contents in the frame, the signatures of the developer, the inspector and the technical manager are put. Technological maps are signed by the compilers: QCD for welding by the chief welder or welding engineer, TC for quality control and input control of materials - by a construction control engineer, etc.

How to compose

You can draw up a PPR on your own by shoveling a bunch of regulatory documentation. But it takes a lot of time and effort of specialists. Its design can be entrusted to developers - specialized companies.
In order to start compiling it, you must first study the MDS and then the composition of the future PPR will be clear. After you have studied it, you need to start studying the entire technical documentation for the work performed, for example, a joint venture for concrete work, a joint venture for the installation of building structures and take only the necessary information and include it in the document. It is possible to take standard projects as a basis, but now it is very difficult to find relevant ones containing new labor protection requirements and construction technology. Everything standard is outdated.

Alteration

During the production of construction and installation works, in most cases, it becomes necessary to make changes to the already developed WEP. This can be facilitated by: underground utilities not specified in the construction plan were discovered; equipment that was supposed to be used is difficult to find and there is a similar one, but the technology needs to be changed (for example, a concrete pump cannot deliver to a certain height, it is necessary to supply concrete using a bucket to the floors); changes in the working draft, etc. Only the developer can make changes and in agreement with the persons who signed it. Those. after that, you need to go through the approval process again.

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