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

To draw up an annual preventive maintenance schedule (preventive maintenance schedule) for electrical equipment, we will need standards for the frequency of equipment repairs. This data can be found in the manufacturer’s passport data for electrical equipment, if the plant specifically regulates this, or use the reference book “System for Maintenance and Repair of Power Equipment.” I use the A.I. reference book. FMD 2008, therefore, further I will refer to this source.

Download the reference book A.I. Foot and mouth disease

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

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

Step 1. We enter our equipment into the empty PPR schedule form.

Step 2. At this stage, we determine the resource standards between repairs and downtime:

a) For our transformer: open the reference book p. 205 and in the table “Standards for the frequency, duration and labor intensity of repairs of transformers and complete substations” we find a description of the equipment that is suitable for our transformer. For our power of 1000 kVA, we select the values of the frequency of repairs and downtime during major and current repairs, and write them down in our schedule.

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

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

Step 3. For the selected electrical equipment, we need to decide on the number and type of repairs in the coming year. To do this, we need to determine the dates of the last repairs - major and current. Let's say we are making a schedule for 2011. The equipment is operational, we know the dates of repairs. For T-1, a major overhaul was carried out in January 2005, the current one in January 2008. For the N-1 pump motor, the major one is September 2009, the current one is March 2010. We enter this data into the chart.

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

For the electric motor we get; major repairs are carried out every 6 years and are planned for September 2015. The current one is carried out 2 times a year (every 6 months) and, according to the latest current repairs, we plan for March and September 2011. Important note: if the electrical equipment is newly installed, then all types of repairs, as a rule, “dance” from the date of commissioning of the equipment.

Our graph looks like this:

Step 4. We determine the annual downtime for repairs. For a transformer it will be equal to 8 hours, because In 2011, we planned one routine repair, and in the resource standards for routine repairs the denominator is 8 hours. For the N-1 electric motor, there will be two routine repairs in 2011; the standard downtime for routine repairs is 10 hours. We multiply 10 hours by 2 and get annual downtime equal to 20 hours. In the annual working time column, we indicate the number of hours that this equipment will be in operation minus downtime for repairs. We get the final look of our graph.

Important note: at some enterprises, power engineers in their annual production schedules, instead of the last two columns of annual downtime and annual capital, indicate only one column - “Labor intensity, man*hour”. This labor intensity is calculated by the number of pieces of equipment and the labor intensity standards for one repair. This scheme is convenient when working with contractors performing repair work.

Do not forget that repair dates must be coordinated with the mechanical service and, if necessary, the instrumentation service, as well as with other structural units directly related to the repair and maintenance of related equipment.

If you have any questions about drawing up the annual PPR schedule, ask questions, I will try, if possible, to answer them in detail.

Main stages of PPR equipment

Planned and preventative well-designed repairs include:

Planning;

Preparation of electrical equipment for scheduled repairs;

Carrying out scheduled repairs;

Carrying out activities related to scheduled maintenance and repairs.

The system of scheduled preventive maintenance of equipment includes a couple of stages:

1. Inter-repair phase

Performed without disturbing the operation of the equipment. Includes: systematic cleaning; systematic lubrication; systematic examination; systematic adjustment of electrical equipment; replacement of parts that have a short service life; elimination of minor faults.

In other words, this is prevention, which includes daily inspection and care, and it must be properly organized in order to maximize the service life of the equipment, maintain high-quality work, and reduce the cost of scheduled repairs.

The main work performed during the overhaul phase:

Monitoring the condition of equipment;

Enforcement of appropriate use policies by employees;

Daily cleaning and lubrication;

Timely elimination of minor breakdowns and adjustment of mechanisms.

2. Current stage

Planned preventative maintenance of electrical equipment is most often carried out without disassembling the equipment, only stopping its operation. Includes the elimination of breakdowns that occurred during operation. At the current stage, measurements and tests are carried out, with the help of which equipment defects are identified at an early stage.

The decision on the suitability of electrical equipment is made by repairmen. This ruling is based on a comparison of test findings during routine maintenance. In addition to scheduled repairs, unplanned work is performed to eliminate defects in equipment operation. They are carried out after the entire resource of the equipment has been exhausted.

3. Middle stage

Carried out for the complete or partial restoration of used equipment. Includes disassembly of components intended for viewing, cleaning mechanisms and eliminating identified defects, replacing some quickly wearing parts. The middle stage is carried out no more than once a year.

The system at the middle stage of scheduled preventive maintenance of equipment includes setting the cyclicity, volume and sequence of work in accordance with the regulatory and technical documentation. The middle stage affects the maintenance of equipment in good condition.

4. Major renovation

It is carried out by opening electrical equipment, checking it completely and inspecting all parts. Includes testing, measurements, elimination of identified faults, as a result of which electrical equipment is modernized. As a result of a major overhaul, the technical parameters of the devices are completely restored.

Major repairs are possible only after the inter-repair phase. To carry it out you must do the following:

Draw up work schedules;

Conduct preliminary inspection and verification;

Prepare documents;

Prepare tools and necessary replacement parts;

Carry out fire prevention measures.

Major repairs include:

Replacement or restoration of worn mechanisms;

Modernization of any mechanisms;

Carrying out preventative checks and measurements;

Carrying out work related to the elimination of minor damage.

Malfunctions discovered during equipment testing are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.

PPR systems and its basic concepts

The system of scheduled preventive maintenance of power equipment (hereinafter referred to as the SystemPPREO) is a set of methodological recommendations, norms and standards designed to ensure the effective organization, planning and implementation of maintenance (MOT) and repair of power equipment. The recommendations given in this System of PPR EO can be used at enterprises of any type of activity and form of ownership that use similar equipment, taking into account the specific conditions of their work.

The planned and preventive nature of the EO PPR System is implemented by: carrying out equipment repairs at a given frequency, the timing and logistics of which are planned in advance; carrying out maintenance operations and technical condition monitoring aimed at preventing equipment failures and maintaining its serviceability and performance in the intervals between repairs.

The EO PPR system was created taking into account new economic and legal conditions, and in technical terms, with maximum use of: the capabilities and advantages of the aggregate repair method; the entire range of strategies, forms and methods of maintenance and repair, including new tools and methods of technical diagnostics; modern computing technology and computer technologies for collecting, accumulating and processing information about the condition of equipment, planning repair and preventive actions and their logistics.

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

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

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

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

Table 5 - number of repairs in 12 months

Table 6 - Planned balance of working time for the year

Payroll ratio

1. For discontinuous production =1.8
2. For continuous production =1.6

DEVELOPING A PREVENTIVE MAINTENANCE SCHEDULE (PPR)

In order to ensure reliable operation of equipment and prevent malfunctions and wear, enterprises periodically carry out scheduled preventive maintenance of equipment (PPR). It allows you to carry out a number of works aimed at restoring equipment and replacing parts, which ensures economical and continuous operation of the equipment.

The rotation 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.

Equipment is stopped for scheduled maintenance while it is still in working order. This (scheduled) principle of bringing equipment out for repairs allows for the necessary preparation for stopping the equipment - both from the service center specialists and from the customer’s production personnel. Preparation for scheduled preventive maintenance of equipment consists of identifying equipment defects, selecting and ordering spare parts and parts that should be replaced during repairs.

Such preparation allows for the full scope of repair work to be carried out without disrupting the normal operation of the enterprise.

Competent implementation of PPR presupposes:

· planning preventive maintenance of equipment;
· preparation of equipment for scheduled maintenance;
· carrying out scheduled preventive maintenance of equipment;
· Carrying out activities related to scheduled preventative repairs and maintenance of equipment.

Scheduled equipment repairs include the following steps:

1. Between-repair phase of maintenance.

The between-repair stage of equipment maintenance is carried out mainly without stopping the operation of the equipment itself.

The between-repair 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 maintenance period between repairs is prevention in other words. The maintenance period between repairs includes daily inspection and maintenance of equipment and must be properly organized in order to:

· radically extend the period of operation of the equipment;
· maintain excellent quality of work;
· reduce and speed up costs associated with scheduled repairs.

The maintenance period between repairs consists of:

· tracking the condition of the equipment;
· implementation of rules of proper operation by workers;
· daily cleaning and lubrication;
· timely elimination of minor breakdowns and regulation of mechanisms.

The maintenance period between repairs is carried out without stopping the production process. This maintenance stage is carried out during breaks in equipment operation.

2. Current stage of scheduled maintenance.

The current stage of preventative maintenance is often carried out without opening the equipment, temporarily stopping the operation of the equipment. The current stage of scheduled preventive maintenance consists of eliminating breakdowns that appear during operation and consists of inspection, lubrication of parts, and cleaning of equipment.

The current stage of scheduled preventative maintenance precedes the capital one. 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 scheduled maintenance, it is adjusted and tested.

A decision on the suitability of equipment for further operation is made by repairmen, based on a comparison of test results at the current stage of scheduled maintenance with existing standards and 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, work outside the plan is carried out to eliminate any defects in the operation of equipment. These works are carried out after the entire working life of the equipment has been exhausted. Also, to eliminate the consequences of accidents, emergency repairs are carried out, which require immediate shutdown of the equipment.

3. Middle stage of scheduled maintenance

The middle stage of scheduled preventive maintenance is intended for partial or complete restoration of used equipment.

The middle stage of scheduled maintenance is to disassemble equipment components to inspect, clean parts and eliminate identified defects, change parts and assemblies that wear out quickly and that do not ensure proper use of the equipment until the next major overhaul. The middle stage of scheduled maintenance is carried out no more than once a year.

The middle stage of scheduled preventative maintenance includes repairs in which normative and technical documentation establishes the cyclicity, volume and sequence of repair work, regardless of the technical condition in which the equipment is located.

The middle stage of preventive maintenance ensures that the operation of the equipment is maintained normally and there is little chance that the equipment will fail.

4. Major renovation

Overhaul of equipment is carried out by opening the equipment, checking the equipment with a meticulous inspection of the “internals”, testing, measurements, eliminating identified breakdowns, as a result of which the equipment is modernized. Major repairs ensure the restoration of the original technical characteristics of the equipment.

Major repairs of equipment are carried out only after the overhaul period. To implement it, the following steps are necessary:

· drawing up work schedules;
· carrying out preliminary inspection and verification;
· preparation of documentation;
· preparation of tools, spare parts;
· implementation of fire prevention and safety measures.

Overhaul of equipment consists of:

· replacement or restoration of worn parts;
· modernization of any parts;
· performing preventive measurements and checks;
· Carrying out work to eliminate minor damage.

Defects that are discovered during equipment inspection are eliminated during subsequent major overhaul of the equipment. Breakdowns that are emergency in 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.

Activities under 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 registration card (appendix to the technical passport).
· Annual cyclical equipment repair schedule.
· Annual plan and estimate for equipment overhaul.
· Monthly plan-report for equipment repairs.
· Acceptance certificate for major repairs.
· Shift log of technological equipment malfunctions.
· Extract from the annual PPR schedule.

Based on the approved annual PPR schedule, a nomenclature plan is drawn up for major and current repairs, broken down by months and quarters. Before starting major or current repairs, it is necessary to clarify the date of equipment delivery for repairs.

The annual PPR schedule and tables of initial data are the basis for drawing up an annual budget plan, which is developed twice a year. The annual amount of the estimate plan is divided into quarters and months depending on the period of major repairs according to the PPR schedule for a given year.

Based on 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.

Currently, computer and microprocessor technology (installations, stands, devices for diagnostics and testing of electrical equipment) are increasingly used for scheduled preventive maintenance (PPR), which influence the prevention of equipment wear and reduction of equipment repair time, reduction of repair costs, as well as helps improve the operating efficiency of electrical equipment.

Preventative maintenance is the simplest and most reliable way to plan repair work.

The main conditions ensuring planned preventive relations regarding equipment repair are as follows:

The main need for electrical equipment to be repaired is satisfied by performing scheduled repairs after a specific number of hours worked, thanks to which a periodically repeating cycle is formed;

Each scheduled preventative repair of electrical installations is carried out to the extent necessary to eliminate all existing defects, as well as to ensure the natural operation of the equipment until the next scheduled repair. The period of planned repairs is determined according to the established periods;

The organization of scheduled preventive maintenance and control is based on the normal scope of work, the implementation of which ensures the operational condition of the equipment;

The normal volume of work is determined due to the established optimal periods between scheduled periodic repairs;

Between scheduled periods, electrical equipment undergoes scheduled inspections and checks, which are a means of prevention.

The frequency and alternation of scheduled equipment repairs depends on the purpose of the equipment, its design and repair features, dimensions and operating conditions. Preparation for scheduled repairs is based on identifying defects, selecting spare parts and spare parts that will need to be replaced during repairs. An algorithm for carrying out this repair is specially created, which ensures uninterrupted operation during repairs. This approach to preparation makes it possible to carry out complete repairs of equipment without disrupting the usual production operations.

Planned and preventative well-designed repairs include:

Planning;

Preparation of electrical equipment for scheduled repairs;

Carrying out scheduled repairs;

Carrying out activities related to scheduled maintenance and repairs.

The system of scheduled preventive maintenance of equipment includes a couple of stages:

1. Inter-repair phase

The main work performed during the overhaul phase:

Monitoring the condition of equipment;

Enforcement of appropriate use policies by employees;

Daily cleaning and lubrication;

Timely elimination of minor breakdowns and adjustment of mechanisms.

2. Current stage

3. Middle stage

4. Major renovation

Major repairs are possible only after the inter-repair phase. To carry it out you must do the following:

Draw up work schedules;

Conduct preliminary inspection and verification;

Prepare documents;

Prepare tools and necessary replacement parts;

Carry out fire prevention measures.

Major repairs include:

Replacement or restoration of worn mechanisms;

Modernization of any mechanisms;

Carrying out preventative checks and measurements;

Carrying out work related to the elimination of minor damage.

Malfunctions discovered during equipment testing are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.

Each individual type of equipment has its own frequency of scheduled preventive maintenance, which is regulated by the Technical Operation Rules. All activities are reflected in the documentation, strict records are kept of the availability of equipment, as well as its condition. According to the approved annual plan, a nomenclature plan is created, which reflects the implementation of major and current repairs. Before starting current or major repairs, it is necessary to clarify the date of installation of electrical equipment for repairs.

Yearly schedule of preventative maintenance- this is the basis that serves to draw up a plan and estimate for the year, developed 2 times a year. The annual budget amount is divided into months and quarters, it all depends on the period of major repairs.

Today, for the system of scheduled preventive maintenance of equipment, computer and microprocessor technology (structures, stands, installations for diagnostics and testing) are most often used, which affects the prevention of equipment wear, reduction of repair costs, and also helps to increase operating efficiency.

PPR work 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, final work, 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 either working or design documentation object, which are only the basis for the development of PPR. Prepared before the start of all construction and installation work.

PPR (abbreviation for work execution plan) is one of the executive documents required for the construction, reconstruction and overhaul of a facility. Its main purpose is to select a technology for construction, installation and/or repair work that allows for the most efficient use of material, logistics and labor resources while ensuring overall safety. Without this document, it is impossible to properly organize and start the work process. With its help you can:

reduce costs for materials and equipment;
ensure the safety of work;
reduce risks;
ensure compliance with the deadlines for the construction or repair of the facility.

In 2019, when drawing up the PPR, it is necessary to take into account only the changes made to the scientific and technical documentation (Urban Planning Code, governing documents of the RD, codes of rules of joint ventures, building codes and regulations of 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 distributed on the Internet, since in 2018 - 2019 many changes were made to the technical documentation and old ones were replaced. Every year a lot of documents are updated and it becomes difficult to undertake the development of a project for the production of work on our own.

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

In the annex 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 by weeks, months or quarters depending on the construction period.

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 contracting organization, or upon request by a specialized organization. The development organization must have on its staff specialists with experience working on construction sites who know the technology of construction production. When using lifting structures, it is necessary to have industrial safety certification protocols for specialists. To develop technical solutions adopted in the PPR, the Customer often requires the developer to become a member of the SRO.

The General Contractor may stipulate in the contract with the Subcontractor the obligation to develop for him. In this case, based on the volumes performed by the Subcontractor, a decision is made to develop a work plan and/or separate technological maps for an already existing project for carrying out work on the site.

Who approves the PPR work project

The PPR is approved by the technical manager of the contracting organization (chief engineer, technical director, deputy director for construction, etc.) performing this work. Thus, accepting all prescribed measures for execution.
The work project is submitted for approval in a completely finished form with all attachments and signatures. After signing, the organization’s seal is affixed and the project is submitted for approval to interested parties involved in construction (Departments of the Customer, Construction Control of the Customer, owners of utility networks, etc.).

Who approves the project for carrying out PPR work?

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

Customer services: department of capital construction of OKS, HSE, fire department, energy service, department of 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 regulations of the Government of the Russian Federation in the territory of work;
Owners of buildings and structures located near the designed facility;
Organizations that own the crossed underground and above-ground communications (water supply, communication cables, gas pipeline, heating, etc.) at their intersection;
Owners of the machines and mechanisms used;
In some cases, also by representatives of Rostechnadzor.

To approve the work project, it includes a separate sheet with the following columns: position, full name, signature and comments. Based on the signatures on the title page, the signature of the technical managers of the approving persons is affixed.

Who signs the work project

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

How to compose

You can draw up a PPR on your own by sifting through a bunch of regulatory documentation. But this takes a lot of time and effort from specialists. Its design can be entrusted to developers - specialized companies.
In order to begin 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 being 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 current ones that contain new labor protection requirements and construction technologies. Everything standard has long been outdated.

Alteration

During the production process of construction and installation works, in most cases there is a need to make changes to the already developed design and construction work. This can be facilitated by: underground communications not indicated in the construction plan were discovered; the equipment that was supposed to be used is difficult to find and there are similar ones, 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 this, you must go through the approval procedure again.

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