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 - actual time equipment operation, 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. - 1

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 calculation given in the guidelines for task 2.

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

Indicators	Option 1	Option 2	Option 3
Equipment	Compressor	Dryer	Autoclave
Working time between repair hours, hours
Capital	7130	14700	8238
Current	2160	2880	2880
RTO
Actual number of days worked per year
Number of shifts
Duration working days, hours
Continued mileage rev. after rem. by the beginning of the year,
Capital	5310	12200	7310
current			1950
RTO

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:

Indicators	Pump	Distillation column	Bake
Labor intensity of repair, man-hour
number
riggers
locksmiths
welders
Working hours
Number of shifts

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.

How to draw up a PPR schedule for electrical equipment?

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

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

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

Download guide

So. Your household has a certain amount of power equipment. All this equipment must be included in the PPR 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 (stock 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, symbol indicate the type of planned repair: K - capital, T - current. In columns 23 and 24, respectively, the annual downtime of equipment in repair and the annual fund of working hours are recorded. Now that we have considered general provisions about the PPR schedule, 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.

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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

January 2005." href="/text/category/yanvarmz_2005_g_/" rel="bookmark">January 2005, the current one is January 2008. For the N-1 pump engine, the capital one is September 2009, the current one is March 2010. We introduce this data in 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 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 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:

https://pandia.ru/text/78/363/images/image011_16.gif" width="622" height="105 src=">

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 useful 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 divisions 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.

Distribution of personnel by groups

After choosing the form of service and the structure of the electrical service of the economy, the distribution of electricians and engineers is carried out by structural links.

The required number of personnel in maintenance and repair groups or in service areas is determined by the formula.

where N x - the number of personnel in the group (at the site, people);

T i - annual labor costs for the implementation of the I-th type of work in the group (on the site), man-hour;

The number of personnel in the operational (duty) group is determined.

where K D is the coefficient of share participation of labor costs for operational (on-duty) maintenance in the planned costs for maintenance, TR, AP

(K D \u003d 0.15 ... .. 0.25).

The number of personnel in the repair group is defined as

where N rem - the number of personnel in the repair group (persons);

T i - annual labor costs for repairs, man-hours;

F D - the actual fund of working time per employee, h.

The number of personnel in the maintenance group is determined

When distributing personnel, it should be borne in mind that, according to the requirements of safety regulations for the operation of electrical installations of consumers, at least two electricians must be assigned to each section (object), one of which is appointed senior.

The total number of electricians in groups (on sites) of the electrical service, determined by labor costs (without major repairs), should not differ sharply from the total number of electricians, determined by the average load.

Drawing up schedules for the maintenance of electrical equipment

Requirements for PPR and maintenance schedules

The basis for the organization of work on the operation of electrical equipment are monthly, quarterly and annual maintenance and repair schedules. When developing them, the following should be taken into account:

The dates of the TR of electrical equipment should be combined with the dates of the repair of the machines on which it is used;

It is advisable to repair electrical equipment used seasonally before the period of its intensive operation;

The planned duration of work must correspond to the category of complexity of electrical equipment;

The time for transitions of electricians to service facilities during the working day must be minimized as much as possible;

The whole working day of electricians should be filled with work as much as possible.

The procedure for scheduling PPR and maintenance

Graphing is done in the following order:

1. A working table is being developed, on the basis of which a monthly schedule of preventive maintenance is compiled. The worksheets (Appendix 1) provide a list of electrical equipment of individual production units of the economy (complex, farm, mechanical repair shops, auxiliary enterprises, etc.) indicating the timing of equipment installation, the last major, current and emergency repairs, maintenance . Each piece of equipment is shown on a separate line.

Service planning begins with a more complex form, i.e. from the overhaul, then the current repair is planned and, lastly, the time for the maintenance is set.

The duration of a particular type of PPR is determined by the frequency and date of its last implementation. If the day of repairs falls on Sundays (Saturdays) or pre-holiday days, then repairs are postponed to a later or earlier date.

If the dates of the MOT, TR or KR coincide, more than complex view repair. Calendar days for the overhaul of equipment are set depending on the specific conditions of the economy or the organization involved. The timing of subsequent MOT and TR is determined by the frequency of their conduct. In case of violation of the frequency of scheduled preventive repairs or maintenance, their implementation is planned for the beginning of the month.

The type of repair (major, current) or maintenance is indicated in the columns calendar days respectively, the letters KR, TR or TO. Weekends (B) and public holidays (P) are also marked in the table.

2. Based on the data of the worksheet, a monthly PPR schedule is compiled (Appendix 2). Using data on the complexity of maintenance and repairs, the labor costs of electricians are determined by day to complete the planned scope of work. CR costs are not taken into account if this species repair is carried out by a third party.

In some cases: with territorial dispersion of units and low labor costs for maintenance (0.5-1h) and current repairs (2-8h); with a lack of means of transporting workers, the frequency of current repairs and maintenance can be neglected. At the same time, planning is carried out on the basis of: a full shift load of electricians (at least two people) and a minimum violation of the terms of the PPR. It is not desirable to violate the periodicity of the PPR of electrical equipment operating in the conditions of ammonia release in damp rooms.

Similarly, schedules for subsequent months are drawn up.

3. Quarterly and annual schedules are compiled on the basis of monthly schedules (Appendix 2).

When compiling general PPR schedules for all departments of the economy, it is necessary to ensure that there is no imposition of work deadlines on various objects for the same services. After drawing up the schedules, they are carefully checked.

To ensure continuity technological processes Maintenance and repair of electrical equipment is carried out during technological breaks. The current repair of electrical equipment is planned simultaneously with the current repair. technological equipment. Seasonal MOT and TR, as well as overhaul electrical wiring of livestock buildings and grain currents is planned for the period of their downtime. These works must be completed before the start of the season of use of the production facility.

At the same time, the schedule should provide: uniform loading of electricians during the day, month and year; minimal loss of time for the transition and moving between objects; observance of the normalized frequency preventive measures(deviations should not exceed ±35%).

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". Let's use the reference book of A.I. FMD 2008.

Let's take a concrete example. Let's assume that in our electrical facilities, in building 541, we have:

1. Three-phase two-winding oil transformer 6/0.4 kV,

2. Pump motor, asynchronous Рн=125 kW;

Step 1. We enter our equipment into the empty form of the table “Initial data for drawing up a 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 the table "Initial data for drawing up a PPR 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 the table “Initial data for drawing up a PPR schedule”.

Table. - Initial data for drawing up a PPR schedule

Regular inspections of electrical equipment (without turning them off) are carried out once a month. The duration and complexity of maintenance of electrical equipment should be 10% of the current repair.

In order to determine how long the repair will last in months, it is necessary to divide the number of hours of the frequency of repairs for equipment by the number of hours per month. We make a calculation for the T-1 transformer: 103680/720 = 144 months.

Step 3 After the table “Initial data for drawing up a PPR schedule”, it is necessary to calculate the number of repairs between inspections and draw up a structure for the repair cycle for each type of equipment.

Step 4

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 2014. The equipment is operational, the dates of repairs are known to us. For the T-1 transformer, the overhaul was carried out in January 2008, the current one - in January 2011. For the N-1 electric motor, the capital one is September 2012, the current one is March 2013.

We determine when and what types of repairs are due for the T-1 transformer in 2014. 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 hours and divide it by the number of hours in a year 8640 hours. 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 2008, so the next one is planned for January 2020.

For current repairs, the same principle of operation: 25920/8640=3 years. The last current repair was carried out in January 2011, thus. 2011+3=2014. The next current repair is in January 2014, it is for this year that we draw up a schedule, therefore, in column 8 (January) for the T-1 transformer, enter “T”.

For the electric motor, we get: a major overhaul is carried out every 6 years and is planned for September 2018. 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 2014.

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.

Step 5 We determine the annual downtime of current repairs. For a transformer, it will be equal to 8 hours, because. in 2014, we planned one current repair, and in terms of resource for current repairs - 8 hours. For the N-1 electric motor in 2014 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 .

Step 6 Determine the annual labor intensity of repairs.

For a transformer, it will be equal to 62 people / hour. in 2014, we planned one current repair, and in terms of resource for current repairs - 62 people per hour. For the N-1 electric motor in 2014 there will be two current repairs, the labor intensity rate in the current repair is 20 people per hour. We multiply 20 people / hour by 2 and get the annual labor intensity - 40 people / hour.

Our chart looks like this:

Step 7 Based on the structure of the repair cycle for each equipment, we put down the number of inspections between repairs and determine the annual downtime for maintenance.

For one transformer, downtime will be equal to 0.8 hours, according to the structure of the repair cycle, the number of inspections between repairs is 35TO. In 2014, we planned one current repair, so the number of inspections will be only 11, the annual maintenance downtime rate will be 8.8 (11 times 0.8).

For the N-1 electric motor, downtime will be equal to 0.1 hours, according to the structure of the repair cycle, the number of inspections between repairs is 5TO. In 2014, we planned two current repairs, so the number of inspections will be 10, the annual maintenance downtime rate will be 1.0 (10 times 0.1).

The labor intensity is calculated by the number of pieces of equipment and the norms of labor intensity of one repair. For a transformer, it will be equal to 68.2 people / hour (we multiply 6.2 people / hour by 11TO).

How to draw up a PPR schedule for electrical 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.

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

Download A.I. foot and mouth disease

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

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

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

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

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

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

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

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

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

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