Operation and repair of power equipment. Alexander Yashchura - System of maintenance and repair of power equipment: Handbook

Power equipment and power grids of all types are an integral part of the company's fixed assets. Note that power equipment includes all equipment designed for the generation, conversion, distribution, transmission and consumption of the main types of energy (electrical and thermal) and energy carriers (water, air and gases) common in industry. In the production process, there is a process of consumption (expenditure) of fixed assets, which is expressed in the wear and tear of equipment and networks. This, in turn, leads to the loss of the passport characteristics of equipment and networks, power, productivity, pressure, accuracy, to failure or to an accident, which in some cases causes not only the shutdown of a particular unit of technological equipment, but also the downtime of sections, workshops, buildings, and sometimes enterprises in general. Distinguish between physical and obsolescence of fixed assets.

Obsolescence consists in reducing the efficiency of the existing physically fit equipment due to the introduction of new technology, the emergence of more advanced and economical machines. Moral wear and tear occurs (as a rule) before complete physical wear. The economic feasibility of replacing obsolete equipment ahead of the full physical wear and tear is determined by special calculations. The efficiency of obsolete equipment can be increased by modernization (technical improvement), the feasibility of which must also be calculated.

Normal physical wear and tear of equipment (chemical, thermal, fatigue, corrosive) is caused by the active operation of equipment, physical and chemical processes associated with production. Deterioration can occur due to natural factors (moisture, temperature changes, etc.) when the equipment is not in operation. Physical wear causes a deterioration in the performance of the equipment - a decrease in productivity (power), an increase in fuel consumption and operating materials. At a certain level of physical wear and tear of the equipment, its further operation becomes economically inexpedient. There is a danger of a sudden (emergency) exit of the equipment from working condition with the consequent losses from violations of the production regime and the cost of subsequent repairs. Deterioration in performance as a result of physical wear and tear of power equipment can be overcome by repairs.

The physical wear and tear of the equipment occurs unevenly: individual parts of the machines serve for different periods of time, and to ensure the operability of the machine during a certain service life, individual units and parts have to be periodically replaced.

All replaceable and repaired parts of the machine can be grouped into groups that differ in terms of use of parts before they are replaced or repaired. In this case, the part can be attributed to the repair group with a slightly shorter service life than the possible period of its use. This grouping allows you to build a calendar-volumetric schedules of equipment repair, characterizing the necessary repair costs in different years (periods) of its operation.

Thus, the repair of equipment and other elements of fixed assets is a necessary production process due to the current level of technology development.

Distinguish the following concepts: repair, modernization, reconstruction.

Repairs - a set of operations to restore the serviceability or serviceability of the product and restore the resource of products or their components.

Modernization existing equipment - a change in the design of existing equipment in order to bring it in accordance with the new requirements, ensuring an improvement in its performance, increasing reliability, reducing energy, material costs and labor resources during operation, technical inspection and repair, reducing obsolescence, as well as using others during operation types of (more affordable) fuels, raw materials and materials.

Reconstruction - a set of measures to improve the functioning of the equipment or to use it for a new purpose through significant changes affecting the fundamental essence of the design.

So, the task of uninterrupted and high-quality power supply is largely and increasingly determined by energy repair production.

In general, repair work is designed to solve the following tasks:

1. Improving the management planning system and organization maintenance.

2. Ensuring the high quality of the repaired equipment and the quality of the performed renovation works.

3. Economy and rational use of labor, material and financial resources.

Maintenance service as a function of the production management of energy enterprises includes:

production program planning;

organization of repair work;

accounting and analysis of production and cost indicators;

analysis of the main technical and economic indicators of energy repair production.

2. Types of power equipment repairs

The complex of organizational and technical measures for the maintenance and repair of equipment, which includes planning, preparation, implementation of maintenance and repair with a given sequence and frequency, is a system of maintenance and repair (TO and R).

There are the following types of repairs: capital, medium, current, emergency and recovery.

Maintenanceincludes the elimination of defects in the operation of the equipment detected on the day the unit was shut down for repair, replacement of wearing parts, identification of details that require replacement or repair during a mid-life or overhaul: performance of preventive work to ensure reliable operation of the equipment in the period between the next medium or overhaul

When average repairpartial disassembly of equipment, replacement of worn parts, inspection and cleaning of parts and assemblies, testing and identification of work that must be carried out during the next major overhaul are carried out.

Major overhaulincludes complete disassembly of equipment, inspection of all parts, replacement of individual parts and assemblies, elimination of all defects, testing and testing. Its purpose is not only to ensure the operability of the equipment, but also to completely restore the technical and economic parameters of the unit. Capital and mid-life repairs in the power industry account for 70% of all repair costs.

Overhaul differs from the current one in a longer overhaul period between two overhauls than between current repairs, a longer repair duration, a large volume of work, a lower frequency of implementation, and a higher cost.

Recovery repairs are carried out after natural disasters and other extraordinary situations.

Monitoring the condition of the equipment, carrying out daily lubrication and cleaning, adjusting mechanisms, eliminating minor faults can be carried out by Maintenance.

Maintenance intervals - the time interval or operating time between this type of maintenance and the next one of the same type or other of greater complexity.

Depending on the nature and scope of the work carried out, it provides for a shift maintenance and periodic maintenance.

The main method of maintenance is inspection, during which the technical condition of the most critical parts and assemblies is determined and the scope of the upcoming repair is specified.

The time between two consecutive repairs is called overhaul period... Overhaul period - is determined from the conditions for ensuring the reliable operation of the equipment without a noticeable decrease in the efficiency of operation.

The alternation of repairs in a certain sequence and at certain intervals is repair cycle structure.

The time period between two major overhauls is repair cycle duration.

3. Organization of repair

Energy repair production requires a high organization of the production process, taking into account the coordination of interaction between sometimes dozens of contractors, and the number of simultaneously employed workers in the repair of large power units, lasting several months, reaches 500-600 people. In the process of preparing for the repair, a rather complex organization project and a network schedule for the repair work are being developed. At the same time, it is taken into account that the annual schedule for the repair of power equipment is related to the balances of capacities in the power system (drawn up in such a way as to cover the annual schedule of monthly maximum electrical load) and financial capabilities. For this reason, major repairs are carried out, as a rule, in the spring-summer months - the period of load decline, and current repairs - on weekends and holidays.

When planning repairs, it is necessary to ensure maximum reliability and create favorable conditions for carrying out repairs. To comply with these conditions, it is recommended:

At CHPPs, time the time to coincide with the summer time, when the heating load is reduced as much as possible;

Repair of block equipment should be carried out simultaneously with the aim of minimizing the power taken out for repair;

HPPs with a regulated watercourse repair equipment at any time of the year, with the exception of floods, in order to use the power of the HPP and save fuel at the TPP;

Repair of equipment at each station should be carried out evenly throughout the year to ensure an even load of resources.

At the same time, in practice, a situation often arises when the approved annual repair schedule undergoes major changes due to:

Financial problems;

Impossibility to provide the repair of several large units with the required number of personnel due to the prolongation of the scheduled repair or an accident at some power facility;

Detection of unforeseen large defects during opening and flaw detection of equipment (especially typical for obsolete equipment and large units that have exhausted their resource);

Accidents on any unit;

Delays in the delivery of spare parts and materials.

Moreover, if a power company desperately needs a power unit to cover the load or operate a power plant in an economical mode, it is often put into operation without eliminating some of the defects - leaving them for the next repair. As a result, the reliability and technical and economic performance of the equipment are reduced.

Energoremont is a very costly production that requires expensive special tools and devices, a well-developed machine tool park, and at nuclear power plants - funds for remote execution of work. In general, the costs of energy repairs in electricity and heat supply systems are very high and were, even with large-scale commissioning of generating capacities in the 70s and 90s of the last century, comparable to the volume of capital investments in the construction of new power facilities.

Alexander Ignatievich Yashchura. 1

Introduction. 1

Part I. 4

1.3. Structure of the Chief Power Engineer Department. 11

2. PRODUCTION OPERATION OF EQUIPMENT.. 13

2.1. Receiving equipment. 13

2.2. Installation of equipment. 14

2.3. Commissioning of equipment... 16

2.4. Organization of equipment operation. 16

2.5. Equipment service life. 20

2.6. Depreciation of equipment. 20

2.7. Equipment storage. 21

2.8. Disposal of equipment. 21

3. MAINTENANCE OF EQUIPMENT.. 21

3.2. Organization of maintenance work... 21

3.3. Equipment technical diagnostics. 21

3.4. Funding for maintenance work... 21

4. REPAIR OF EQUIPMENT.. 21

4.1. Methods, strategies and organizational forms of repair. 21

4.2. Repair standards.. 21

4.4. Preparation of repair work. 21

4.5. Organization and implementation of repairs. 21

4.6. Shutdown equipment repair. 21

4.7. Funding for equipment repairs. 21

4.8. Demarcation functional responsibilities between the services of the enterprise when repairing equipment. 21

5. FORMS OF REPAIR DOCUMENTATION.. 21

6. LABOR PROTECTION AND INDUSTRIAL SAFETY.. 21

6.1 Occupational safety. 21

6.2. Industrial safety during equipment operation. 21

6.3 Industrial safety during installation and repair of equipment. 21

6.4. State supervision over the operation of equipment. 21

6.5. Investigation and accounting of accidents and incidents. 21

Part II. 21

STANDARD NOMENCLATURE OF REPAIR WORKS, REPAIR STANDARDS, RATES OF CONSUMPTION OF MATERIALS AND SPARE PARTS FOR REPAIR OF ELECTRICAL EQUIPMENT .. 21

7. ELECTRIC MACHINES... 21

7.1. Maintenance. 21

7.2. Typical nomenclature of repair work during current repair. 21

7.3. Typical nomenclature of overhaul repairs. 21

7.4. Features of the organization of repair of explosion-proof electrical machines.. 21

7.5. Standards for the frequency, duration and labor intensity of repair. 21

7.6. Consumption rates of materials for current and major repairs. 21

8. ELECTRICAL NETWORKS.. 21

8.1. Maintenance. 21

8.2. Typical nomenclature of repair work during current repair. 21

8.3. Typical nomenclature of overhaul repairs. 21

8.4. Standards for the frequency, duration and labor intensity of repair. 21

9. ELECTRICAL APPARATUS AND COMPLETE DEVICES OF LOW VOLTAGE (UP TO 1000 V). 21

9.1. Maintenance. 21

9.2. Typical nomenclature of repair work during current repair. 21

9.3. Typical nomenclature of overhaul repairs. 21

9.4. Standards for the frequency, duration and labor intensity of repair. 21

9.5. Consumption rates of materials for current and major repairs. 21

10. HIGH VOLTAGE ELECTRICAL DEVICES (OVER 1000 V) AND POWER CONVERTERS.. 21

10.1. Maintenance. 21

10.2. Typical nomenclature of repair work during current repair. 21

10.3. Typical nomenclature of overhaul repairs. 21

10.4. Standards for the frequency, duration and labor intensity of repair. 21

10.5. Consumption rates of materials and spare parts for current and major repairs 21

11. POWER TRANSFORMERS... 21

11.1. Maintenance. 21

11.2. Typical nomenclature of repair work during current repair. 21

11.3. Typical nomenclature of overhaul repairs. 21

11.4. Standards for the frequency, duration and labor intensity of repair. 21

11.5. Consumption rates of materials and spare parts for current and major repairs 21

12. BATTERIES.. 21

12.1. Maintenance. 21

12.2. Typical nomenclature of repair work during current repair. 21

12.3. Typical nomenclature of overhaul repairs. 21

12.4. Standards for the frequency, duration and labor intensity of repair. 21

13. MEANS OF COMMUNICATION AND SIGNALING.. 21

13.1. Maintenance. 21

13.2. Typical nomenclature of repair work during current repair. 21

13.3. Typical nomenclature of overhaul repairs. 21

13.4. Standards for the frequency, duration and labor intensity of repair. 21

13.5. Consumption rates of materials and spare parts for repairs. 21

14. RELAY PROTECTION DEVICES AND ELECTRIC AUTOMATION.. 21

14.1. Maintenance. 21

14.2. Maintenance intervals. 21

15. ELECTRIC WELDING EQUIPMENT. 21

15.1. Maintenance. 21

15.2. Typical nomenclature of repair work during current repair. 21

15.3. Typical nomenclature of overhaul repairs. 21

15.4. Standards for the frequency, duration and labor intensity of repair. 21

15.5. Consumption rates of materials and spare parts for overhaul. 21

16. MEASURING AND CONTROL INSTRUMENTS.. 21

16.1. Maintenance. 21

16.2. Maintenance. 21

16.3. Consumption rates of materials for maintenance and repair. 21

Part III. 21

STANDARD NOMENCLATURE OF REPAIR WORKS, REPAIR STANDARDS, RATES OF CONSUMPTION OF MATERIALS AND SPARE PARTS FOR REPAIR OF HEATING EQUIPMENT .. 21

17. BOILERS, AUXILIARY AND STEAM POWER EQUIPMENT. 21

17.1. Maintenance. 21

17.2. Typical nomenclature of repair work during current repair. 21

17.3. Typical nomenclature of overhaul repairs. 21

17.4. Standards for the frequency, duration and labor intensity of repair. 21

17.5. Consumption rates of materials and spare parts for current and major repairs 21

order of the Ministry of Industry and Science No. 05-900 / 14-108 of 01.01.2001 "On the development of a single regulation on scheduled preventive maintenance of technological and mechanical equipment",

as well as a number of other documents of the federal level concerning the organization of repair production in Russia.

Today, enterprises are independently responsible for planning and organizing repairs to ensure the continued availability of equipment. At the same time, their rights are expanding in many important areas, including:

financing of repairs and their material support;

regulation of the number of repair and operating personnel;

applying different repair strategies;

planning of repairs taking into account the beneficial use and the tightened service life of the equipment and other issues.

In the current conditions, the release of this Handbook seems to be extremely relevant.

The materials of the reference book, which are of a recommendatory nature, will help enterprises in the development of their own Regulations on PPR equipment, will serve as the necessary methodological base for the implementation of new rights and responsibilities, a regulatory framework for ensuring effective planning of repair work, needs for material and financial resources, as well as a tool for developing the right organizational decisions to improve the repair service.

The handbook consists of four parts:

Part I. Operation, maintenance and repair of power equipment.

Part II. Typical nomenclature of repair work, repair standards, rates of consumption of materials and spare parts for the repair of electrical equipment.

Part III. Typical nomenclature of repair work, repair standards, rates of consumption of materials and spare parts for the repair of heating equipment.

Part IV. Appendices containing the necessary methodological and reference materials.

For correct perception of the text and elimination of discrepancies in the wording, it is recommended to carefully read Appendix 1 "Basic concepts, terms, definitions", as well as the abbreviations adopted in the Handbook (Appendix 10).

Suggestions and comments on this Handbook should be sent Russia, Moscow, Derbenevskaya nab., 11, Pollars Business Center, bldg. B, Publishing house NTs ENAS.

Part I

OPERATION, MAINTENANCE AND REPAIR OF POWER EQUIPMENT

1. ENERGY SERVICE OF THE ENTERPRISE AND PREVENTIVE REPAIR SYSTEM

1.1. General concept of the system of preventive maintenance of power equipment

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

1.1.2. The planned preventive nature of the PPR EO System is implemented:

carrying out equipment repairs with a given frequency, the timing and material and technical support of which are planned in advance;

carrying out maintenance operations and monitoring the technical condition aimed at preventing equipment failures and maintaining its serviceability and operability in the intervals between repairs.

1.1.3. The PPR EO system was created taking into account new economic and legal conditions, and in technical terms - with maximum use:

the possibilities and advantages of the aggregate repair method;

the whole range of strategies, forms and methods of maintenance and repair, including new means and methods of technical diagnostics;

modern computing technology and computer technology collection, accumulation and processing of information about the state of equipment, planning of repair and preventive actions and their material and technical support.

1.1.4. The action of the PPR EO System applies to all equipment of power and technological workshops enterprises regardless of the place of its use.

1.1.5. All equipment operated at enterprises is subdivided into basic and non-basic.

The main equipment is 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 an interruption 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.

1.1.6. Depending on the production significance and functions performed in the energy and technological processes equipment of the same type and name can be attributed to both primary and non-primary.

1.1.7. The PPR EO system provides that the need for equipment for repair and preventive actions is satisfied by a combination different types Maintenance and scheduled repairs of equipment, differing in frequency and scope of work.

Depending on the production significance of the equipment, the impact of its failures on the safety of personnel and the stability of energy technological processes, repair effects are implemented in the form of regulated repairs, repairs based on operating time, repairs based on technical conditions, or in the form of a combination of these.

1.1.8. In practice, the list of equipment, the repair of which can be based only on the principles and strategies of regulated repair, is extremely narrow. In fact, the repair of most of the equipment is inevitably based on a combination (in various proportions) of regulated repairs and technical condition repairs. In this case, the "frame" of the structure of the repair cycle is determined by a set of equipment elements, the repair of which is based on the strategies of regulated repair or repair by operating time. The resulting "rigid" basis of the structure of the repair cycle is superimposed (in the "non-rigid" version) the timing of the repair of elements serviced according to the technical condition.

1.1.9. The most promising method of repairing equipment for enterprises of any form of ownership is the aggregate-nodal method, in which faulty replaceable elements (aggregates, assemblies and parts) are replaced with new or repaired ones taken from the circulating fund.

1.1.10. Timely replacement of faulty units, assemblies and parts - the implementation of a planned preventive repair system - is most successfully solved during the implementation technical diagnostics equipment in the process of its maintenance and repair.

1.1.11. Equipment repair can be carried out on their own by the enterprises operating the equipment, by third-party specialized repair companies, as well as by specialized subdivisions of manufacturers. The specific weight of each of the listed organizational forms of repair for a particular enterprise depends on many factors: the development of its own repair base, its equipment, remoteness from equipment manufacturers and specialized repair organizations, as well as financial capacity enterprises.

1.1.12. Maintenance and repair of power equipment (including power technology boilers, waste heat boilers, steam and gas turbine units, desiccant devices and communications, etc.) located in the production shops is carried out by the services of the chief mechanic and the chief power engineer.

1.1.13. Maintenance and repair of equipment in the energy sector of the enterprise and energy carriers (stationary and mobile power plants, distribution and transformer substations, in-plant air and cable networks, in-plant networks of natural gas used as fuel, steam and boiler installations, condensate collection and return devices, plant-wide water intake facilities and pre-treatment facilities for water supply power plants and make-up of water circulation systems, networks and installations for supplying enterprises with heat, steam, water, compressed air, communication and signaling equipment, etc.) is carried out by the service of the chief power engineer.

1.1.14. The boundary of the division of repair objects between the services of the chief mechanic and the chief power engineer is established according to the following criterion. If an energy medium is supplied or removed to the equipment and communications of the facility (technological workshop, site, etc.) assigned to the service of the chief mechanic, then the separation boundary is the first shut-off element (shut-off valves, shut-off device, etc.) before entering the shop. The service of the chief mechanic is responsible for the tightness of the connection and the serviceability of the shut-off body.

1.1.15. The standards for the frequency, duration and labor intensity of repairs given in this PPR EO System are calculated as weighted average values \u200b\u200bbased on the following considerations:

medium (in terms of severity) operating conditions of the equipment;

the equipment is repaired under normal temperature conditions;

the service life of the equipment has not exceeded the standard.

If the conditions differ from those specified above, the standards are adjusted in accordance with the coefficients given in the relevant sections of this PPR EO System.

1.1.16. The power equipment included in the PPR EO System is conditionally divided into the following two groups:

electrical equipment (electrical machines, electrical networks and relay protection devices, electrical devices of low and high voltage, power transformers, batteries, communication and signaling equipment), the standards and norms for which are given in the second part of this Handbook;

heat engineering equipment (boilers and auxiliary boiler elements, waste heat boilers, steam turbines, pipelines and pipeline fittings, compressors and pumps, fans, smoke exhausters, blowers, ventilation and exhaust systems, air heaters, air conditioners, water intake and water treatment equipment), standards and norms which are given in the third part of the Handbook.

1.1.17. For effective implementation PPR EO systems must meet the following conditions:

the energy service of the enterprise must be staffed with qualified personnel in accordance with staffing table, have a repair base with the necessary technological equipment and high-performance tools;

repair, duty and operational personnel must know and follow the rules technical exploitation equipment, industrial and fire safety rules;

equipment shutdown for scheduled repairs is carried out according to approved annual and monthly schedules in accordance with the standard frequency and taking into account the maximum use of stops for maintenance and equipment diagnostics;

repairs are carried out with high quality, in the planned volume, with maximum mechanization of heavy labor-intensive work;

during repair, the aggregate-nodal method and the method of repairing large objects according to the network schedule are widely used;

the organization of supplies of units, assemblies and parts from manufacturers is ensured. Only parts of a simple configuration are manufactured in our own workshops;

systematically, according to a special plan, work is carried out to increase the durability, reduce the indicators of emergency failure of power equipment.

1.1.18. This PPR EO System is a recommendation material of direct action, but it can also serve as a guide when enterprises develop their own "Regulations for the scheduled preventive maintenance of power equipment" in accordance with the requirement Federal Service for technological supervision (hereinafter - Federal supervision) PB 05-356.00, p. 242.

1.2. Tasks and functions of the chief power engineer department

1.2.1. As the experience of enterprises operating in new economic conditions, especially in the last 5–7 years, shows that the centralized command management system that existed in the recent past turned out to be unsuitable for solving the main task: making a profit.

1.2.2. It became necessary not in words, but in deeds to centralize the management of the technical operation of all types of fixed assets of the enterprise, concentrating it in one hand: the deputy director - chief engineer of the enterprise. At some enterprises, the centralization of technical operation was even more closely linked with the efficient use of fixed assets, subordinating it to the deputy head of the enterprise for equipment.

1.2.3. At enterprises it is necessary:

2.1.6. Upon receipt of the equipment, it must be ensured that it is properly unloaded from railway platforms and wagons, trucks and other types of transport. For this purpose, permanent mechanized means must be equipped at the place of receiving the equipment or special unloading means must be pre-arranged and delivered for temporary use.

2.1.7. Personnel unloading arrived equipment should be trained to keep the equipment intact and prevent breakdown or damage that could adversely affect the operation of the equipment during operation.

2.1.8. Equipment acceptance certificates, fully executed and signed by all members of the commission, are transferred to the accounting department of the enterprise for balance sheet accounting, where the equipment is assigned an inventory number.

2.1.9. An inventory number can be assigned to equipment both on an item-by-item basis and to a group of equipment that is part of an inventory item.

2.1.10. Inventory of fixed assets in accordance with clause 6 of the Accounting Regulations (PBU) 6/01 is:

an object with all fixtures and fittings;

separately constructively isolated object designed to perform certain independent functions;

a separate complex of constructively articulated objects, which is a single whole and is designed to perform a specific job.

2.1.11. A complex of structurally articulated objects is one or more objects of the same or different purpose, having common adaptations and accessories, general management, mounted on the same foundation, as a result of which each object included in the complex can perform its functions only as part of the complex, and not independently.

2.1.12. When determining the composition of each inventory item, one should be guided by the All-Russian Classifier of Fixed Assets (OKOF), approved by the Resolution of the State Committee of the Russian Federation for Standardization, Metrology and Certification No. 359 dated 01.01.01. this document the composition of the classification objects is indicated, which, according to the definition given in the OKOF, correspond to the concept of an inventory object in accounting. The composition of inventory objects is determined depending on the groups and types of fixed assets.

2.1.13. The OKOF does not take into account certain provisions of clause 6 of PBU 6/01. In particular, this applies to cases where one object has several parts with different useful lives. According to the rules accounting each such part is accounted for as an independent inventory item. In this case, the issue of assigning specific equipment to the amortization group should be decided by the equipment acceptance commission.

2.2. Installation of equipment

2.2.1. Installation of equipment is the last pre-operational period when obvious and partially hidden defects in manufacturing and assembly of equipment can be identified and eliminated. Installation work must be performed in such a way as not to increase the number of hidden defects remaining in the equipment.

2.2.2. Serious attention should be paid to the composition of the preparatory work that has crucial both for the timely and high-quality installation of equipment, and for its future efficient operation.

2.2.3. For equipment, the installation of which must be carried out or completed only at the place of use, work must be performed in accordance with the special instructions for installation, start-up, adjustment and running-in of the product at the place of use.

Machine-building plants are obliged to attach this instruction to the supplied equipment, which is provided for by the nomenclature of operational documents in GOST 2.601-68 (Appendix 5). The implementation of the specified instructions will prevent the possibility of an increase in hidden defects in the equipment, as well as identify and eliminate obvious and partially hidden defects in the manufacture and assembly of equipment, a possible list of which is given in Appendix 6.

A. I. YASHCHURA

TECHNICAL

MAINTENANCE AND REPAIR OF POWER EQUIPMENT

Directory

Moscow "Publishing house NTs ENAS" 2006

A. I. Yashchura

Ya99 System of maintenance and repair of power equipment. Directory. - M .: Publishing house NTs ENAS, 2006 .-- 504 p. silt

ISBN 5 93196 572 6

Considered organizational principles production operation, maintenance, as well as modern methods and forms of organizing the repair of power equipment, taking into account the requirements of new regulatory legal acts issued in recent years.

Typical nomenclature of repair work, refined service life, repair standards, consumption rates of materials and spare parts for all main types of electrical and heat engineering equipment are given.

Particular attention is paid to the system of organizing repairs based on the technical condition of equipment based on the use of modern methods and means of technical diagnostics.

The handbook is designed for engineering and technical workers engaged in production operation, maintenance and repair of power equipment at enterprises of various industries. It can be used to train students of technical universities and colleges.

UDC 621.313 / 316. (004.5 + 004.67) BBK 31.16

All rights reserved. No part of this book may be printed, translated into any language, or reproduced in any form without the written permission of the publisher.

INTRODUCTION

In recent years, radical changes have taken place in the organization of equipment repair at industrial enterprises of the country. Simultaneously with the reduction of most of the industrial ministries, the sectoral departments of the chief mechanic and the chief power engineer, which coordinated the organization of equipment repair, ceased to exist. All-Union and branch repair organizations (repair associations, trusts, etc.) were disbanded for the centralized repair of specialized equipment. Almost simultaneously, the development, revision and publication of Regulations (Systems) on the planned preventive maintenance of equipment, which provided enterprises with a methodological and regulatory framework for planning and organizing equipment repair, stopped in all industries. The system of centralized supply of enterprises with equipment, spare parts, repair equipment and repair materials collapsed. The revision of the norms of depreciation deductions (service life of equipment), repair standards, consumption rates of materials, the procedure and financing of repairs has ceased.

The economic crisis has led to a complete or partial shutdown of many industries. The utilization of operating enterprises dropped sharply. Energy repair services of enterprises have lost up to 50% of qualified workers. Most of the industrial equipment (over 70%) has exhausted its amortization period and requires replacement or major refurbishment.

The overwhelming majority of enterprises operating today are small and medium-sized enterprises that appeared in 1990-2003. Some of them arose on the basis of the former industrial giants as a result of their kind of "downsizing" in the course of privatization. Most were created from scratch in order to fill small niches in the increasingly demanding market of industrial products, goods and services. As a rule, newly formed enterprises do not have not only any serious material repair base and specialists who are familiar with the basic principles of planning, organizing and carrying out equipment repair, but even an outdated methodological and regulatory framework for building a more or less efficiently functioning repair service and organization. equipment repair at the enterprise. As a preventive measure, the Gosgortekhnadzor of Russia requirement PB 05 356.00 appeared on the need to have at each enterprise its own Regulation on scheduled preventive maintenance of equipment belonging to it. This requirement is a big "headache" for very many enterprises, especially newly created ones.

After the release of PB 05 356.00, government bodies received about a thousand proposals on the need to issue a single document governing the operation, maintenance and repair of machinery and equipment. Work begun in 2003 on the creation of the Handbook "Unified Regulation on the planned preventive maintenance of equipment industrial enterprises Russia ”(Order No. 05 900/14 108, dated May 29, 2003) were terminated due to the reorganization of the main customer of the development - the Ministry of Industry and Science of Russia.

This Handbook is a new, substantially revised and supplemented edition of the book "Production Operation, Maintenance and Repair of Power Equipment" (Moscow: Energoservice Publishing House, 1999).

In the new edition of the Handbook, taking into account the changes that have occurred, the following main provisions have been clarified, supplemented and finalized.

1. The optimal structure of the energy service of an enterprise (organization) for market conditions of management is given. The distribution of responsibilities and powers of the service divisions was clarified, a complete list of incoming and outgoing information was given, the terms of work performance and interaction with other services were considered. Section 1 is devoted to these issues.

2. The section "Production operation of equipment" has been revised and supplemented. The subsection "Acceptance of equipment" has been reintroduced, which includes the following issues:

identification of external defects of the equipment during its acceptance; requirements for operational and repair documentation; installation and assembly requirements; list of defects that can be identified at different stages

operation; the procedure for detecting hidden defects in equipment and materials.

3. A new grouping and new rates of depreciation of fixed assets (service life of equipment) are given. A methodology for calculating the amounts of depreciation deductions has been developed.

4. The section "Equipment maintenance" has been supplemented with new information. For the first time, technical diagnostics is considered as an element of the System for scheduled preventive maintenance of power equipment (PPR EO System). The technique for determining the serviceability of equipment and predicting the residual life using technical diagnostics is presented.

5. The standards for the labor intensity of equipment repairs have been adjusted by including labor costs for machine tools.

6. The forms of repair documentation in the conditions of technical operation of equipment in market economic relations have been revised.

7. Developed by new order financing equipment repairs by creating a reserve and applying a future expense account.

8. Introduced new section "Labor protection and industrial safety".

9. The terms and definitions were clarified and supplemented in connection with the release after 1999 of new normative documents.

After the release of the previous edition of the Handbook, new normative legal acts appeared, considering the technical operation of equipment in a new way, in particular:

Federal Law No. 57 FZ of July 27, 2002 "Tax Code of the Russian Federation";

government Decree No. 1 of 01.01.2002 “Classification of Fixed Assets Included in Depreciation Groups”;

order of the Ministry of Finance of the Russian Federation No. 264n dated March 30, 2001 “Regulations on accounting”;

order of the Ministry of Industry and Science No. 05 900/14 108 of May 29, 2003 "On the development of a Unified Regulation on scheduled preventive repairs of technological and mechanical equipment",

as well as a number of other documents of the federal level concerning the organization of repair production in Russia.

Today, enterprises are independently responsible for planning and organizing repairs to ensure the continuous operation of equipment. At the same time, their rights are simultaneously expanded in many important areas, including:

financing of repairs and their material support; regulation of the number of repair and operating personnel; applying different repair strategies; planning repairs taking into account useful use and

the exact service life of the equipment and other issues.

In the current conditions, the release of this Handbook seems to be extremely relevant.

The materials of the reference book, which are of a recommendatory nature, will help enterprises in the development of their own Regulations on PPR equipment, will serve as the necessary methodological base for the implementation of new rights and responsibilities, a regulatory framework for ensuring effective planning of repair work, needs for material and financial resources, as well as a tool for working out the right organizational decisions to improve the repair service.

The handbook consists of four parts:

Part I. Operation, maintenance and repair of power equipment.

Part II. Typical nomenclature of repair work, repair standards, rates of consumption of materials and spare parts for the repair of electrical equipment.

Part III. Typical nomenclature of repair work, repair standards, rates of consumption of materials and spare parts for the repair of heating equipment.

H part IV. Appendices containing the necessary methodological

and reference materials.

For correct perception of the text and elimination of discrepancies in the wording, it is recommended to carefully read Appendix 1 "Basic concepts, terms, definitions", as well as the abbreviations accepted in the Handbook (Appendix 10).

Suggestions and comments on this Handbook should be sent to the following address: 115114, Russia, Moscow, Derbenevskaya nab., 11, Pollars Business Center, bldg. B, Publishing house NTs ENAS.

Part I

OPERATION, MAINTENANCE AND REPAIR OF POWER EQUIPMENT

1. ENERGY SERVICE OF THE ENTERPRISE AND SYSTEM OF PLANNED PREVENTIVE REPAIRS

1.1. General concept of the system of scheduled preventive maintenance of power equipment

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

1.1.2. The planned preventive nature of the EO PPR System is implemented:

carrying out equipment repairs with a given frequency, the timing and material technical support of which is planned in advance;

carrying out maintenance operations and monitoring the technical condition aimed at preventing equipment failures and maintaining its serviceability and operability in the intervals between repairs.

1.1.3. The PPR EO system was created taking into account new economic

and legal conditions, and in technical terms - with maximum use:

the possibilities and advantages of the aggregate repair method; the whole range of strategies, forms and methods of maintenance and repair, including but

out means and methods of technical diagnostics; modern computer technology and computer technology

collection, accumulation and processing of information on the state of equipment, planning of repair and preventive actions and their material and technical support.

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

1.1.5. All equipment operated at enterprises is subdivided into primary and non-primary.

The main equipment is 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 the termination or sharp reduction in the output of products (energy).

The non-core equipment ensures the full flow of energy and technological processes and the operation of the main equipment.

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

to main and non-main.

1.1.7. The PPR EO system provides that the need for equipment in repair and prophylactic actions is satisfied by a combination of various types of maintenance and scheduled equipment repairs, differing in the frequency and scope of work.

Depending on the production significance of the equipment, the impact of its failures on the safety of personnel and the stability of power engineering processes, repair effects are implemented in the form of regulated repairs, repairs based on operating time, repairs based on technical conditions, or in the form of a combination of these.

1.1.8. In practice, the list of equipment whose repair can be based only on the principles and strategies of regulated repair is extremely narrow. In fact, the repair of most of the equipment is inevitably based on a combination (in various proportions) of scheduled repairs and technical condition repairs. In this case, the "frame" of the structure of the repair cycle is determined by a set of equipment elements, the repair of which is based on the strategies of regulated repair or repair by operating time. The resulting "rigid" basis of the structure of the repair cycle is superimposed (in the "non-rigid" version) the timing of the repair of elements maintained according to their technical condition.

1.1.9. The most promising method of repairing equipment for enterprises of any form of ownership is the aggregate nodal method, in which faulty replaceable elements (units, assemblies and parts) are replaced with new or repaired ones taken from the circulating fund.

1.1.10. Timely replacement of faulty units, assemblies and parts - the implementation of a planned preventive repair system - is most successfully solved when introducing technical diagnostics of equipment in the process of its maintenance and repair.

1.1.11. Equipment repair can be carried out by the enterprises operating the equipment, by third-party

specialized repair companies, as well as specialized subdivisions of manufacturers. The specific weight of each of the listed organizational forms of repair for a particular enterprise depends on many factors: the development of its own repair base, its equipment, remoteness from enterprises - equipment manufacturers and specialized repair organizations, as well as the financial capabilities of the enterprise.

1.1.12. Maintenance and repair of power equipment (including power engineering boilers, utilization boilers, steam and gas turbine units, desiccant devices

and communications, etc.), located in the production shops, are carried out by the services of the chief mechanic and the chief power engineer.

1.1.13. Maintenance and repair of equipment in the energy sector of the enterprise and energy carriers (stationary and mobile power plants, distribution and transformer substations, in-plant air and cable networks, in-plant networks of natural gas used as fuel, steam and boiler plants, collection devices and condensate return, general water intake facilities and facilities for preliminary water treatment for powering power plants and feeding water circulation systems, networks and installations for supplying enterprises with heat, steam, water, compressed air, communication and signaling equipment, etc.) is carried out by the main energy.

1.1.14. The boundary between the division of repair objects between the services of the chief mechanic and the chief power engineer is established according to the following criteria. If an energy medium is supplied or removed to the equipment and communications of an object (process shop, site, etc.) assigned to the service of the chief mechanic, then the separation boundary is the first shut-off element (shut-off valves, shut-off device, etc.) .) before entering the workshop. The service of the chief mechanic is responsible for the tightness of the connection and the serviceability of the shut-off element.

1.1.15. The standards for the frequency, duration and labor intensity of bone repair given in this PPR EO System are calculated as weighted averages based on the following considerations:

medium (in terms of severity) operating conditions of the equipment; the equipment is repaired under normal conditions

temperature regime; the service life of the equipment has not exceeded the standard.

If the conditions differ from those specified above, the standards are adjusted in accordance with the coefficients given in the relevant sections of this PPR EO System.

1.1.16. The power equipment included in the PPR EO System is conditionally divided into the following two groups:

electrical equipment (electrical machines, electrical networks and relay protection devices, electrical devices

low and high voltage, power transformers, batteries, communication and signaling equipment), standards and norms for which are given in the second part of this Handbook;

heat engineering equipment (boilers and auxiliary boiler elements, waste heat boilers, steam turbines, pipelines and pipeline fittings, compressors and pumps, fans, smoke pumps, blowers, ventilation and exhaust systems, air heaters, air conditioners, water intake and water treatment equipment), standards and the norms for which are given in the third part of the Handbook.

1.1.17. For the effective implementation of the SPR EO System, the following conditions must be met:

the energy service of the enterprise must be staffed with qualified personnel in accordance with the staffing table, have a repair base with the necessary technological equipment and high-performance tools;

repair, duty and operational personnel must know and follow the rules for the technical operation of equipment, industrial and fire safety rules;

equipment shutdown for scheduled repairs is carried out according to approved annual and monthly schedules in accordance with

from standard frequency and taking into account the maximum use of stops for maintenance and diagnostics of equipment;

repairs are carried out with high quality, in the planned volume, with maximum mechanization of heavy labor-intensive work;

during repair, the aggregate nodal method and the method of repairing large objects according to the network schedule are widely used;

the organization of supplies of units, assemblies and parts from manufacturers is ensured. Only parts of uncomplicated configuration are manufactured in our own workshops;

systematically, according to a special plan, work is carried out to increase the durability, reduce the indicators of emergency failure of power equipment.

1.1.18. This PPR EO System is a recommendatory material of direct action, but it can also serve as a guide when enterprises develop their own "Regulations for the planned preventive maintenance of power equipment" in accordance with the requirement of the Federal Service for Technological Supervision (hereinafter - Federal Supervision) PB 05 356.00, p. 242.

1.2. Tasks and functions of the chief power engineer department

1.2.1. As the experience of enterprises operating in new economic conditions, especially in the last 5–7 years, shows, the centralized command management system that existed in the recent past turned out to be unsuitable for solving the main task: making a profit.

"Austria-Hungary: the fate of an empire" is a fascinating story about an extremely colorful and surprisingly interesting country, a kind of European Atlantis, known to the Russian reader much less than it deserves. The Habsburg state has long been absent on the maps, the First World War destroyed this, perhaps the most comfortable empire in history, but the experience of coexistence accumulated by its peoples is still relevant for Central Europe. Travels across a dozen independent states, whose territories were once parts of Austria-Hungary, confirm that bygone times are still echoing today.

The first edition of the book was published in 2010 under the title "Roots and Crown. Essays on Austria-Hungary: The Fate of an Empire", and since then it has become a real bibliographic rarity.

Never before has such a deep analysis of historical processes been accompanied by such a fascinating story about the everyday life and holidays of the Danube monarchy, such vivid portraits of the Habsburg dynasty and their subjects, such vivid essays about large and small Habsburg cities.

Andrey Shary, Yaroslav Shimov
Austria-Hungary. Empire destiny

Unknown empire

In 1846, the Bavarian sculptor Ludwig Schwanthaler, commissioned by the Vienna authorities, installed the Austria fountain on Freyung Square, Austriabrunnen... Allegorical figures above the bowl of the fountain and under the statue of victorious Austria with a spear and shield in hand represent the main rivers of the Habsburg empire: Elbe, Po, Danube and Vistula. Of these four beautiful bronze maidens, loyalty to Austria to today preserved only one - the Danube. Elba (Laba) "fled" to the Czech Republic and Germany, Po returned to the Italians, and the Vistula went to the Poles. Together with the waters of these rivers, the fountain quietly sighs, and the Habsburg glory has flowed into history.

Austriabrunnen flaunts on Viennese square, recalling the former greatness of the country, which a century ago included in its borders the lands on which thirteen independent states are now located in whole or in part. To the contemporaries of the Habsburg Empire, these borders must have seemed a natural whole, even on geographical maps logically delineated by brackets of mountain ranges and a soft semicircle of the sea coast. The country was spacious and harmonious in its relief and ethnic diversity: the Alps - in the German-Italian west, the Sudetes - in the Czech-German north, the Carpathians - in the Hungarian-Romanian-Ukrainian east, the Dinaric ridge - in the South Slavic south. The thousand-kilometer coast of the Adriatic with the largest port in the Mediterranean, Trieste; the endless channel of the Danube, which pierced Europe like a repeatedly bent spoke; the fertile plains of Hungary and Vojvodina, the dense forests of Galicia, Transylvania, Tyrol - all this was united under their scepter by the Habsburgs, an ancient dynasty of dukes, emperors and kings. Their empire rose unshakably in the middle of Europe.

In the middle of everything.

Decade after decade, century after century, this monarchy grew with new peoples and new territories, it was built slowly, like a temple of God, stone upon stone. The Habsburgs patiently and painstakingly, with cunning and tenacity, talent and intelligence, occasionally cruelty, much more often through compromises, over six hundred years of domination, equipped a multinational state. Perhaps, in a certain sense, it can be called the forerunner of the European Union, if only because history has not given a better prototype of supranational unity in Europe. At the beginning of the twentieth century, the second in area and the third in population of the European power, Austria-Hungary was one of the few countries that determined the main content of socio-political, social and cultural processes in the Old World.

It was a complex state, the structure of which was paradoxically based on its contradictions. An empire in which the monarchs were not averse to ruling authoritarianly, but on second thought gave way to liberal trends. "Prison of Nations" (according to the conviction of several generations of nationalists), in which the idea of \u200b\u200bethnic tolerance almost always turned out to be stronger than chauvinistic sentiments. Quite powerful - even at sunset - a power that more willingly expanded its limits by dynastic marriages and diplomatic combinations than by conquests and wars. A country of age-old, even decrepit traditions, invariably open to modernity in painting, architecture, music ...

Let's look for parallels. The Habsburg state developed as a continental empire, unlike Britain or Spain, but, like Russia, did not have serious overseas possessions. A dozen of the peoples subject to the Hapsburgs lived in a compact country, and even before the advent of the telegraph, a dispatch from the farthest outskirts made it to the capital of the empire in just a week. At the same time (one more similarity with Russia) the Danube monarchy in some ways remained mysterious not only for its Western European neighbors, but sometimes, it seems, for itself. It is not for nothing that the Habsburg Chancellor Clemens Metternich is credited with the phrase: "Asia begins on Landstrasse." This Viennese street led east, and east of Vienna, for refined Europeans, it was as if civilization did not exist. Different realities coexisted in the Habsburg Empire. Vienna was rightfully considered one of the brilliant capitals, rivaling luxury with Paris and London, the Austrian court enjoyed the fame of the most ceremonial in Europe, but the eastern outskirts of the Danube monarchy - Transylvania, Bukovina, Galicia - frightened the savagery of the Austrians themselves, seemed like mystical reserves in which they could dwell not only humans, but also vampires.

The Habsburgs rightly considered themselves a special merit in the collective struggle against the Ottoman Empire, in the arduous and bloody resistance of the cross to the crescent. Their armies have held back the Turkish offensive for centuries. The territorial expansion of the Ottomans in Europe was stopped precisely near Vienna: the city twice, in 1529 and in 1683, withstood the siege of a huge Ottoman army. The first failure, the chronicles testify, only alarmed Sultan Suleiman the Magnificent. The second defeat of the Turks turned out to be more sensitive: the battle near Vienna, in which the armies of many Christian countries united on the side of the Habsburgs, put the final limit on the Ottoman penetration into the interior of the continent. But the Central European empire after that for a long time served as a security belt and a barrage of the Western world.

Handbook as a handbook, a lot of generalizations, authors, covering for review large volume, missed the nuances. So, for example, references to the fact that maintenance or repair of lightning protection systems or protection against static electricity is carried out jointly by the mechanical and energy service, give only a reason for further interpretation of this problem in an arbitrary form. Meanwhile, none of the power engineers have the responsibilities of maintaining pipelines for the transportation of technological raw materials, oils, etc., where a static charge can occur. In my opinion, for the protection from static electricity of equipment whose duties include the repair of this equipment. Also, the issue of grounding cabinets with instrumentation and equipment is not objectively reflected, the personnel of which has at least 3 tolerance groups and is electrical, the grounding of the equipment under their supervision must be carried out by employees of this service, the grounding network in the premises, and the grounding devices - run by the electrical service. There is also a lack of agreement with lightning protection systems. Often metal structures (overpasses, chimneys, silos, towers, etc.) act as lightning rods when delimiting duties, according to the order on assigning persons in charge, it should be taken into account that both the installation and operation of lightning rods should be responsible for the mechanical services (or construction, if this is the roof of a building), behind the switches - electrical service, while at the same time racking up at the junction of the circuit with the down conductor. There is also a question about the repair of explosion-proof electrical equipment, this is a licensed type of activity, especially in terms of restoring protection gaps, here it is more appropriate to refer to the original source: "Explosion-proof electrical equipment. Repair" RD 16.407-89. The PPR system is shown in more detail in regulatory documents, which today should be subject to revisions, tk. new types of equipment require different standards, references to old ones are often difficult to prove, if necessary, in regulatory bodies and services that defend the economic interests of enterprises. But as a reference, the book is convenient to use.

Evaluation 3 out of 5 stars from Alexander 01/20/2014 14:22

Everyone forgot about the repairs. It's good if the owner buys new equipment. And if they work on the old, then from the wheels. Have forgotten what an irreducible stock of boiler equipment is. Boiler water samples are not taken weekly. As there is no refrigerator for cooling samples in stock. I find out during the checks. And we are talking about the safe operation of steam boilers. Education is at zero from school to university. The service personnel, including the chief power engineer of the enterprise, asks: "where is it written?" Now I will say: “Read this book, it is written here in an accessible language, as we were taught earlier, in the 80s of the last century. Thank you for the book.

Evaluation 5 out of 5 stars from heat power engineers 03/09/2013 02:37

it all depends on the amount of work

Vitaly 03.03.2011 19:07

 

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