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

Power equipment and power networks of all kinds 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 common in industry (electrical and thermal) and energy carriers (water, air and gases). In the process of production, there is a process of consumption (spending) of fixed assets, which is expressed in the wear and tear of equipment and networks. This, in turn, leads to the loss of passport characteristics of equipment and networks, power, productivity, pressure, accuracy, to failure or to an accident, which in a number of cases causes not only the shutdown of a particular piece of technological equipment, but also downtime of sections, workshops, buildings, and sometimes enterprises as a whole. Distinguish between physical and moral depreciation of fixed assets.

Obsolescence is to reduce the efficiency of 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 before the period of complete physical deterioration is determined by special calculations. The profitability of obsolete equipment can be improved through modernization (technical improvement), the feasibility of which must also be calculated.

Normal physical deterioration of equipment(chemical, thermal, fatigue, corrosion) is caused by the active operation of the equipment, physical and chemical processes associated with production. Wear and tear 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 equipment - a decrease in productivity (power), an increase in fuel consumption and operating materials. At a certain level of physical deterioration of the equipment, its further operation becomes economically inexpedient. There is a danger of a sudden (emergency) exit of the equipment from the working state with the ensuing losses from violations of the production regime and the costs of subsequent repairs. Deterioration in performance as a result of physical wear and tear of power equipment can be overcome by repair.

The physical wear of the equipment occurs unevenly: individual parts of the machines serve for different times, and in order to ensure the operability of the machine during a certain service life, it is necessary to periodically replace individual components and parts.

All replaceable and repairable parts of the machine can be summarized in groups that differ in terms of the use of parts before they are replaced or repaired. In this case, the part can be assigned to the repair group with a slightly shorter service life than the possible period of its use. Such a grouping makes it possible to build calendar-volumetric schedules for equipment repair, characterizing the necessary costs for repairs 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 technological development.

should be distinguished the following concepts: repair, modernization, reconstruction.

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

Modernization operating equipment - a change in the design of existing equipment in order to bring it in line with new requirements, which improves its performance, increases reliability, reduces energy, material costs and labor resources during operation, technical inspection and repair, reduces obsolescence, as well as the use in the operation of other types of (more accessible) 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 that affect 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 and organization planning system Maintenance.

2. Ensuring the high quality of the repaired equipment and the quality of the performed repair work.

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

Maintenance maintenance 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

A set 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.

Maintenance includes the elimination of defects in the operation of the equipment identified on the day the unit was shut down for repair, the replacement of wear parts, the identification of parts that require replacement or repair during medium or major repairs: the implementation of preventive maintenance to ensure reliable operation of the equipment between the next medium or major repairs.

At average repair partial disassembly of equipment, replacement of worn parts, inspection and cleaning of parts and assemblies, testing and identification of work that needs to be carried out during the next overhaul.

Overhaul includes a complete disassembly of the equipment, inspection of all parts, replacement of individual parts and assemblies, elimination of all defects, testing and testing. Its goal is not only to ensure the operability of the equipment, but also to completely restore the technical and economic parameters of the unit. The cost of capital and medium repairs in the electric power industry account for 70% of all repair costs.

A major overhaul differs from the current one by a longer overhaul period between two major overhauls than between current repairs, a longer duration of repairs, a large amount of work, a lower frequency of carrying out, and a greater cost.

Restorative 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 interval- the time interval or operating time between a given type of maintenance and a subsequent one of the same type or another of greater complexity.

Depending on the nature and volume of work performed, shift maintenance and periodic maintenance are provided.

The main method of maintenance is inspection, during which the technical condition of the most critical details and nodes and the scope of the forthcoming repair is specified.

The time between two successive repairs is called overhaul period. overhaul period - is determined from the conditions for ensuring 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 overhauls is repair cycle time.

3. Repair organization

Power repair production requires a high organization of the production process, taking into account the coordination of the interaction of sometimes dozens of contractors, and the number of workers simultaneously employed during repairs 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 power balances in the energy system (drawn up in such a way as to ensure that the annual schedule of monthly electrical load peaks is covered) and financial capabilities. For this reason, major repairs are carried out, as a rule, in the spring and 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 repairs. To comply with these conditions, it is recommended:

At CHPPs, time the roment to summer time, when the heating load is reduced to the maximum;

Repair of block equipment should be carried out simultaneously in order to minimize the reduction in power put 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 HPPs and save fuel at TPPs;

Repair of equipment at each station should be carried out evenly throughout the year to ensure a uniform use 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;

Inability to ensure the repair of several large units with the necessary number of personnel due to the extension of scheduled repairs or an accident at some power facility;

Identification of unforeseen major defects during the opening and fault finding of equipment (especially typical for obsolete equipment and large units that have exhausted their service life);

Accidents on any unit;

Delays in the supply of spare parts and materials.

Moreover, if a power company urgently needs a power unit to cover the load or operate the 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.

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

Alexander Ignatievich Yashchura. 1

Introduction. 1

Part I. 4

1.3. Structure of the chief power engineer department. 11

2. PRODUCTION OPERATION OF THE EQUIPMENT.. 13

2.1. Acceptance of equipment. 13

2.2. Installation of equipment. 14

2.3. Putting equipment into operation... 16

2.4. Organization of equipment operation. 16

2.5. Equipment service life. 20

2.6. Equipment depreciation. 20

2.7. Equipment storage. 21

2.8. Disposal of equipment. 21

3. EQUIPMENT MAINTENANCE.. 21

3.2. Organization of maintenance work... 21

3.3. Technical diagnostics of equipment. 21

3.4. Funding for maintenance work... 21

4. EQUIPMENT REPAIR.. 21

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

4.2. Repair standards.. 21

4.4. Preparation of production of repair work. 21

4.5. Organization and carrying out repairs. 21

4.6. Stop repair of equipment. 21

4.7. Equipment repair financing. 21

4.8. delimitation functional duties between the company's services during equipment repair. 21

5. FORMS OF REPAIR DOCUMENTATION.. 21

6. HEALTH AND SAFETY.. 21

6.1 Labor protection. 21

6.2. Industrial safety during equipment operation. 21

6.3 Industrial safety during installation and repair of equipment. 21

6.4. State supervision of equipment operation. 21

6.5. Investigation and recording of accidents and incidents. 21

Part II. 21

TYPICAL 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 repairs. 21

7.3. Typical nomenclature of repair work during a major overhaul. 21

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

7.5. Standards for the frequency, duration and complexity of repairs. 21

7.6. Consumption rates of materials for the current and overhaul . 21

8. ELECTRIC NETWORKS.. 21

8.1. Maintenance. 21

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

8.3. Typical nomenclature of repair work during a major overhaul. 21

8.4. Standards for the frequency, duration and complexity of repairs. 21

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

9.1. Maintenance. 21

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

9.3. Typical nomenclature of repair work during a major overhaul. 21

9.4. Standards for the frequency, duration and complexity of repairs. 21

9.5. Consumption rates of materials for maintenance and overhaul. 21

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

10.1. Maintenance. 21

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

10.3. Typical nomenclature of repair work during a major overhaul. 21

10.4. Standards for the frequency, duration and complexity of repairs. 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 repairs. 21

11.3. Typical nomenclature of repair work during a major overhaul. 21

11.4. Standards for the frequency, duration and complexity of repairs. 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 repairs. 21

12.3. Typical nomenclature of repair work during a major overhaul. 21

12.4. Standards for the frequency, duration and complexity of repairs. 21

13. COMMUNICATIONS AND SIGNALS.. 21

13.1. Maintenance. 21

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

13.3. Typical nomenclature of repair work during a major overhaul. 21

13.4. Standards for the frequency, duration and complexity of repairs. 21

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

14. DEVICES OF RELAY PROTECTION AND ELECTRIC AUTOMATICS.. 21

14.1. Maintenance. 21

14.2. Maintenance Interval Guidelines. 21

15. ELECTRIC WELDING EQUIPMENT. 21

15.1. Maintenance. 21

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

15.3. Typical nomenclature of repair work during a major overhaul. 21

15.4. Standards for the frequency, duration and complexity of repairs. 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

TYPICAL NOMENCLATURE OF REPAIR WORKS, REPAIR STANDARDS, RATES OF CONSUMPTION OF MATERIALS AND SPARE PARTS FOR REPAIR OF HEAT ENGINEERING EQUIPMENT .. 21

17. BOILERS, AUXILIARY BOILER AND STEAM POWER EQUIPMENT. 21

17.1. Maintenance. 21

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

17.3. Typical nomenclature of repair work during a major overhaul. 21

17.4. Standards for the frequency, duration and complexity of repairs. 21

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

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

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

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

financing of repair and its material support;

regulation of the number of repair and operational personnel;

application of various repair strategies;

repair planning taking into account beneficial use and toughened service life of equipment and other issues.

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

The materials of the handbook, which are advisory in nature, will help enterprises develop their own Provisions for the outage of equipment, serve as the necessary methodological basis for the implementation of new rights and responsibilities, the regulatory framework for ensuring effective planning of repair work, the need for material and financial resources, as well as a tool for developing the right organizational decisions to improve the repair service.

The guide consists of four parts:

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

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

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

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

For the correct perception of the text and the 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 Guide should be sent to 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 THE SYSTEM OF SCHEDULED PREVENTIVE REPAIRS

1.1. The general concept of the system of preventive maintenance of power equipment

1.1.1. The system of preventive maintenance of power equipment (hereinafter referred to as the PPR EO System) is a set of methodological recommendations, norms and standards designed to ensure the effective organization, planning and conduct of maintenance (TO) 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 that use 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 repairs of equipment with a given frequency, the timing of which and the logistics 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 performance in the intervals between repairs.

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

opportunities and advantages of the aggregate repair method;

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

contemporary computer science And computer technology collection, accumulation and processing of information about the state of equipment, planning of repair and preventive actions and their logistics.

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

1.1.5. All equipment operated at enterprises is divided into main and non-main.

The main equipment is the equipment, with the direct participation of which the main energy and technological processes of obtaining the product (final or intermediate) are carried out, and the failure of which leads to the 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.

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 classified as both main and non-main.

1.1.7. The PPR EO system provides that the need for equipment in repair and preventive actions is satisfied by a combination of various kinds Maintenance and scheduled repairs of equipment, 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 energy technological processes, repair actions are implemented in the form of regulated repair, repair after running time, repair after technical condition, or as a combination of them.

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 repairs according to technical condition. In this case, the "skeleton" 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. On the obtained "hard" basis of the structure of the repair cycle are superimposed (in the "non-rigid" version) the timing of the repair of elements serviced according to their technical condition.

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

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

1.1.11. Equipment repair can be carried out on your own enterprises operating the equipment, third-party specialized repair enterprises, as well as specialized divisions of manufacturing plants. Specific gravity each of the listed organizational forms 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 financial opportunities enterprises.

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

1.1.13. Maintenance and repair of equipment for the energy economy of the enterprise and communications of energy carriers (stationary and mobile power plants, distribution and transformer substations, intra-factory overhead and cable networks, intra-factory networks natural gas used as fuel, steam and boiler plants, condensate collection and return devices, plant-wide water intake facilities and pre-treatment facilities for supply water power plants and make-up of water circulation systems, networks and installations for supplying enterprises with heat, steam, water, compressed air, communications and signaling, 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 feature. If an energy medium is supplied or removed to the equipment and communications of an object (process shop, section, etc.) assigned to the chief mechanic service, then the separation boundary is the first shut-off element (shut-off valves, disconnecting device, etc.) in front of entry into the shop. The service of the chief mechanic is responsible for the tightness of connection and serviceability of the locking body.

1.1.15. The standards for the frequency, duration and complexity of repairs given in this PPR EA System are calculated as weighted averages based on the following considerations:

medium (by severity) operating conditions of the equipment;

repair of equipment is carried out in conditions with normal temperature conditions;

the service life of the equipment did not exceed the standard.

If the conditions differ from those specified above, the adjustment of the standards is carried out 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, low and high voltage electrical apparatus, power transformers, batteries, communication and signaling equipment), the standards and norms for which are given in the second part of this Directory;

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, heaters, air conditioners, water intake and water treatment equipment), the standards and norms for which are given in the third part of the Directory.

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

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

repair, duty and operational personnel must know and comply with the rules technical operation equipment, industrial and fire safety rules;

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

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

the organization of deliveries of aggregates, assemblies and parts from manufacturers is ensured. Only parts of a simple configuration are made in our own workshops;

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

1.1.18. This PPR EO System is a direct action recommendatory material, but can also serve as a guide for enterprises to develop their own "Regulations for 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 in the 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.

1.2.2. There was a need 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 - the chief engineer of the enterprise. At some enterprises, the centralization of technical operation was even more closely connected with the efficient use of fixed assets, subordinating it to the deputy head of the enterprise for equipment.

1.2.3. Enterprises need:

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

2.1.7. Personnel unloading arriving equipment must be prepared to work to keep the equipment intact and prevent breakdowns or damage that could adversely affect the operation of the equipment during operation.

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

2.1.9. An inventory number can be assigned to equipment both by object and for a group of equipment included in the inventory object.

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

object with all fixtures and fittings;

a separately structurally isolated object designed to perform certain independent functions;

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

2.1.11. A complex of structurally articulated items is one or more items of the same or different purposes that have common devices and accessories, general management mounted on the same foundation, as a result of which each item 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 object, one should be guided by All-Russian classifier fixed assets (OKOF), approved by the Decree of the State Committee of the Russian Federation for Standardization, Metrology and Certification dated 01.01.01 No. 359. In this document the composition of the objects of classification 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 paragraph 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 depreciation 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 the manufacture 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, the work must be carried out 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 required to apply 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 this instruction 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. YASCHURA

TECHNICAL

MAINTENANCE AND REPAIR OF POWER EQUIPMENT

Directory

Moscow "Publishing house NTs ENAS" 2006

Yashura A.I.

Y99 Maintenance and repair system for power equipment. Directory. - M.: Publishing House in NC ENAS, 2006. - 504 p. ill.

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, updated 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 for organizing repairs according to the technical condition of equipment based on the use of modern methods and technical diagnostic tools.

The reference book is intended for engineering and technical workers engaged in production operation, maintenance and repair of power equipment at enterprises of various industries. Can be used to train students of technical universities and technical schools.

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

INTRODUCTION

In recent years, fundamental changes have taken place in the organization of equipment repair at the industrial enterprises of the country. Simultaneously with the reduction of most industrial ministries, the sectoral departments of the chief mechanic and 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 centralized repair of specialized equipment. Almost simultaneously, the development, revision and publication of Regulations (Systems) for scheduled preventive maintenance of equipment, which provided enterprises with a methodological and regulatory framework for planning and organizing equipment repairs, ceased in all industries. The system of centralized supply of enterprises with equipment, spare parts, repair equipment and repair materials collapsed. The revision of depreciation rates (equipment service life), repair standards, material consumption rates, repair procedures and financing has ceased.

The economic crisis has led to a complete or partial shutdown of many industries. The load on operating enterprises has 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 depreciation period and needs to be replaced or overhauled.

The vast 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 "unbundling" in the course of privatization. Most were created from scratch to fill small niches in an increasingly demanding market for industrial products, goods and services. As a rule, newly formed enterprises do not have not only any serious material repair base and specialists 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. repair of equipment at the enterprise. As a preventive measure, the requirement of the Gosgortekhnadzor of Russia PB 05 356.00 appeared on the need to have at each enterprise its own Regulation on the planned preventive maintenance of its equipment. This requirement is a big headache for many enterprises, especially newly created ones.

After the issuance of PB 05 356.00, government agencies received about a thousand proposals for the need to issue a single document regulating the operation, maintenance and repair of machinery and equipment. Work begun in 2003 on the creation of the Handbook “Unified Regulations on Scheduled Preventive Maintenance of Equipment industrial enterprises Russia” (Decree 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" (M.: Publishing House "Energoservis", 1999).

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

1. Given optimal structure energy service of the enterprise (organization) for market conditions of management. The division of responsibility and powers of the departments of the service has been clarified, a complete list of incoming and outgoing information has been given, the terms of work performance and interaction with other services have been considered. Section 1 is devoted to these issues.

2. The section "Industrial operation of the equipment" has been revised and supplemented. The subsection "Reception of equipment" has been re-introduced, which includes the following issues:

identification of external defects of equipment upon its acceptance; requirements for operational and repair documentation; installation and assembly requirements; a list of defects that can be detected at different stages

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

3. A new grouping and new norms for 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). A technique for determining the serviceability of equipment and predicting the residual resource using technical diagnostic tools is given.

5. Labor input standards for equipment repairs have been adjusted by including labor costs for machine work.

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

7. Designed new order financing equipment repairs by creating a reserve and using a future expense account.

8. Introduced new section"Occupational Health and Industrial Safety".

9. The terms and definitions have been 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 regulatory legal acts have appeared that consider 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";

Decree of the Government No. 1 dated 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”;

Decree of the Ministry of Industry and Science No. 05 900/14 108 dated 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.

financing of repair and its material support; regulation of the number of repair and operational personnel; application of various repair strategies; repair planning taking into account useful use and already

accurate service life of equipment and other issues.

Under the current conditions, the release of this Handbook seems to be extremely timely.

The materials of the handbook, which are advisory in nature, will help enterprises develop their own Provisions for the maintenance of equipment, serve as the necessary methodological basis for the implementation of new rights and responsibilities, the regulatory framework for ensuring effective planning of repair work, the need for material and financial resources, as well as a tool for development of correct organizational decisions to improve the repair service.

The guide consists of four parts:

P a rt I. Operation, maintenance and repair of power equipment.

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

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

H a ct IV. Applications containing the necessary methodological

And reference materials.

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.

P a rt I

OPERATION, MAINTENANCE AND REPAIR OF POWER EQUIPMENT

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

1.1. The general concept of the system of 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 methodological recommendations, norms and standards designed to ensure the effective organization, planning and conduct of maintenance (MS) and repair of power equipment. The recommendations given in this PPR EO System can be used at enterprises of any type of activity and forms of ownership that use 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 of which and the 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 performance in the intervals between repairs.

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

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

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

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

gy of collecting, accumulating and processing information about the state of the equipment, planning the repair and preventive impacts and their logistics.

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

1.1.5. All equipment operated at enterprises is divided into main and non-main.

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 basic as well as non-basic.

1.1.7. The PPR EO system provides that the need for equipment in repair and preventive actions is satisfied by a combination of various types of maintenance and scheduled repairs of equipment that differ 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 actions are implemented in the form of regulated repair, repair by operating time, repair by technical condition, or in the form of a combination of them.

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 scheduled repairs and repairs according to technical condition. In this case, the “skeleton” of the repair cycle structure 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. On the obtained "rigid" basis of the structure of the repair cycle are superimposed (in the "non-rigid" version) the timing of the repair of elements serviced 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 (aggregates, components and parts) are replaced with new or repaired ones taken from the circulating fund.

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

1.1.11. Repair of equipment can be carried out by the enterprises operating the equipment on their own, by third parties

specialized repair enterprises, as well as specialized divisions of manufacturers. The share 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 technology boilers, waste heat boilers, steam and gas turbine units, dehumidifiers

And communications, etc.), located in the production shops, carry out the services of the chief mechanic and chief power engineer.

1.1.13. Maintenance and repair of energy facilities equipment of the enterprise and communications of 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, devices for collecting and condensate return, general plant water intake facilities and facilities for preliminary water treatment for supplying power plants and replenishing water circulation systems, networks and installations for supplying enterprises with heat, steam, water, compressed air, communications and signaling equipment, etc.) is carried out by the service of the main energy.

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 feature. If an energy medium is supplied or removed to the equipment and communications of an object (technological workshop, site, etc.) assigned to the service of the chief mechanic, then the separation boundary is the first shut-off device (shut-off valves, disconnecting device, etc. .) before entering the workshop. The service of the chief mechanic is responsible for the tightness of the connection and serviceability of the locking device.

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

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

operating mode; the service life of the equipment did not exceed the standard.

If the conditions differ from those specified above, the adjustment of the standards is carried out 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 facilities), the standards and norms for which are given in the second part of this Handbook;

heat engineering equipment (boilers and boiler auxiliary elements, waste heat boilers, steam turbines, pipelines and pipeline fittings, compressors and pumps, fans, smoke exhausters, superchargers, 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 EA PPR 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 comply with the rules for the technical operation of equipment, industrial and fire safety rules;

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

from regulatory 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;

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

the organization of deliveries of aggregates, components and parts from manufacturers is provided. Only parts of a simple configuration are made in our own workshops;

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

1.1.18. This PPR EO System is a non-binding material of direct action, but can also serve as an aid in the development by enterprises of their own "Regulations for scheduled preventive maintenance of power equipment" in accordance with the requirement of the Federal Service for Technological Supervision (hereinafter - Federal Supervision) PB 05 356.00, 242.

1.2. Tasks and functions of the chief power engineer department

"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 powers have not been on the maps for a long time, 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. Traveling through a dozen independent states, the territories of which were once parts of Austria-Hungary, confirm that the bygone times are 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 the 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 an exciting story about the everyday life and holidays of the Danube monarchy, such vivid portraits of the Habsburg dynasty and their subjects, such lively essays on large and small Habsburg cities.

Andrey Shary, Yaroslav Shimov
Austria-Hungary. The fate of the empire

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 their hands personify the main rivers of the Habsburg empire: the Elbe, Po, Danube and Vistula. Of these four beautiful bronze maidens, the loyalty of Austria to today retained 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. Along with the waters of these rivers, the fountain quietly sighs, the Habsburg glory has also flowed into history.

Austriabrunnen flaunts on the Viennese square, recalling the former greatness of the country, a century ago included in its borders the land on which now thirteen independent states are wholly or partially located. 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 Sudetenland - in the Czech-German north, the Carpathians - in the Hungarian-Romanian-Ukrainian east, the Dinaric Range - in the South Slavic south. A thousand-kilometer coast of the Adriatic with the largest port of Trieste in the entire Mediterranean; the endless course of the Danube, which pierced Europe like a repeatedly curved 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, built slowly, like a temple of God, stone upon stone. The Habsburgs patiently and painstakingly, by cunning and perseverance, by talent and intelligence, occasionally by cruelty, more often through compromises, over the six hundred years of their rule, equipped a multinational state. Perhaps, in a certain sense, he can be called the forerunner European Union if only because history has not given a better prototype of supranational unity in Europe. At the beginning of the 20th century, the second largest European power and the third largest in terms of population, 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, paradoxically, was based on its contradictions. An empire in which monarchs were not averse to ruling authoritarianly, but on mature reflection were inferior to liberal trends. "Prison of peoples" (according to several generations of nationalists), in which the idea of ethnic tolerance almost always turned out to be stronger than chauvinistic sentiments. A rather powerful - even at sunset - power, which was more willing to expand its borders 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 power developed as a continental empire, unlike Britain or Spain, but, like Russia, did not have serious overseas possessions. A dozen peoples subject to the Habsburgs lived in a compact country, and even before the advent of the telegraph era, a dispatch from the farthest outskirts kept pace with the capital of the empire in just a week. At the same time (another similarity with Russia), the Danube monarchy remained somewhat mysterious not only for its Western European neighbors, but sometimes, it seems, for itself. The Habsburg Chancellor Clemens Metternich is not in vain credited with the phrase: "Asia begins on the Landstrasse." This Viennese street led to the east, and to the east of Vienna for refined Europeans then it was as if civilization did not exist. Different realities coexisted in the Habsburg Empire. Vienna was rightfully considered one of the brilliant capitals that competed in luxury with Paris and London, the Austrian court enjoyed the fame of the most ceremonious in Europe, but the eastern outskirts of the Danubian monarchy - Transylvania, Bukovina, Galicia - frightened the Austrians themselves with savagery, seemed to be mystical reserves in which they could live Not only humans, but also vampires.

The Habsburgs rightly considered themselves a special merit in the collective struggle against the Ottoman Empire, in the difficult and bloody resistance of the cross to the crescent. Their armies held back the offensive impulses of the Turks 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 joined on the side of the Habsburgs, put the final limit to the Ottoman penetration into the depths of the continent. But the Central European empire after that for a long time served as a security belt and a defensive rampart for the Western world.

Handbook, like a reference book, a lot of generalizations, authors, covering for review large volume missed the nuances. So, for example, references to the fact that the maintenance or repair of lightning protection systems or protection against static electricity is carried out jointly by the mechanical and energy services, give only a reason for further interpretation of this problem in an arbitrary form. Meanwhile, none of the energy companies is responsible for maintaining pipelines for the transportation of technological raw materials, oils, etc., where a static charge can occur. In my opinion for the protection against static electricity of equipment whose responsibility is to repair this equipment. Also, the issue of grounding cabinets with instrumentation and A equipment is not objectively reflected, the personnel of which has at least 3 access groups and is electrical, the grounding of equipment under their jurisdiction should be carried out by employees of this service, the grounding network for the premises, and grounding devices - run by the electrical service. There is also some disagreement with lightning protection systems. Often, metal structures act as lightning rods (flyovers, chimneys, silos, towers, etc.) when separating duties, according to the order on assigning responsible persons, it would be necessary to take into account that mechanical services should be responsible for both installation and operation of lightning rods (or construction, if it is the roof of a building), for grounding - electrical service, while decoupling 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 would be 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 normative documents, which today should be subject to revision, because 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.

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

Everyone forgot about renovations. It's good if the owner buys new equipment. And if they work on the old one, then from the wheels. They forgot what an irreducible supply of boiler equipment is. Boiler water samples are not taken weekly. Since there is no refrigerator for cooling samples in stock. I find this out during checks. And we are talking about the safe operation of steam boilers. Education 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 before, in the 80s of the last century. Thank you for the book.

Grade 5 out of 5 stars from heat power engineer 09.03.2013 02:37

it all depends on the amount of work

Vitaly 03.03.2011 19:07

It might be useful to read:

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

Andrey Shary, Yaroslav Shimov Austria-Hungary. The fate of the empire

unknown empire

Andrey Shary, Yaroslav Shimov
Austria-Hungary. The fate of the empire