5. FORMS OF REPAIR DOCUMENTATION

5.1. The repair documentation of this Handbook is maximally unified with the documentation of the industry-specific "Systems for the maintenance and repair of power equipment". It is planned to maintain the following forms of repair documentation (forms 1-19):

a shift log of identified defects and work to eliminate them; repair log; list of defects; cost estimate;

certificate of delivery for major repairs;

an act for issuance from a major overhaul;

annual schedule of preventive maintenance;

monthly plan-schedule-report PPR or monthly repair report;

statement of annual costs for repairs;

an act to change the calendar period of repair;

shutdown schedule;

log of installation and removal of plugs;

act of acceptance of works after stop repair;

power equipment passport;

nomenclature of the main equipment of the workshop;

nomenclature of auxiliary equipment;

work permit for carrying out repair work;

production license earthworks in the territory.

5.2. Changes and additions to the pre-existing forms of repair documentation were made based on the results of approbation of the “Unified Regulation on Scheduled Preventive Repairs of Equipment industrial enterprises Russia” (Decree of the Ministry of Industry and Science of Russia dated May 29, 2003, 05.900 114–108).

5.3. The main document by which equipment is repaired is the annual repair schedule (form 7), on the basis of which the need for repair personnel, materials, spare parts, and purchased components is determined. It includes every unit of the subject overhaul equipment. The basis for drawing up the annual schedule is the standards for the frequency of equipment repairs given in this Handbook.

5.4. In order to link the terms of repair of power equipment with technological equipment the annual schedule is coordinated with the OGM of the enterprise. If it is necessary to use the services of the chief instrument operator, the planned repair time is agreed with the OCP. Terms of repair of the main equipment, limiting the performance production program coordinated with the planning department of the enterprise.

5.5. In columns 11-22 of the annual schedule (form 7), each of which corresponds to one month, symbol in the form of a fraction is indicated: in the numerator - the planned type of repair (K - capital, T - current), in the denominator - the duration of downtime in hours. Marks on the actual implementation of repairs in these columns are made by painting over the planned numbers with a colored pencil.

In columns 23 and 24, respectively, the annual downtime of equipment in repair and the annual fund of working hours are recorded.

5.6. The operational document for the repair of equipment is a monthly plan-schedule-report approved by the chief power engineer of the enterprise for each power shop and section (form 8). Instead of a monthly plan-schedule-report, it is allowed to maintain a monthly repair report (form 8A).

5.7. In this case, monthly planning of repairs is carried out according to the annual repair schedule.

5.8. In columns 7-37 (form 8), each of which corresponds to one day of the month, the symbol in the form of a fraction indicates: in the numerator - the type of repair (K - capital, T - current), in the denominator - its duration (current - in hours , capital - in days).

5.9. A mark on the actual implementation of repairs is made after they are completed by a specially appointed responsible person in the OGE, in production workshops - by the workshop foreman.

5.10. The record book for installing and removing plugs (form 14) is maintained by the deputy head of the power department (head of the department, installation, shift supervisor).

5.11. Explanations on the procedure for maintaining the rest of the repair documentation are given above in the relevant sections.

5.12. The forms of repair documentation given in this section are typical. Depending on the specifics of accounting for repair and preventive measures that are not regulated by this Handbook (repair inspections, inspections, tests, etc.), established in the repair services of enterprises, additional columns (paragraphs) may be included in the repair documentation forms.

Form 1

Form 2

Form 3

Form 4

Form 5

Form 6

Form 7

Form 8

Form 8A

Form 9

Form 10

Form 11

Form 12

Form 13

Form 14

Today, scheduled preventive maintenance is the simplest, but at the same time reliable method implementation of work. With regard to the resumption of the operation of the equipment, the list of basic conditions that ensure it includes the following:

The units have already worked out a specific number of hours and a new periodic work cycle is coming, which must necessarily precede the scheduled preventive maintenance.

The normal level of repair work is clearly indicated by determining the optimal periods between scheduled periodic maintenance.

Organization of approved works. Control over them is based on the standard scope of work. Their responsible implementation ensures the further full functioning of the existing units.

Scheduled preventive maintenance of electrical installation equipment is carried out to the extent necessary to effectively eliminate all existing defects. It is also carried out to ensure the natural course of operation of the equipment until the subsequent repair. Typically, a scheduled preventive maintenance schedule is drawn up taking into account established periods.

In the intervals between scheduled repair work, electrical equipment is also subject to pre-scheduled inspections and a number of checks, which, in fact, are preventive.

Repair work of electrical equipment

Alternation, frequency of scheduled repairs of units depend both on their purpose and on their design features, operating conditions, dimensions. The basis of preparation for this work is the clarification of defects, the selection of spare parts and spare parts, which will subsequently need to be replaced. An algorithm for performing this type of manipulation is specially developed, due to which uninterrupted operation of equipment (machines) during repair is possible. Proper preparation such a plan of action makes it possible to carry out a complete resumption of the functioning of all devices without disturbing the usual operating mode of production.

Organization of the process

Competent planned preventive maintenance provides for the following sequence:

1. Planning.

2. Preparation of units for repair.

3. Carrying out repair work.

4. Implementation of activities related to repair and scheduled maintenance.

The considered system of scheduled preventive maintenance of equipment has stages: overhaul, current. They can be considered in more detail.

Interrepair stage

The overhaul stage allows repairing the equipment without disturbing production process. It includes systematic cleaning, lubrication, inspection, adjustment of units. This also includes the elimination of minor faults, the replacement of parts with a short service life. In other words, this is prevention, which is not complete without daily examination and care. It must be properly organized in order to maximize the life of existing equipment.

A serious approach to this issue can significantly reduce the cost of future repairs and contributes to a better and more efficient implementation of the tasks set by the enterprise. The main work that is carried out during the overhaul stage is daily lubrication and cleaning of the units, compliance by all employees with the rules for using devices, monitoring the current state of the equipment, adjusting mechanisms and timely elimination of minor breakdowns.

current stage

This stage scheduled preventive maintenance of electrical equipment often does not involve disassembly of devices, but it includes the rapid elimination and elimination of all breakdowns that have occurred during the period of operation. In this case, only the units stop. During the current phase, tests and measurements are carried out, thanks to which equipment defects are detected even at an early stage, and this is very important.

The decision on whether electrical equipment is suitable is made by repair specialists. This is within their purview. They base the issued decision on a comparison of the available conclusions obtained during the tests during the implementation of the planned current repair work.

The elimination of defects in the functioning of the units can be carried out not only during scheduled repairs, but also outside of it. This usually happens after the resource of the equipment has completely exhausted itself.

Carrying out scheduled preventive maintenance: medium stage

Allows you to partially or completely restore the units that have already served their purpose. The stage includes disassembly of the necessary units for viewing them, elimination of identified defects, cleaning of mechanisms and replacement of some rapidly wearing spare parts and parts. It is held annually.

The system of preventive maintenance at the middle stage includes setting the volume, cyclicity and sequence of the works indicated here in strict accordance with all regulatory and technical documents. Thanks to this, the normal operation of the equipment occurs.

Overhaul and its preconditions

It is carried out after opening the equipment, its full check with the study of the presence of defects in all parts. This stage includes measurements, tests, elimination of identified faults, due to which the modernization of the units is necessary. There is a 100% recovery here. technical parameters the devices in question.

When is the overhaul of electrical equipment carried out?

Such manipulations are possible only after the completion of the overhaul stage. The following conditions must also be met:

A work schedule has been drawn up.

Conducted preliminary checks and inspections.

All necessary documents have been prepared.

Replacement parts and tools provided.

Fire fighting measures have been taken.

What does a major overhaul include?

The process of repairing electrical equipment in this case consists of:

1. Replacement / restoration of worn out mechanisms.

2. Upgrading devices that require it.

3. Perform measurements and preventive checks.

4. Implementation of work to eliminate minor damage.

Malfunctions and defects that are discovered during the inspection of equipment (machines) are eliminated during the subsequent repair. Breakdowns classified as emergency are repaired immediately. Equipment different types has its own frequency of activities related to repair work, which is regulated by the rules technical operation. All manipulations carried out are reflected in the documentation, the strictest records of the availability of units and their condition are kept.

According to the approved plan for the year, a nomenclature plan is created, which records the current / major repairs. Before proceeding with them, the date of stopping the electrical equipment (machines) for repair must be specified.

The scheduled preventive maintenance schedule is the official basis for drawing up a budget plan for the year, developed twice a year. specified period. The total amount of the plan-estimate is distributed by months, quarters, taking into account the period of capital repair work.

Peculiarities

To date, the preventive maintenance system provides for the use of microprocessor and computer technology (rigs, structures, test and diagnostic facilities). This prevents equipment wear and tear and reduces refurbishment costs. Also, all this contributes to an increase in operational efficiency, and consequently, the profits of enterprises.

Scheduled preventive maintenance: drawing up a schedule for the year

Consider how the schedule for the year is drawn up. Scheduled preventive maintenance of buildings or electrical equipment is a full-fledged complex of organizational and technical measures closely related to supervision and maintenance. It applies to all types of repairs and is carried out periodically according to a previously drawn up plan. This helps to prevent premature partial or complete wear of equipment, accidents. All systems fire protection are in constant readiness.

Scheduled preventive maintenance is organized according to a system that includes such types of maintenance as:

Weekly technical fix.

Monthly maintenance work.

Annual pre-scheduled preventive maintenance.

The developed regulation on preventive maintenance is approved by the sectoral ministries, as well as departments. The document is obligatory for execution by the enterprises of the industry.

Scheduled preventive maintenance is always carried out in strict accordance with the existing annual work schedule, which includes each mechanism subject to current or major repairs. When compiling this schedule, the standards for the frequency of equipment maintenance are used. They are taken from the passport data of the units prepared by the manufacturer. All available mechanisms, devices are included in the schedule, which indicates brief information about them: quantity, resource standards, labor intensity of one current or major repair. It also records information about the last ongoing current and major repairs.

Additional Information

The regulation on scheduled preventive maintenance contains information on intra-shift maintenance (supervision, care) and preventive inspection of existing equipment. It is usually assigned to operational and duty personnel. It also contains information about the implementation of the planned work.

The benefits of preventive maintenance systems include:

Fixing downtime of units, equipment, machines.

Control over the duration of overhaul periods of operation of devices.

Forecasting the cost of repairing equipment, mechanisms, units.

Accounting for the number of personnel involved in the activity, which depends on the repair complexity.

Analysis of the causes of equipment failure.

Disadvantages of preventive maintenance systems:

The complexity of calculating labor costs.

Lack of convenient and suitable tools for planning (implementing) repair activities.

The complexity of taking into account the parameter/indicator.

The complexity of the operational adjustment of the planned work.

Each preventive maintenance system has an accident-free model of operation/repair of units, but in case of accidents or as a result of wear and tear, unscheduled work can also be carried out related to the full resumption of the operation of the units.

The frequency of stopping the operation of equipment for major or current repairs is determined by the service life of wear mechanisms, parts, assemblies. And their duration is determined by the time that is necessary to perform the most time-consuming manipulations.

Lifting machines (aggregates), in addition to routine inspection, are also subject to technical examination. It is carried out by specialists responsible for the supervision of this equipment.

The main stages of PPR equipment

Well-planned preventive maintenance includes:

Planning;

Preparation of electrical equipment for planned repairs;

Carrying out scheduled repairs;

Carrying out activities related to scheduled maintenance and repair.

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

1. Stage overhaul

It is carried out without disrupting the operation of the equipment. Includes: systematic cleaning; systematic lubrication; systematic examination; systematic adjustment of the operation of electrical equipment; replacement of parts that have a short service life; fixing minor problems.

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

The main work performed at the overhaul stage:

Tracking the state of equipment;

Enforcement by employees of the rules of appropriate use;

Daily cleaning and lubrication;

Timely elimination of minor breakdowns and adjustment of mechanisms.

2. Current stage

Scheduled preventive maintenance of electrical equipment is most often carried out without dismantling the equipment, only its operation stops. Includes the elimination of breakdowns that occurred during the period of work. At the current stage, measurements and tests are carried out, with the help of which flaws in equipment are detected at an early stage.

The decision on the suitability of electrical equipment is made by repairmen. This decision is based on a comparison of test results during scheduled maintenance. In addition to scheduled repairs to eliminate defects in the operation of equipment, work is carried out outside the plan. They are carried out after the exhaustion of the entire resource of the equipment.

3. Stage middle

It is carried out for the full or partial restoration of obsolete equipment. Includes disassembly of units, designed to view, clean the mechanisms and eliminate the identified defects, replace some wear parts. The middle stage is carried out no more than once a year.

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

4. Overhaul

It is carried out by opening electrical equipment, its full check with inspection of all details. It includes tests, measurements, elimination of identified faults, as a result of which the modernization of electrical equipment is carried out. As a result of the overhaul, the technical parameters of the devices are completely restored.

Major overhaul is possible only after the overhaul stage. To carry it out, you must do the following:

Draw up work schedules;

Carry out preliminary inspection and verification;

Prepare documents;

Prepare tools and necessary replacement parts;

Carry out fire fighting measures.

Major overhaul includes:

Replacement or restoration of worn mechanisms;

Modernization of any mechanisms;

Perform preventive checks and measurements;

Carrying out minor repairs.

Malfunctions found during equipment checks are eliminated during subsequent repairs. And breakdowns of an emergency nature are eliminated immediately.

PPR systems and its basic concepts

The system of preventive maintenance of power equipment (hereinafter referred to as System PPREO) is a complex guidelines, norms and standards designed to ensure the effective organization, planning and implementation 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.

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

The PPR EO system was created taking into account the new economic and legal conditions, and in technical terms, with the maximum use of: the capabilities 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; modern computer technology and computer technologies for collecting, accumulating and processing information about the state of equipment, planning maintenance and preventive actions and their logistics.

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.

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.

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.

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 by operating time, repair by technical condition, or in the form of a combination of them.

Table 5 - number of repairs in 12 months

Table 6 - Planned balance of working hours for the year

Payroll ratio

• 1. For interrupted production = 1.8
• 2. For continuous production = 1.6

SCHEDULE PREVENTIVE REPAIR (PPR)

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

The alternation and frequency of scheduled preventive maintenance (PPR) of equipment is determined by the purpose of the equipment, its design and repair features, dimensions and operating conditions.

The equipment is stopped for scheduled preventive maintenance while it is still in working order. This (scheduled) principle of taking equipment out for repair makes it possible to necessary training to stop the equipment - as from the side of specialists service center, and from the production personnel of the customer. Preparation for scheduled preventive maintenance of equipment consists in clarifying equipment defects, selecting and ordering spare parts and parts that should be replaced during repairs.

Such preparation allows carrying out the full scope of repair work without disturbing the normal operation of the enterprise.

Competently conducting PPR involves:

• planning of scheduled preventive maintenance of equipment;
• preparation of equipment for scheduled preventive maintenance;
• Carrying out scheduled preventive maintenance of equipment;
• Carrying out activities related to preventive maintenance and equipment maintenance.

Scheduled maintenance of equipment includes the following steps:

1. Interrepair maintenance phase.

The overhaul stage of equipment maintenance is carried out mainly without stopping the operation of the equipment itself.

The overhaul stage of equipment maintenance consists of:

• systematic cleaning of equipment;
• systematic lubrication of equipment;
• systematic inspection of equipment;
• systematic adjustment of equipment operation;
• replacement of parts with a short service life;
• elimination of minor faults and defects.

The overhaul stage of maintenance is prevention in other words. The TBO includes daily inspection and maintenance of the equipment and should be properly organized to:

• drastically extend the period of operation of the equipment;
• Maintain excellent quality of work
• Reduce and accelerate the costs associated with scheduled repairs.

The overhaul phase of maintenance consists of:

• Tracking the state of the equipment;
• · implementation by the workers of the rules of proper exploitation;
• Daily cleaning and lubrication
• Timely elimination of minor breakdowns and regulation of mechanisms.

The overhaul stage of maintenance is carried out without stopping the production process. This stage of maintenance is carried out during breaks in the operation of the equipment.

2. The current stage of scheduled preventive maintenance.

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

The current stage of scheduled preventive maintenance precedes the overhaul. At the current stage of preventive maintenance, important tests and measurements are carried out, leading to the identification of equipment defects at an early stage of their occurrence. Having assembled the equipment at the current stage of preventive maintenance, it is adjusted and tested.

Decree on the suitability of equipment for further work issued by repairmen based on a comparison of test results at the current stage of preventive maintenance with existing standards, the results of past tests. Testing of equipment that cannot be transported is carried out using electrical mobile laboratories.

In addition to scheduled preventive maintenance, to eliminate any flaws in the operation of the equipment, work is carried out outside the plan. These works are carried out after the exhaustion of the entire working resource of the equipment. Also, to eliminate the consequences of accidents, emergency repair is carried out, which requires the immediate cessation of equipment operation.

3. Middle stage of preventive maintenance

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

The middle stage of preventive maintenance is to disassemble the equipment components to review, clean parts and eliminate identified flaws, change parts and components that wear out quickly and which do not provide proper use of the equipment until the next overhaul. The middle stage of scheduled preventive maintenance is carried out no more than once a year.

The middle stage of scheduled preventive maintenance includes repairs, in which the regulatory and technical documentation establishes the cyclicality, volume and sequence of repair work, even regardless of technical condition where the equipment is located.

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

4. Overhaul

Overhaul of equipment is carried out by opening the equipment, checking the equipment with a meticulous inspection of the “insides”, testing, measuring, eliminating the identified breakdowns, as a result of which the equipment is being modernized. The overhaul ensures the restoration of the original specifications equipment.

Overhaul of equipment is carried out only after the overhaul period. For its implementation, the following steps are required:

• drawing up work schedules;
• Carrying out a preliminary inspection and verification;
• preparation of documentation;
• Preparation of tools, spare parts;
• · performance fire fighting measures and safety.

Major overhaul of equipment consists of:

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

Flaws that are discovered during the inspection of the equipment are eliminated during the subsequent overhaul of the equipment. Breakdowns that are of an emergency nature are eliminated immediately.

A specific type of equipment has its own frequency of scheduled preventive maintenance, which is regulated by the rules of technical operation.

Measures for the PPR system are reflected in the relevant documentation, with strict consideration of the availability of equipment, its condition and movement. The list of documents includes:

• · Technical certificate for each mechanism or its duplicate.
• · Equipment accounting card (appendix to the technical passport).
• · Annual cyclic plan-schedule of equipment repair.
• · Annual cost estimate for equipment overhaul.
• · Monthly plan-report of equipment repair.
• · Acceptance certificate for major repairs.
• · Replaceable log of process equipment malfunctions.
• · Extract from the annual PPR schedule.

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

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

On the basis of the report plan, the accounting department is provided with a report on the costs incurred for major repairs, and the manager is provided with a report on the implementation of the nomenclature repair plan according to the annual PPR schedule.

At present, for scheduled preventive maintenance (PPR), computer and microprocessor technology tools (installations, stands, devices for diagnostics and testing of electrical equipment) are increasingly being used, which affect the prevention of equipment wear and tear of equipment repair, reduction of repair costs, as well as helps to increase the efficiency of electrical equipment operation.

Director of CIT Projects and Solutions LLC (Kazan)

In my opinion, there is a certain stagnation in this issue at many enterprises. Namely, inherited from Soviet period, at one time a well-established and well-established PPR system, is currently left without development and adaptation to new conditions at most enterprises. This has led to the fact that at enterprises a large proportion of equipment is actually repaired to failure or an emergency stop, and the PPR system lives its own separate life and is almost formal in nature - like a habit inherited from the past. The danger of this state of affairs lies in the fact that Negative consequences This situation accumulates gradually and may not be noticeable for a short time interval: an increase in the number of accidents and equipment downtime, increased wear and tear of equipment, and an increase in the cost of its repair and maintenance. Many business leaders are unaware of what significant losses can be hidden here. One of the regulatory documents that determines the conduct of scheduled preventive maintenance is the PPR schedule.

Speaking about the PPR schedule, one cannot do without a purely symbolic digression into history. The first mentions of PPR are found in the mid-30s of the last century. From then until the early 1990s, Soviet era, an extensive volume was formed technical documentation necessary for routine repair and maintenance of a wide variety of equipment. The PPR schedule, as one of the main documents of the technical service, performed not only an organizational and technical function, but also served as the basis for calculating the financial resources necessary to provide material and labor resources for the entire annual and monthly MRO program.

And what is happening now? As shown by our experience and numerous meetings with technical staff various enterprises, in most cases, the PPR schedule has lost its original purpose. The process of preparing the annual PPR schedule in many cases has acquired a more symbolic, ritual character. There are several reasons for this situation, both objective and subjective, but all of them are mainly related to the fact that over the past 10-15 years the situation both inside and outside enterprises has changed radically. Let's try to deal with some of the reasons for the current situation and offer our vision of how to change the situation for the better.

First, let's describe typical scheme preparation of the PPR schedule: how it looks at many enterprises. By the end of the year, the financial department of the enterprise prepares a draft budget for the enterprise for next year and coordinate it with other services. The technical service must prepare its part of the budget, namely: the amount of expenses for materials, components, labor costs for repair personnel and services of third-party contractors. As a basis for the preparation of the MRO budget for the next year, an annual PPR schedule should serve. However, when preparing the annual PPR schedule for the next year, it is formed virtually unchanged on the basis of the PPR schedule for the current year, i.e. list of equipment, types and list maintenance work, as well as their periodicity, remain unchanged. In turn, the PPR schedule for the current year was obtained in a similar way - based on last year. We have come across a situation where such copying has been done for many years, and the personnel of the enterprise could not remember the origin of the original source. Of course, some amendments to the budget are still being made, but not on the basis of the future PPR schedule, but on the basis of the current year's budget. As a rule, all changes are limited to adjusting the budget amounts for the inflationary component of the cost of materials and work. As for the actual planned dates, the list and volume of maintenance work, these data are practically not adjusted, remaining unchanged from year to year, and they do not take into account either the actual technical condition of the equipment, or the residual resource and operating time, or the history of equipment breakdowns, and much more. . Thus, the PPR schedule, as a document, performs a formal bureaucratic function and is not a product of an engineering calculation.

The next stage - the coordination of the expenditure budget - is a consequence of how this schedule is formed. Namely, at the enterprise, all services related to technical know and understand that the PPR schedule is drawn up “in general” and “enlarged”. Therefore, the budget drawn up on its basis can be safely cut: by 10-15% percent, which, in fact, the financial service does. The technical service, as a rule, is forced to agree. Why? Firstly, the technical service cannot substantiate the presented figures with real statistics: there is simply no data that could be trusted. Secondly, last year the finance department also cut the budget, and got the desired result: money was saved and everything seems to be fine. "Normal" most often means that the equipment broke down as usual. Thirdly, it will always be possible to find a reserve in the “copied” PPR schedule: some of the PPR will not be carried out or will be completed in a reduced volume, because the schedule is drawn up formally, and local specialists know what exactly can be done and what - not necessary. Let us repeat once again that such a “copied” PPR schedule has no connection with the actually required volume and timing of technical measures. Fourthly, if something suddenly breaks down and production stops, then the money for the next urgent purchase will still be allocated, even if it is over the limit. Who will allow idle production?

It turns out that the preparation of the PPR schedule and the budget for maintenance and repair costs is more like a formal process focused solely on justifying the budget for the next year. The main consumer of this document is the financial service, not the technical staff. And even during the year, the technical service refers to the annual PPR schedule mainly in order to report on the costs of the allocated limits. Is the situation described above someone's malicious intent? Unlikely. I will give an overview of some of the reasons that led to the described state of affairs.

Regulatory documentation for domestic equipment that has remained at enterprises since Soviet times is outdated. Many of the pieces of equipment have exhausted their resource, and the standards provided for them did not take into account such "extra wear". And for new domestic equipment, reference books of that time do not take into account that other components are now used in equipment, often imported, with different characteristics.

A significant part of the equipment fleet at enterprises is imported equipment, for which there is no documentation. In Europe, the level of development of services is very high, and the lion's share of European enterprises use the services of third-party organizations to service their equipment: as a rule, equipment manufacturers. Our practice has developed in such a way that maintenance and repair has traditionally been carried out by the technical specialists of the enterprise itself. Therefore, domestic specialists, accustomed to receiving necessary documentation along with the equipment, ended up in difficult situation: there is no documentation, and they are not ready to use the expensive service of a western manufacturer.

Another factor that has had a serious impact on the degradation of the PPR methodology is related to the fact that in Soviet time in the conditions of mass serial production of goods for national and industrial use, manufacturers were provided with mass-produced equipment. Therefore, it was technically and organizationally much easier to create and update standards for mass-produced equipment under centralized planning than at present. This was done by sectoral institutions, many of which no longer exist.

The next reason is that the production capacities of domestic enterprises assumed a constant and uniform load on the equipment. For such production, standards were also developed for Maintenance. Namely, a rhythmically working machine or a line is guaranteed to accumulate its motorcycle hours after a clearly established calendar period, which are necessary for the next MOT, MOT-1, etc. Now the situation is completely different: the equipment is loaded unevenly. Therefore, with the calendar approach, PPR is very often carried out either obviously earlier than the standard operating time, or with a serious “overmileage”. In the first case, costs increase, and in the second, equipment reliability decreases.

It should also be noted that the standards developed in the 60-80s were redundant and included a serious safety stock. Such insurance was associated with the very methodology for developing standards - this is, firstly, and secondly, at that time, diagnostic tools were not as developed and available as they are now. Therefore, one of the few criteria for planning maintenance work was the calendar period.

What is the future of the PPR schedule? What to do: leave everything as it is or try to get an effective management tool? Each company decides for itself. I am sure that most experts will agree with me: only a “live” PPR schedule will allow an enterprise to plan competently and economically spend the enterprise’s budget funds. Obtaining such an outage schedule is impossible without the transition of the maintenance and repair system to modern management methods, which include the introduction automated system management needed to store, process and analyze data on the state of the equipment, and use modern methods preventive diagnostics of equipment, for example: thermography, vibration diagnostics, etc. Only with the help of this combination of methods (ACS MRO and diagnostics) it is possible to achieve an increase in equipment reliability, as well as significantly reduce the number of emergency stops and technically substantiate the reduction in the cost of maintaining and servicing equipment. How exactly, in practice, the introduction of modern maintenance and repair methods removes the acute issues and problems identified in this article - I will share these thoughts in the second part of the article. If you, Dear reader, have comments or additions to this article, write, I'm ready to discuss!