To the terms "Assigned service life", "Assigned resource", "Assigned storage period. The main indicators of the durability of machine parts
For administrative use
Ex. No.
GOST RV 15.702-94
For administrative use
Ex. No.
GOST RV 15.702-94
STATE STANDARD OF THE RUSSIAN FEDERATION
PRODUCT DEVELOPMENT AND DELIVERY SYSTEM
FOR PRODUCTION
MILITARY EQUIPMENT
INSTALLATION PROCEDURE
AND RENEWAL ASSIGNED RESOURCE,
SERVICE LIFE, SHELF LIFE
Official edition
GOSSTANDART OF RUSSIA
Foreword
1. DEVELOPED AND INTRODUCED by the Ministry of Defense of the Russian Federation.
2. ADOPTED AND PUT INTO EFFECT by the Decree of the State Standard of Russia dated 31.03.94 No. 83.
3. INTRODUCED FOR THE FIRST TIME.
This International Standard may not be reproduced in whole or in part,
replicated and distributed as an official publication without the permission of the State Standard of Russia
1 area of use. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . one.
3. Definitions. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . one.
4. Designations and abbreviations. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 2.
5. General provisions. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 2.
6. The procedure for establishing the assigned indicators. . . . . . . . . . . . . . . . . . 3.
7. The procedure for extending the assigned indicators. . . . . . . . . . . . . . . . . . . . 7.
Annex A Scheme for selecting the nomenclature of assigned indicators
Annex B Title page of the decision to carry out work on
extension. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fifteen.
Appendix B Title page of the program. . . . . . . . . . . . . . . . . .. . . . . eighteen.
Annex D Title page of the conclusion. . . . . . . . . . . . . . . .. . . . . . . 21.
Annex E Cover page of the decision to extend the appointments
indicators. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.
STATE STANDARD OF THE RUSSIAN FEDERATION
System for the development and production of products
MILITARY EQUIPMENT. PROCEDURE FOR ESTABLISHING AND RENEWING
ASSIGNED RESOURCE, SERVICE LIFE, SHELF LIFE
Introduction date 1995---01---01
1 AREA OF USE
This standard applies to samples (systems, complexes) of military equipment, their components and components of intersectoral use, materials and substances (hereinafter referred to as products), for which the technical documentation (TTZ, TK, CD) establishes the assigned resource, period service life, storage period, range or duration of transportation, including before repair, re-preservation or decommissioning (hereinafter referred to as assigned indicators).
The standard establishes general requirements for the organization and procedure for carrying out work on the establishment and extension of the assigned indicators of products.
GOST 2.503-90 ESKD. Rules for making changes
GOST V 15.501-90 SRPP VT. Operational and repair documentation for VT. General requirements for the nomenclature, construction, content, presentation, design, publication and methods of making changes.
GOST 27.002-89 Reliability in engineering, Basic concepts, Terms and definitions
GOST 27.410-87 Reliability in engineering, methods for monitoring reliability indicators and plans for control tests for reliability.
3. DEFINITIONS
In this standard, terms are used in accordance with GOST 27.002
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4. SYMBOLS AND ABBREVIATIONS
In this standard, the following symbols and abbreviations apply:
T r..n. - assigned resource;
T r..n. R. - assigned resource before repair of a certain type;
T r..n. cn. - assigned resource before decommissioning;
T sl..n. - assigned service life;
T sl..n.r. - the appointed service life before repair of a certain type;
T sl..n.sp. - assigned service life before decommissioning;
T chr..n. - assigned period of storage;
T chr..n. PC. - the appointed period of storage before reconservation;
T chr..n. cn. - assigned period of storage before write-off;
L so-called - assigned distance of transportation under given conditions;
t so-called - the designated duration of transportation under given conditions;
TD - technical documentation;
ZIP - spare parts, tools and accessories;
TK - terms of reference;
TTZ - tactical and technical task;
KD - design documentation;
ED - operational documentation;
ND - normative documentation;
OKR - experimental design work;
TU - technical conditions.
5. GENERAL PROVISIONS
5.1. The establishment of assigned indicators is understood as a set of works carried out by organizations and enterprises of the customer, developer and manufacturer, as a result of which the values of assigned indicators are set in the TTZ, TOR and CD for products.
5.2. The extension of the assigned indicators is understood as a set of works carried out by organizations and enterprises of the customer, developer and manufacturer, to determine the possibility of operating products beyond the values of the assigned indicators established in the TTZ, TOR and CD, developing and implementing measures to ensure the operation of products for an extended period.
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5.4. Upon reaching the set value of one of the assigned indicators, the operation (storage) of products is stopped and one of the following decisions is made:
Continued operation of products (with positive results of work to extend the assigned indicators);
Direction of products for repair or re-preservation (for stored products;
Transfer of products for use for another purpose until they are written off or disposed of.
5.5. The required values of the assigned indicators of products provide:
Creation of a design, including the selection of components, components, assemblies, parts, materials and substances that retain the main indicators of quality and reliability within the required values of the assigned indicators;
Development (selection) of technology for manufacturing products, ensuring the full implementation of design solutions;
Operation of products in strict accordance with the requirements of the ED and ND of the customer, regulating the issues of operation;
Carrying out the necessary modifications and repairs of products in accordance with the requirements of the relevant design and repair documents.
5.6. The assigned indicators of products are confirmed by carrying out the necessary theoretical and experimental studies using the results of calculations, testing of prototypes and serial samples (including accelerated methods), leader operation of samples, as well as the results of operation of analogues and prototypes of products.
5.7. The establishment and extension of the assigned indicators is carried out in accordance with the requirements of this standard, taking into account the features and specifics of the creation and operation of specific types of products.
5.8. Disagreements related to the establishment and extension of the assigned indicators are resolved by higher organizations according to the subordination of the parties.
6. PROCEDURE FOR ESTABLISHING THE ASSIGNED INDICATORS
6.1 Assigned indicators are set based on the purpose
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6.2. The assigned indicators based on the customer’s studies, research work, preliminary projects by industry and taking into account the achieved (expected) level of durability and shelf life of similar products are set in the TTZ (TOR) for the implementation of R&D and, based on the results of the R&D, are entered in the design documentation: (TU for products and ED).
6.3. In the general nomenclature of assigned indicators, four types of assigned indicators are distinguished:
Assigned resource indicators ( T r..n., T r..n. R., T r..n. sp.);
Assigned service life indicators ( T sl..n. , T sl..n.r. , T sl..n.sp.);
Assigned storage metrics ( T chr..n. , T chr..n. PC., T chr..n. sp.);
Assigned transportation indicators ( L so-called, t so-called).
Assigned indicators ( T r..n. R, T r..n. sp., T sl..n.r. , T sl..n.sp. , T chr..n. PC., T chr..n. sp.) refer to indicators that are specified by the type of technical solution.
Assigned indicators ( T r..n. , T sl..n. , T chr..n. , L so-called , t so-called) refer to indicators that are not specified by the type of technical solution.
6.4. By agreement between the customer and the product developer, along with the general range of assigned indicators, it is allowed to use other assigned indicators that take into account the specifics of specific types of military equipment.
6.5. The choice of the nomenclature of assigned indicators is carried out on the basis of the classification of products according to the following criteria:
The nature of the main processes that determine the transition of products to the limit state;
Availability for products of data on the dynamics of the technical condition and reliability of their analogues and prototypes during operation;
Possibilities of restoring the resource (service life) of products by carrying out scheduled repairs of a certain type;
The method of restoring the resource (service life) of products during scheduled repairs of a certain type;
Criticality of products to external influencing factors (mechanical, climatic, etc.) characteristic of the accepted (estimated) method of transportation
6.5.1. According to the nature of the main processes that determine the transition to the limit state, products are divided into:
Aging;
wearable;
Aging and worn out at the same time.
Note - When classifying products according to the indicated features, the characteristics of the purpose of the products, conditions and modes of operation, data on the reliability of analog products and prototype products are used.
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6.5.2. According to the availability of data on the dynamics of the technical condition and reliability of analogues and prototypes, products are divided into:
Having data on the dynamics of the technical condition and reliability of analogues and prototypes;
Having no data on the dynamics of the technical condition and reliability of analogues and prototypes.
6.5.3. If possible, scheduled repairs of a certain type of product are divided into:
Non-repairable;
Repaired.
6.5.4. According to the method of carrying out scheduled repairs, products of a certain type are divided into:
Repaired in an impersonal way;
Repaired in a non-depersonalized way.
6.6. The range of assigned product indicators is established in accordance with Appendix A.
6.7. For products, several assigned indicators can be set, specified by the type of technical solution.
6.8. The assigned shelf life (including before write-off, before re-preservation) is set for products, the transition of which to the limit state is possible as a result of aging processes.
The assigned shelf life is set for products in the absence of data on the dynamics of the technical condition and the reliability of their analogues and prototypes in storage conditions.
The designated shelf life before write-off is set for products in the presence of data on the dynamics of the technical condition and the reliability of their analogues and prototypes in storage conditions.
The designated shelf life before re-preservation is established for products, the conservation of which uses materials and substances, the designated service life (protection period) of which is less than the designated shelf life before the products are written off.
6.9 The assigned range and (or) duration of transportation under given conditions is set for products whose external influences are characteristic of the accepted (intended) method of transportation, and are limiting.
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For individual products, by agreement between the customer and the developer, both of these designated indicators can be set.
6.10. If the composition of products includes components that are not replaced during operation, components, materials and substances for which the assigned indicators are established, all corresponding indicators of the same name must be established in the TTZ (TR) and design documentation for products of a higher level of disaggregation, up to products in general.
Example- The following assigned indicators are established for the components, components, materials and substances of a complex product:
For solid fuel - the designated shelf life;
On the turbine - the assigned resource.
Replacement of solid fuel and turbine during operation is not provided. No other assigned indicators for components, components, materials and substances have been established.
In this case, for the product as a whole, along with other assigned indicators, the following should be established: the assigned shelf life and the assigned resource.
6.11. If necessary, but in agreement with the customer, for various modes and operating conditions in the design documentation, the values of the assigned indicators corresponding to them are set and the distinctive characteristics of these modes and conditions are given.
6.12. By decision of the customer, agreed with the developer and manufacturer, it is allowed to set preliminary values of individual assigned indicators indicating the stage of development, production or operation, at which the values \u200b\u200bof the indicators should be clarified, as well as to revise the previously established individual values of the assigned indicators upward or downward, if this is confirmed by the results of operation.
6.13. The values of the assigned indicators of the components, components, materials and substances used in the products must not be less than the corresponding values of the assigned indicators of the products as a whole.
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6.14. In the process of operation, accounting for the operating time (service life, shelf life) of components, components, materials and substances for which the assigned indicators are established should be carried out.
When the components, components, materials and substances reach the established values of the assigned indicators, one of the decisions must be made in accordance with 5.4.
6.15. If the composition of products includes redundant components, components for which an assigned resource or service life is established, the corresponding assigned indicators for products as a whole should be established taking into account the nature of the resource consumption (service life) of the components and components included in the reserve group.
6.16. When setting the values of the assigned indicators, the requirements for the methods, technical means and accuracy of measuring the operating time should be determined.
6.17. The operating time of products (batch of products) is calculated from the moment of its acceptance by the representative of the customer.
The representative of the customer enters into the ED for the products accepted by him the operating time during acceptance tests.
The service life and storage period are calculated from the day (date) of acceptance of the products by the customer's representative.
The distance (duration) of transportation of products is calculated after they are accepted by the customer's representative from the moment the transportation begins.
7. PROCEDURE FOR RENEWAL OF ASSIGNED INDICATORS
7.1. The extension of the assigned indicators is carried out for a specific type of product or its individual batches, combined according to the period of their manufacture (commissioning), taking into account operating conditions, safety requirements for human life and health, and environmental protection.
Work to extend the assigned indicators is carried out for the most complete use of the resource, service life and shelf life of products in order to save material and financial resources.
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7.2. Work to extend the assigned indicators is planned and carried out taking into account the following levels of disaggregation of products:
Samples (systems, complexes) in general;
Components;
Components;
Materials and substances.
In each specific case, the composition of product breakdown levels at which the necessary research is planned and carried out is determined taking into account:
The amount of possible material, technical and financial damage in the event of an erroneous decision to extend, in which the products can reach the limit states within the established value of the assigned indicator;
The actual technical condition of product samples, which provide for the establishment of new values of assigned indicators, assessed by the totality of all available a priori information for the period of work planning (including the results of architectural and technical supervision);
Values of the expected costs for carrying out work to extend the assigned indicators of products.
7.3. The relationship and mutual obligations of the developer, manufacturer and customer for the period of extension of the assigned indicators in excess of the values originally established in the TD are determined by a joint decision to extend the assigned indicators of products.
7.4. With the new values of the assigned indicators established as a result of work on their extension, full compliance of all product quality indicators with the requirements originally established in the TD must be ensured.
In justified cases, it is allowed to reduce individual product quality indicators to a level determined by a joint decision of the customer, developer and manufacturer.
7.5. In the general case, work to extend the assigned indicators of products in operation (storage) (hereinafter referred to as work to extend the assigned indicators) includes:
Development, coordination and approval of a decision to carry out work on the extension, a program with a work schedule;
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Preparation, coordination and approval of a decision to extend the assigned indicators and an action plan to ensure the operation of products for an extended period;
Implementation of the measures provided for by the decision to extend the assigned indicators.
Note - In justified cases, it is allowed to develop only a work schedule instead of a program.
7.6. Work to extend the assigned indicators is organized by the product developer or the customer in accordance with the terms of the contract for the performance of work to extend the assigned indicators.
7.7. Work to extend the assigned indicators is carried out by:
Product manufacturers;
Product developers;
Leading industrial enterprises by types of equipment;
Customer organizations.
7.8. Product manufacturers:
Conduct an assessment of the technical condition of the dismantled components, components, materials and substances;
Conduct tests of components, components, materials and substances;
Summarize and analyze data on the quality and reliability of products based on test results, information on complaints, technical condition of products;
Participate in the development of methods for assessing the technical condition and testing of products carried out in the interests of extending the assigned indicators;
Develop conclusions based on the results of the work.
7.9. Product developers and (or) parent companies by type of equipment:
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Summarize and analyze information about the dynamics of the technical condition and reliability of analogues and prototypes of products;
Carry out the analysis of statistical data on the reliability of products, the results of assessing the technical condition of products and their tests;
Carry out forecasting of the technical condition and reliability of products;
Evaluate the economic efficiency of extending the assigned indicators of products;
Carry out the development of a technical solution on the possibility and expediency of extending the assigned indicators of products;
Develop conclusions on the possibility and expediency of extending the assigned indicators of products.
7.10. Customer organizations:
Methodological documents are developed for the performance of work to extend the assigned indicators, which, in accordance with the program, are provided for in the operating organizations or in the repair bodies of the customer (methods for studying the technical condition of products, operating and assessing the technical condition of the lead or leader samples, control launches and firing, etc.). d.);
Carry out the work provided for by the program, the executors of which they are determined;
Develop conclusions based on the results of the work;
They conduct a feasibility study of conclusions on the possibility of extending the assigned indicators of products developed by industrial enterprises.
7.11. The organizer of the work to extend the assigned indicators (the developer or customer of products in accordance with clause 7.6.) develops a decision to carry out work to extend the assigned indicators.
The decision must indicate the developer of the program of work to extend the assigned indicators and the deadline for completion of its development.
The decision may provide for periodic work to extend the assigned indicators during the operation of the products in order to gradually increase the values of the assigned indicators.
In this case, separate decisions for the work to be carried out for each subsequent stage are not made.
The decision to carry out work to extend the assigned indicators is agreed with the developer and manufacturer of products in general, with the customer's organizations, as well as with the developers and manufacturers of those components, components, materials and substances for which the assigned indicators are set in the TD, and is approved by the customer.
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The form of the decision to carry out work to extend the assigned indicators is given in Appendix B.
7.12. The work program for the extension of the assigned indicators is developed by the product developer or the enterprise-holder of the original design documents. In general, the program may include the following types of work:
Development, if necessary, organizational and methodological documents for the implementation of individual work to extend the assigned indicators;
Collection, analysis and generalization of information available at the beginning of work on the durability and shelf life of products for which the assigned indicators are extended, as well as domestic and foreign products of a similar type or design and technological design;
Assessment of the technical condition of products at the sites of operation and repair;
Testing products in general according to special programs and methods and assessing their technical condition during and after testing;
Dismantling (dismantling) of products into components and components and assessment of the technical condition of components, components, materials and substances dismantled from products;
Conducting tests of components, components, materials and working substances according to special programs and methods and assessing their technical condition during and after testing;
Forecasting the technical condition of products for an extended period and making a decision on the possibility and expediency of extending the assigned indicators;
Evaluation of the technical and economic efficiency of extending the assigned indicators of products;
Development of reporting documents (private and final conclusions) based on the results of the work performed;
Development of a draft decision to extend the assigned indicators with an action plan to ensure the operation of products for an extended period.
The program is agreed with the performers of the work, the customer and is approved by the product developer as a whole.
If the program provides for the performance of work and the preparation of conclusions by the customer's organizations, the work program is approved by the product developer as a whole and the customer.
The form of the work program for the extension of assigned indicators is given in Appendix B.
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7.13. In each case, the choice of types of work to be included in the program is determined by:
Purpose of products;
Structural and technological features of products and features of their placement at the operation site or in the carrier object;
Conditions and modes of operation and storage of products;
The number of samples of products that make up the operational fleet;
Actual and required operating time, service life, shelf life, distance or duration of transportation of products;
Expected costs for the implementation of work to extend the assigned indicators.
7.14. The possibility and expediency of extending the assigned indicators is assessed on the basis of:
Initial and additionally received information about the reliability and technical condition of products during the assigned resource, service life, storage period and during transportation to the designated distance (time);
Results of predicting the reliability and technical condition of products for an extended period;
The results of the technical and economic analysis of the work carried out to extend the assigned indicators.
7.15. As initial information for assessing the possibility and feasibility of extending the assigned indicators, in the general case, the following data are used, obtained at the stages of development, manufacture and operation of products:
The results of the work carried out to substantiate the values of the assigned indicators established in the design documentation for products;
The results of the calculation, calculation-experimental and experimental evaluation of durability and shelf life indicators during development, testing and according to operation data in accordance with GOST 27.410;
Information about new ways and methods to ensure the durability and shelf life of products;
Data on the improvements made to products and changes in the technological process of manufacturing products aimed at increasing durability and shelf life;
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Data on the reliability of maintenance and repairs, collected during operation in accordance with the requirements of the current regulatory and technical documents on information systems on the reliability of products.
7.16. To predict the technical condition of products, methods based on:
On the use of data on changes in the technical condition and the results of diagnosing components and components during operation;
On tests of dismantled components, components, materials and substances in laboratory conditions, including accelerated ones.
Forecasting methods are chosen taking into account:
Features of the purpose, principle of operation, design, manufacturing technology of products, conditions and modes of operation, maintenance and repair during operation;
The required accuracy and reliability of the forecast.
7.17. Reporting documents based on the results of the work performed are drawn up in the form of conclusions.
The conclusions must be accompanied by protocols with the results of measurements of technical parameters carried out in accordance with the programs and methods for testing and assessing the technical condition of products, and the standards for the values of these parameters established in the technical specifications for products.
In general, the conclusions are:
Manufacturers of component parts, materials and substances - to developers of component products, materials and substances or head industry enterprises by type of product;
Developers of component parts, materials and substances or head enterprises of the industry on samples of equipment - manufacturers of components and the customer's organization - the head of the component parts;
Developers of component parts - to the manufacturer of products in general;
The manufacturer of products in general - to the developer of products in general;
Product developer as a whole - to the customer;
Customer organizations - the customer and the product developer as a whole.
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The conclusions developed by the customer's organizations are approved by the heads of these organizations.
The form of the conclusion is given in Appendix G.
7.18. The product developer as a whole, together with the customer, on the basis of the submitted conclusions, develop a draft decision on the extension of the assigned indicators with an action plan to ensure the operation of products for the extended period.
It is allowed to include the following works in the action plan to ensure the operation of products for an extended period:
Replacement of components and components based on the results of assessing their technical condition for products of the current release or promising analogues before resuming operation or during operation;
Carrying out repairs of individual components and components before resuming operation in order to restore the properties lost by them as a result of wear and aging;
Reconservation of products in storage;
Clarification of the nomenclature and quantity of spare parts and components contained in spare parts kits;
Clarification of the scope and timing of maintenance and medium repairs;
Amendments to the design documentation for products in accordance with GOST 2.503, GOST B 15.501;
Issuance of bulletins for the relevant work.
The draft decision on the extension is agreed with the performers of the work provided for by the action plan and approved by the customer.
The form of the decision to extend the assigned indicators is given in Appendix D.
7.19. It is allowed to create an interdepartmental commission to carry out individual stages of work on the extension, as well as to prepare a decision on the extension of the assigned indicators. The composition, functions and procedure for the work of the interdepartmental commission are agreed between the customer and the product developer.
Aircraft classification(Sun). Airplanes and helicopters of civil aviation, depending on their mass, are assigned a class (Table 1.1).
Table 1.1
Aircraft are also classified according to the flight range in kilometers:
Main distant………………………………more than 6000
Main medium………………………………2500 – 6000
Main near……………………………..1000 – 2500
Aircraft of local airlines (IL)…………up to 1000
Aviation resources . During operation, wear of moving elements and aging of materials, accumulation of fatigue phenomena in AT products occur. The consequence of this is an increase in the failure rate of products. Therefore, the resources and service life are established for AT products.
Warranty resource (warranty operating time) Tg - operating time of the product (in hours, cycles or other units of measurement), within which the manufacturer guarantees normal operation and provides (free) restoration of failed products, subject to the rules of operation, storage, transportation.
Warranty period (warranty period) - a calendar period during which the manufacturer guarantees normal operation and provides (free) restoration of failed products, subject to the rules of operation, storage, transportation.
Warranty resources and service life are established for each AT product. The manufacturer's warranty is terminated after the end of any of these periods. So, for example, let the unit have a warranty resource (operating time) of 1000 hours and a warranty service life of 3 years. If the unit has run 1000 hours in 1.5 years, or if it has run 500 hours in 3 years, then the warranty for the unit is terminated in both cases.
Currently, the warranty period for AT products is set, as a rule, within 3-5 years.
Assigned (or Shared) Technical Resource (Tdzn) - the total operating time of the product, upon reaching which the operation must be terminated regardless of the state of the product.
Total service life - the total calendar duration of operation of the product to the limit state, in which its repair is technically impossible or economically unfeasible.
overhaul life (Tmr) - the operating time of the product between two consecutive scheduled overhauls. For a new product, a resource is set before the first major overhaul.
Overhaul life - calendar duration of operation of the product between two consecutive scheduled overhauls.
Within the assigned resource (total service life) there may be several overhaul resources.
The warranty resource and service life are established by a special agreement between the Department of Aviation Industry and the Department of Civil Aviation for each specific aircraft and type of aviation equipment. This resource has both legal and financial implications. During the warranty period, the manufacturer is obliged to restore the failed product free of charge.
Overhaul and assigned resources and service life are established jointly by the above named Departments based on test results and operating experience of similar products.
During operation, mandatory accounting AT resource consumption. This expense includes:
For airplanes - flight hours and number of landings;
For helicopters - flying hours and 1/5 of the time of operation of their main rotors and transmissions on the ground;
For aircraft engines - the flight time and 1/5 of the time they work on the ground.
Some products of on-board systems have special counters (hours) of their operating time. For devices, assemblies, units that do not have a special record of their operating time, it is assumed that their operating time is equal to the flight time of the aircraft.
Only serviceable aircraft that meet the technical conditions (TS), which have been checked and trained in accordance with the Manual for the technical operation and repair of aircraft, are allowed to fly.
To increase the durability of repaired machines, individual components, connections, and parts by restoring them, choosing a rational method of restoration and coating material, determining the consumption of spare parts, it is very important to know and be able to evaluate the limit values! wear and other indicators of durability.
According to GOST 27.002-83, durability is the property of an object (part, assembly, machine) to maintain a healthy state until the limit state occurs with the established maintenance and repair system. In turn, the operational state is the state of the object, in which the value of all parameters characterizing the ability to perform the specified functions meets the requirements of regulatory and technical and (or) design documentation; limiting state - the state of an object in which its further use for its intended purpose is unacceptable or impractical, or the restoration of its serviceable or operable state is impossible or impractical. At the same time, it should be borne in mind that for non-repairable objects, the limit state can reach not only an inoperable object, but also a functional one, the use of which is unacceptable according to the requirements of safety, harmlessness, economy, and efficiency. The transition of such a non-repairable object to the limit state occurs before the failure occurs.
On the other hand, the object may be in an inoperable state before reaching the limit state. The operability of such an object, as well as an object that is in a limiting state, is restored with the help of a repair, in which the resource of the object as a whole is restored.
The main technical evaluation indicators of durability are resource and service life. When characterizing the indicators, the type of action after the onset of the limit state of the object should be indicated (for example, the average resource before overhaul; gamma-percentage resource before the average repair, etc.). In the case of the final decommissioning of an object due to the limit state, the durability indicators are called: full average resource (service life), full gamma-percentage resource (service life), full assigned resource (service life). The full service life includes the duration of all types of repair of the object. Consider the main indicators of durability and their varieties, specifying the stages or nature of operation.
Technical resource - the operating time of an object from the beginning of its operation or its renewal after a certain type of repair to the transition to the limit state.
Service life - the calendar duration from the beginning of the operation of the object or its renewal after the repair of a certain type until the transition to the limit state.
Operating time - the duration or amount of work of the object.
The operating time of an object can be:
1) time to failure - from the start of operation of the facility until the first failure occurs;
2) time between failures - from the end of the restoration of the operable state of the object after a failure until the next failure occurs.
A technical resource is a reserve of the possible operating time of an object. The following types of technical resource are distinguished: pre-repair resource - the operating time of an object before the first major overhaul; overhaul life - the operating time of an object from the previous one to the subsequent repair (the number of overhaul resources depends on the number of major repairs); post-repair resource - operating time from the last major overhaul of an object to its transition to the limit state; full resource - the operating time from the beginning of the operation of the object to its transition to the limit state corresponding to the final cessation of operation. Lifetime types are subdivided in the same way as resources.
The average resource is the mathematical expectation of the resource. Indicators "average resource", "average service life", "average operating time" are determined by the formula
where is the mean time to failure (average resource, average service life); f(t) - distribution density of time to failure (resource, service life); F(t) - distribution function of time to failure (resource, service life).
Gamma-percentage resource - operating time during which the object does not reach the limit state with a given probability γ, expressed as a percentage. Gamma percent resource, the gamma percentage life is determined by the following equation:
where t γ - gamma-percentage time to failure (gamma-percentage resource, gamma-percentage service life).
At γ = 100%, the gamma-percentage operating time (resource, service life) is called the established fail-safe operating time (established resource, established service life). At γ=50%, the gamma-percentage operating time (resource, service life) is called the median operating time (resource, service life).
Failure is an event consisting in violation of the operable state of an object.
Assigned resource - the total operating time of the object, upon reaching which the intended use should be terminated.
The assigned resource (service life) is set for the purpose of forced early termination of the use of the object for its intended purpose, based on safety requirements or: economic analysis. At the same time, depending on the technical condition, purpose, features of operation, the object, after reaching the assigned resource, can be further operated, put into overhaul, decommissioned.
Limit wear is the wear corresponding to the limit state of the wear item. The main signs of approaching wear limit are an increase in fuel consumption, a decrease in power, a decrease in the strength of parts, i.e., further operation of the product becomes technically unreliable and economically unfeasible. When the wear limits of parts and connections are reached, their full resource (T p) is exhausted, and measures must be taken to restore it.
Permissible wear - wear at which the product remains operational, i.e. when this wear is reached, parts or connections can work without their restoration for another whole overhaul period. Permissible wear is less than the limit, and the residual life of the parts has not been exhausted.
ANNOTATION. The concepts of "assigned resource" and "assigned service life of equipment" are considered. The relationship of these indicators with the technical condition of the equipment is discussed.
KEY WORDS: park resource, assigned resource, assigned service life, individual resource, technical condition, technical diagnostics.
Doing
The main cause of the disaster at hydroelectric unit No. 2 of the Sayano-Shushenskaya HPP in August 2009 is associated by many with a high degree of equipment wear. As the main argument, data are given on the expiration of the designated service life of this hydroelectric unit in November 2009. In other words, the accident occurred three months before reaching this period. This statement does not look indisputable, moreover, the temporary impeller of the hydraulic turbine (its most critical and damaged unit) was replaced with a regular one on the GA b 2 in November 1986. To understand this cable, it is necessary to once again refer to the terms related to the indicators reliability of the equipment, and recall the history of the purpose of these characteristics.
What is "assigned resource" and "assigned life"
According to GOST 27.002-89, the assigned resource is understood as “the total operating time, upon reaching which the operation of the object must be terminated, regardless of its technical condition”, and the concept of “assigned service life” is “the calendar duration of operation, upon reaching which the operation of the object must be terminated regardless of its technical condition.
Both definitions are quite categorical and do not allow for their different interpretations, if it were not for the note given in the same standard: “Note. After the expiration of the assigned resource (service life ...), the object must be withdrawn from operation, and a decision must be made, provided for by the relevant regulatory and technical documentation - sending for repair, write-off, destruction, verification and establishment of a new appointed period, etc. ".
It turns out that the life of the equipment does not end with the exhaustion of its assigned resource (service life). This is what is being implemented in practice both in our country and abroad. The Russian economy is not ready today to decommission power equipment that has worked out its assigned resource or service life.
But this does not mean that the country's power plants should operate equipment that does not meet the requirements of safety and reliability. The extension of the resource (service life) of equipment, buildings and structures in excess of the designated one must be justified and properly documented.
The definitions of assigned resource and assigned life should be explained.
Despite the similarity of the definitions of these terms, they are fundamentally different from each other. The resource, as a rule, is assigned to elements of equipment operating at a temperature of 450 ° C and above, i.e. under the conditions of creep processes and active structural transformations occurring in the metal, leading to the inevitable achievement of the limiting state of the metal, loss of the operating state by the equipment. Under the assigned resource, the equipment designer selects the standard size of the parts, the material and the conditions for their operation. Equipment resource can be calculated and predicted.
The assigned service life is chosen for economic reasons and is interpreted as the period of accumulation of depreciation charges sufficient to replace obsolete equipment with new one. Often, for equipment with different assigned service life, the same strength calculation standards are used. It is assumed that the equipment should be used for at least the specified service life. When the designated service life is exhausted and the equipment is in a satisfactory condition, a new period is assigned, which is justified by operating experience and is guaranteed not to lead to failure of the equipment until the next revision. It is wrong to demand from the organization operating the equipment and expert organizations conducting technical diagnostics to calculate and justify the residual life of low-temperature elements of power plants, since it is impossible to correctly calculate the residual life for these parts.
The purpose of the service life does not exclude the occurrence of low-temperature wear processes that lead to earlier failure of equipment, such as corrosion, erosion, etc. If the risk of early equipment failure cannot be eliminated structurally, it is assigned the status of a wearable one. For such equipment, the procedure for monitoring and replacing is specifically described in regulatory documents.
For equipment of thermal power plants, a resource for high-temperature elements and a service life for other parts are separately assigned. So, in GOST 27625-88 it is noted:
“2.1.4. The total designated service life of the power unit and its main equipment manufactured before 1991 is at least 30 years, equipment manufactured since 1991 is 40 years, except for wear parts of equipment, the list and service life of which are established in the standards or technical conditions for a specific type of equipment.
2.1.5. The total assigned resource of the components of the power unit equipment operating at a temperature of 450 ° C and above is not less than 200,000 hours, except for high-wear elements, the list and service life of which are established in the standards or technical specifications for a specific type of equipment.
The history of the appearance of the terms park resource and individual resource
According to the park resource, it is understood: "the operating time of elements of heat and power equipment of the same type in design, steel grades and operating conditions, within which their trouble-free operation is ensured, subject to the requirements of the current regulatory documentation." An individual resource is "an assigned resource of specific units and elements, established by calculation and experience, taking into account the actual dimensions, condition of the metal and operating conditions."
When creating power units of 150 - 300 MW, the assigned resource of their high-temperature elements was 100 thousand hours. The operating time of head blocks approached this resource by the end of the 70s of the last century. With the degree of workload of power engineering enterprises that existed at that time, it was not possible to implement a program for the widespread replacement of equipment that had reached its designated resource. Therefore, on the initiative, first of all, of turbine-building plants, a wish was expressed to increase the assigned resource of power units. To solve this problem, on the instructions of three ministries (ministries of energy, power engineering and heavy engineering), several interdepartmental commissions were formed, which organized a series of complex research works. Within the framework of these works, the operating experience of power units was analyzed, long-term metal of critical equipment elements was studied, methods and means of metal control and technical diagnostics were developed. Selective control of these elements at power plants was carried out by specialized teams. The result of the work of interdepartmental commissions was the decision to increase the assigned resource of power units, first to 170 thousand hours, and then to 220 - 270 thousand hours. In order to distinguish the newly assigned resource from the resource assigned during the design of the equipment, it was called a park resource. A volitional decision was made to equate the resource of the power unit with the resource of the steam turbine, and its resource, in turn, with the resource of high-temperature rotors. It is believed that the replacement of this most critical and expensive part of the turbine and block makes it unprofitable and impractical to extend the life of the remaining units and parts of the block. At the same time, other high-temperature elements of boilers, turbines and steam pipelines may have their own park resource, which does not coincide with the park resource of the power unit. In the event of an earlier exhaustion of their resource by these elements, they must be replaced, and the operation of the unit will continue.
The concept of a park resource refers only to high-temperature elements of thermal mechanical equipment of TPPs.
Two factors made it possible to more than double the assigned resource of power units:
The approach to strength analysis that existed earlier in the design was excessively conservative;
In 1971, due to massive damage to the pipes of the heating surfaces of steam boilers, the temperature of live steam and hot reheat steam was reduced from 565 to 545°C. For the class of steels used in thermal power engineering, a decrease in temperature by 20 ° is equivalent to an increase in the residual resource of the metal of high-temperature elements, approximately four times.
Later (in the mid-1980s) a similar attempt to increase the assigned resource was made with regard to 500-800 MW units. But for these power units, based on the results of a comprehensive review, the value of the park resource was left at the level of 100 thousand hours, since these units were already initially designed for a resource of 100 thousand hours at an operating temperature of 540 ° C, and the standards for calculating strength by that time were updated.
In fairness, it should be noted that not for all elements of equipment of power units, the park resource exceeded the values of the originally assigned resource of 100 thousand hours. For some standard sizes of steam pipelines, the park resource of bends, according to the results of the analysis, amounted to 70-90 thousand hours.
By the 90s, the operating time of the head units approached the values of the park resource, but the relevance of extending their service life remained. The second stage of the campaign to extend the life of installed equipment was associated with the introduction of the concept of individual resource. The values of the park resource are set based on the most unfavorable combination of indicators characterizing the operation of the equipment and the properties of the metal of the critical elements. When considering the possibility of extending the service life of specific equipment, as a rule, there are additional reserves that allow you to assign an additional service life without reducing reliability indicators. According to the experience of VTI, it is predicted that the individual resource of critical elements of thermal mechanical equipment will exceed the park resource by an average of one and a half times. Due to the uncertainty factor, when assigning an individual equipment resource, it is not allowed to simultaneously extend its resource (service life) by more than 50 thousand hours. or 8 years. Therefore, during the life of the equipment, several procedures for extending the resource (service life) are possible.
In relation to modern conditions, the most updated procedure for extending the service life is described in the organization standard STO "7330282.27.100.001-2007. Responsibility for organizing the procedure for extending the service life of installed power equipment rests with the head of the operating organization. A specialized or qualified expert organization should be involved in the technical diagnosis of critical equipment elements. Based on the results of technical diagnostics, taking into account the assessment of the feasibility of further operation, the decision to extend the individual life of the equipment is made by the owner of the equipment.The federal executive body authorized in the field of industrial safety approves the conclusion of a specialized or expert organization if the object belongs to equipment operating under excessive pressure, or at temperatures over 115°C.
In exceptional cases, even when the state of the metal approaches the limit, the life of the equipment can be extended by applying appropriate repair technologies or by imposing restrictions on its operating modes. Among the repair technologies, the most widespread is the reductive heat treatment (RHT) of steam pipelines. In some cases, after the WTO, it is possible to reassign a steam pipeline a resource equal in value to the park one.
The relationship of the technical condition of equipment with its operating time and service life
The technical condition of the equipment can be assessed both in terms of reliability and operational efficiency.
There is an opinion that the physical resource of the equipment installed at electric power facilities has been exhausted and, just look, mass destruction and failures will begin tomorrow. In fact, the resource (service life) of the equipment can be extended indefinitely, but provided that the equipment undergoes technical diagnostics in a timely and high-quality manner and its elements that have exhausted the physical (limiting) resource are repaired or replaced in a timely manner. Not the technical devices themselves have a limiting resource, but their highly loaded elements and parts. For example, it is not a steam boiler that has a limiting resource in terms of reliability, but its elements, such as pipes of heating surfaces, collectors, a drum, bypass pipes. Often, during the life of the boiler, its often damaged elements are replaced several times.
However, this does not mean that it is expedient to operate power equipment for an arbitrarily long time. With the operating time of the equipment, the costs of its repair and maintenance will inevitably increase. In the context of curbing the growth of tariffs for electricity and heat, starting from a certain point, it will be unprofitable to operate equipment that has been operating for a long time. This moment should be identified with the physical wear and tear of the equipment.
As noted above, not only reliability indicators characterize the technical condition of the equipment. With the operating time of the equipment, its technical indicators, reflecting the efficiency of the power plant, will inevitably deteriorate. When repairing thermal mechanical equipment, a large amount of work is associated with restoring gaps, reducing suction cups, etc. The requirement to maintain technical performance at an acceptable level will also lead to higher repair costs as equipment ages. Since the operating efficiency of power plants does not belong to the safety category, the decision on the acceptable level of equipment efficiency is made by its owner independently without the participation of federal authorities.
The assessment of the technical condition for both indicators directly depends on the quality of the technical diagnostics of the equipment, namely, on the methods and diagnostic tools used, the qualifications of experts and their understanding of the real processes that lead to the exhaustion of the resource. With regard to most elements of thermal mechanical equipment of thermal power plants, the experience accumulated over many decades allows us to formulate the necessary and sufficient scope of metal control and other types of diagnostics, which excludes mass failure of equipment. For some elements of equipment, the processes occurring in the metal have not yet been sufficiently studied. For example, since 2003, massive damage to the shafts of prefabricated rotors of steam turbines of low and medium pressure parts began to be detected. Until the final study of the nature of these damages and the solution of this problem, in order to exclude the destruction of the rotors during operation, the current standards provide for the control of the shafts of all types of rotors after an operating time of 100 thousand hours, then every 50 thousand hours with the removal of mounted disks.
In the electric power industry, along with the described approach based on the study of the physical processes occurring during the operation of equipment, a formalized approach is becoming more widespread, directly linking the technical condition of the equipment with its operating time. An example of such a methodology is the regulatory document of OAO RAO "UES of Russia", which is based on the Deloitte&Touche methodology widely used in international practice.
According to this methodology, the physical wear of equipment is calculated as the ratio of its actual service life to the designated one. The analysis of the degree of physical deterioration of equipment is carried out according to the scale given in Table. 2. According to this methodology, CJSC IT Energy Analytics conducted an assessment of the technical condition of the equipment of hydroelectric power plants in Russia. According to his analysis, more than half of the hydraulic turbines installed at HPPs have physical wear exceeding 95% (group “3” in Table 2). In other words, this equipment can only be used as scrap metal. Only 23% of the analyzed fleet of hydraulic turbines fell into the workable groups (from "A" to "D"). At the same time, hydroelectric unit No. 2 of the Sayano-Shushenskaya HPP, according to this assessment, occupied far from the worst position.
This approach can, of course, serve as a kind of guideline for the owner about the timing of preparation for the replacement of equipment, but in no case relieves him of the responsibility for diagnosing the equipment and adequately responding to its results.
findings
1. Not the expiration of the service life of the equipment determines the threat to the safety and reliability of its operation, but the lack of objective information about the technical condition of the equipment.
2. A formalized approach to assessing the technical condition of equipment, based on a comparison of the actual and assigned service life, cannot replace the need for technical diagnostics of specific objects, but only supplements it.
The main source of all our problems is the human factor, which determines the level of safety and reliability of equipment at all stages of its life cycle, including the formation of a common technical policy in the industry.
Literature
1. GOST 27.002-89. Reliability in technology. Basic concepts. Terms and Definitions.
2. GOST 27625-88. Power blocks for thermal power plants. Requirements for reliability, maneuverability and economy.
3. RD 10-577-03. Standard instruction for metal control and life extension of the main elements of boilers, turbines and pipelines of thermal power plants. M., Federal State Unitary Enterprise "STC "Industrial Safety", 2004.
4. STO 17230282.27.100.005-2008. The main elements of boilers, turbines and pipelines of thermal power plants. Monitoring the state of the metal. Norms and requirements. M., NP "INVEL", 2009.
5. Tumanovsky A.G., Rezinskikh V.F. Strategy for extending the resource and technical re-equipment of thermal power plants. "Heat power engineering", No. 6, 2001, p. 3-10.
6. STO 17330282.27.100.001 - 2007. Thermal power plants. Methods for assessing the condition of the main equipment. M., NP "INVEL", 2007.
7. Methodology and guidelines for conducting business and/or asset valuation of RAO UES of Russia and JSC RAO UES of Russia, Deloitte&Touche, 2003
8. Rankings of physical deterioration of HPP equipment. CJSC IT Energy Analytics. M., 2009, p. 49.
Eleron, read the GOST, not the form ;-).
Although the last time I looked into the forms (a long time ago), there were "resources" and "lifetime".
The bourgeois use the vague term "Life".
On this topic, I already somehow posted one of my old "essays". If the people do not condemn, then I can reproduce for reflection (but a bit long ;-)):
1. GENERAL PRINCIPLES OF ORGANIZING WORKS TO ENSURE THE LONG LIFE OF AIRCRAFT EQUIPMENT ABROAD
The requirements of paragraphs of the aviation regulations FAR 25.571 and JAR 25.571 do not regulate the establishment of assigned resources (service life), but require a computational-analytical and experimental justification of the lists of airframe units and assemblies operated according to the resource (safe life) or in accordance with the concept of "resistance to damage" or "safe damage" (damage tolerance), ie. TES methods.
These basic provisions of FAR 25 are:
" 25.571(a). General. Evaluation must show that catastrophic failure due to fatigue, corrosion, or accidental damage will be prevented during the airplane's operational life....";
" 25.571(b). ... An assessment of the extent to which damage affects the residual strength of a structure at any point during its service life must take into account its initial detection and subsequent growth under repeated loading....";
" 25.571(c). Evaluation of fatigue strength (safe service life). ... This structure must be capable of withstanding repeated loading ... for a service life without detectable cracks, which must be shown by analysis, confirmed test results...
It is interesting to note that even in the ETC terminology abroad, the term "assigned resource" is practically not used, either simply "life" is used as a term that combines the concepts of resource and service life and is used in context (as, for example, in quotes from FAR given above - operational life). It should be pointed out that the English terms "ultimate life" or "declared life (maximum permitted life)" are analogues of the Russian terms "assigned resource (service life)", which are absent in the FAR text.
The term "time between overhaul (TBO)" is not defined as an assigned overhaul resource, but refers to the frequency of scheduled control and restoration work (CWR) performed on the product after it is dismantled from the aircraft (the operating time between the next scheduled CWR) .
Thus, the development of aircraft and CI is carried out on the basis of the maximum economically justified service life of the aircraft (CI), and their durability is characterized and evaluated using a set of reliability indicators that do not include such indicators traditional for domestic practice as assigned resources and service life.
Gradual extension of Armed Forces resources is also not practiced. Aircraft abroad are supplied to customers with the lists of units and CIs established during certification and reflected in the aircraft maintenance and repair program, operated by resource and technical condition, as well as with warranty obligations established in the contract, including the service life limit (see Section 3 ).
All possible refinements of the conditions for ensuring the durability of AT are implemented in the form of changes in the maintenance and repair program, in particular, in the form of the release of a program for additional control of the airframe structure (Supplemental Structural Inspection Program - SSIP). Such clarifications and additional conditions are typical, as a rule, for aging products and are in no way connected with the limitation or extension of the resources (service life) of the aircraft as a whole, which is provided for by the fundamental regulatory documents (FAR, etc.).
For CI, the situation abroad is closer to domestic practice, however, the values of the frequency of CWR are limited at the initial stage of operation only for especially complex products (for example, aircraft engines) and not by all firms. Most firms supply CI to an aircraft manufacturer or operator without limiting resources and service life in the sense accepted in domestic practice, but with a certain system of guarantees. Naturally, all products are certified "before installation on the aircraft", that is, they meet the requirements of FAR (JAR) and technical specifications (standards Technical Standard Order - TSO).
In practice, this means that after the end of all guarantees, the operator can use the CI without restrictions (except for those that are in the type certificate), but he himself bears all the costs associated with damage and failure of the CI.
The practical interpretation of these requirements in terms of durability can be illustrated by the example of two medium-haul aircraft BAe.146 and RJ (Canadair Regional Jet) based on materials.
1. The following requirements were imposed on the BAe.146 aircraft at the stages of creation (with a typical flight duration of 45 minutes):
service life "before the appearance of cracks" (crack free life - CFL) - 40,000 flights;
the term of normal operation (with minimal control and restoration of the structure - normal operation with minor repair) - 55,000 flights;
service life before the start of structural inspection (threshold inspection life - TIL) - 16,000 flights (plus two more forms of control and restoration work with a frequency of 2 years);
the period of normal operation with an economically justified amount of control and restoration work (economic repair life - ERL or economic design goal - EDG) - 80,000 flights.
At the same time, the scope of the program of "fatigue" tests of the structure was 140,000 flight cycles.
It is also interesting to note that in accordance with the practice of the British CAA for the BAe.146 aircraft, a requirement was put forward by the time of obtaining the airworthiness certificate to confirm the possibility of safe operation for 2 years with 4000 flights per year and a safety factor of 5 by the time of receipt of the airworthiness certificate, this requirement is consonant with domestic practice establishing an initial assigned resource, however, it regulates the scope of "fatigue" tests, and not the permitted duration of operation of the aircraft fleet.
2. The RJ aircraft, already in operation, was subject to the following basic requirements in terms of its durability:
CFL - 30,000 flight hours (45,000 flights); TIL - 15,000 flight hours (subsequent checks are combined with form C and are carried out every 3,000 hours);
ERL (EDG) - 60,000 hours (80,000 flights) or 20 years.
Thus, it can be summarized that, in accordance with the requirements of airlines and state regulations (FAR, JAR), aircraft and CI can and should be operated according to the state, and their durability is ensured by methods different from the domestic practice of establishing and gradually extending the assigned resources and service life. An important component of these methods is the use of an extensive system of guarantees of the AT supplier.
2. WARRANTY OBLIGATIONS OF SUPPLIERS AND MAINTENANCE OF THE DURABILITY OF AIRCRAFT EQUIPMENT DURING ITS OPERATION
The formation of these guarantees and maintenance of operation are carried out abroad in accordance with the ATA recommendations set out in the ATA specifications (in particular, ATA Spec. 200, 300 and 400 on the supply of CI and other logistics issues) and the ATA Guide for AT suppliers.
This guide recommends that suppliers (in the interests of successful cooperation with leading airlines and MRO centers) support the following types of guarantees for the supplied equipment:
standard warranty,
Lifetime guarantee
guarantee of the level of reliability of CI,
guarantee of regular departures,
maintenance and repair volume guarantee,
Guaranteed cost of materials and spare parts,
post-repair guarantees.
The standard warranty corresponds to the warranty obligations accepted in domestic practice.
The guarantee of the maximum service life and level of reliability are exactly those guarantees that provide the necessary level of durability and reliability of the supplied AT. Below they will be considered in more detail.
Departure regularity and MRO cost guarantees are not ubiquitous and are not directly related to durability and therefore are not considered in detail.
The guarantee of post-repair reliability consists in the obligation to extend the original guarantee after repair of the instrument, i.e. accounting for its expiration, starting from the moment the CI is restored after a break at the time of its failure.
With regard to all types of guarantees, there are a number of general conditions for the supply of AT, related to the organization of maintaining the durability of aircraft and CI in operation, in particular, it is expected that suppliers of airframe and aircraft engines will:
receive certificates from CI sub-suppliers and enter into agreements with them to maintain guarantees, and will themselves support the obligations of CI suppliers in case they fail to perform work on guarantees for CI installed on the aircraft or engine;
provide the operator with general guidance on the entire system of guarantees for aircraft and CT, the procedure for their implementation and control;
allow the operator to independently eliminate failures and damages at the expense of suppliers during the warranty period, if it has a material and technical base attested (certified) by the state for this, and the technology and equipment meet the requirements of the CI supplier or the aircraft as a whole;
to share with the operator the costs of repairing breakdowns and damage to AT by foreign objects, if the design is created taking into account resistance to such damage;
carry out warranty repair of CI within a time frame shorter than the scheduled maintenance and repair forms for this CI;
allow operators to transfer the rights to guarantees to a third party in the case of lease, sale and transfer of AT;
reimburse the costs of warranty repairs performed by the operator (labor costs, including overheads, at the rates agreed for the current period and the costs of materials and spare parts at current prices).
The Standard Warranty meets all of the above conditions and also contains a number of additional conditions.
1. Products must not have failures and damages and meet the requirements of the terms of delivery (technical specifications) within the time period agreed by the parties.
2. Guaranteed elimination is subject to CT failures, and sometimes (under a supply contract) secondary damage caused by them.
3. Mandatory modifications (airworthiness directives) are subject to implementation at the expense of the AT supplier and with the participation, if necessary, of its specialists.
4. The warranty period should begin from the beginning of the use of the CI (AC) and may cover the entire period of its operation, however, this period cannot be less than the frequency of the first scheduled maintenance type outlined according to the scheme.
5. If a structural defect is identified and eliminated during the warranty repair of CIs, all CIs of the fleet must be replaced with modified ones.
6. In the event of a failure of a CI operated within its service life during the warranty period, it must be replaced with a new one, if the failed CI has worked out at least 50% of the resource, otherwise the failed CI is subject to restoration (repair).
Typical terms of a standard warranty range from 6 months to 5 years of operation, depending on the type and reason for failure. Airbus Industrie's contracts are characterized by a standard warranty from 6 months to 4.5 years. At the same time, it should be noted the opinion expressed in the report (apparently the general opinion of all operators) that the standard warranty period should be at least 5 years. Such obligations are assumed, in particular, by Dassault (for example, for the Falcon 900B aircraft).
The Life Limit Guarantee is intended to provide a level of durability to the satisfaction of the operator for the main structural elements of the airframe and aircraft engines. It is set in units of operating time and / or calendar period as agreed by the parties. Usually, for large aircraft, its value is higher and can reach 60,000 flight cycles and 20 years of operation. For light aircraft, it is significantly less, for example, for the Falcon 900B aircraft, the airframe service life guarantee is 10 years or 10,000 flight hours.
The meaning of this guarantee is that within its framework, all costs associated with airframe (engine) failures after the end of the standard guarantee are reimbursed by the supplier and the operator jointly and severally on the basis of a proportional division (apparently, in proportion to the working out of the warranty period).
The Reliability Level Guarantee is another guarantee related to maintaining the longevity of the CI. It consists in the obligations of the supplier to provide on their own a quick replacement of failed CTs, if:
these CIs are operated according to their resource;
they have a guaranteed time between failures (MTBF) or time to unscheduled removal from board (MTBUR) and this value is not confirmed during the warranty period.
The value of the warranty period is usually set at least 5 years and it is extended beyond that, if necessary, until the value of the guaranteed level of reliability is confirmed within an interval of 18 consecutive months. The methodology for calculating this level is usually included in the agreement on the guarantees of the contract for the supply of aircraft (AC).
Thus, maintaining the level of durability of aircraft in operation is carried out abroad by implementing a system of guarantees, in particular, in terms of the level of reliability of CI and the maximum service life of the airframe and aircraft engines.
Abroad, as well as in domestic practice, there is a system for performing additional inspections and modifications of the aircraft design, however, this is typical for aging aircraft (at the end of the warranty period of the maximum service life or beyond) and is not intended to "extension of the resource", but to preserve the already declared level of durability, or an increase in the technical and economic efficiency of operation. In a number of cases, Supplemental (Structural) Inspection Programs (SSIP (SIP)) are quite extensive work packages, however, within the limits of the service life guarantee, their implementation is financed jointly by the supplier and the aircraft operator. In the case of identifying the need for improvements due to the insufficient level of fail-safe design identified in operation, i.e. implementation of airworthiness directives, all costs are borne by the aircraft (engine) supplier.
In some cases, the implementation of special inspection programs (such as SSIP) and supplier-based modifications provide an increase in the guarantee of the ultimate service life. For example, for Sabreliner Corporation aircraft, it is possible to increase the lifetime guarantee from 10,000 to 15,000 hours of flight time (after performing a special form of KVR Excalibur Inspection in the corporate MRO center of the corporation), or even up to 30,000 hours of flight time when performing a more labor-intensive form of control and refinement of the airframe design .
In conclusion, it can be summarized that, in contrast to domestic practice abroad, maintenance of the durability of AT in operation is carried out not on the basis of a phased extension of resources, but through the implementation of a wide system of guarantees and a phased (with a "big step" of 5 ... 15 thousand hours of operation ) clarifying the conditions (in terms of CWR) for working out the calculated or guaranteed values of EDG. At the same time, as the resource is worked out, the costs of the operator and the supplier for these works are constantly regulated, carried out on a mutually acceptable contractual basis and in accordance with the current advisory documents, for example, ATA.
LIST OF USED SOURCES
1. Falcon 20 Retrofit. Bendix/King, Allied Signal Inc., 1990.
2. Requirements for Future Advanced Short/Medium Range Aircraft, AEA, 1983.
3. ATA World Airlines and Suppliers Guide, ATA, January 1994.
4. Program Plan - National Aging Aircraft Research Program, FAA/DOT USA, 1989.
5. World Airlines Technical Operations Glossary (WATOG), 10th Edition, ATA, IATA, ICCAIA, 1983.
6. Whittington H. RJ Rolls Out.- Commuter World, June-July, 1991.
7. Grigg R.E. Development of Maintenance Program Through Flight Test Phase. Proceedings of Aircraft Engineering Conference AIRMECH"81, February 10-12, Zurich, 1981.
8. Meline J. What the Operator Wants. There.
9. Olcott J.M. Dassault Falcon 900B.- Business and Commercial Aviation, October, 1991.
10. Sabreliner Maintenance and Repair, Sabreliner Corp., 1991.
11. Edwards T.M., Wilson R.G. Maintenance Program Analysis for Aircraft Structures of the 80"s: MSG-3.- SAE Technical Paper Series, 1980, N 801214.
12. Maintenance Review Board Report. MDD DC-10-10 Maintenance Program, FAA/DOT USA, 1971.
13. Supplement to MDD DC-10-10 MRB Report (Applicable to MDD DC-10-30, -30F, -40), FAA/DOT USA, 1973.
14. Bradbury S.J. MSG-3 as Viewed by the Manufacturer (Was It Effective?).- SAE Technical Paper Series, 1984, N 841482.
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