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To ensure the efficiency of the machine-building enterprise, maintenance of industrial equipment is periodically carried out. The life of the machine or machine is limited, and to extend it, you need to monitor the technical condition, change consumables, perform complex repair work.
Terms and definitions
Equipment depends on the profile, capacity, level of technical training of enterprises. For each type of production, repair and maintenance of industrial equipment, that is, a set of works that ensure serviceability and efficiency, differ in terms of carrying out and the scope of work.
Machine-building enterprises install equipment for the manufacture of parts and components, assembly of components and products. For these purposes, machines and machines for metal processing, metalworking, welding are used, industrial robots, automated lines and CNC machines are used.
Military products are subject to increased requirements for manufacturing accuracy, reliability, operating conditions. At the enterprises of aviation, space and other branches of the military-industrial complex, constant modernization of equipment, a high degree of automation of production, requiring special qualifications, is carried out. The feature of metallurgical enterprises is large dimensions of units and increased loads during operation.
How to maintain industrial equipment, the frequency and composition of work is determined by the enterprise itself, taking into account the requirements of the manufacturer’s documentation, GOST 18322-78 “System of maintenance and repair of equipment.” Terms and definitions” and industry-specific recommendations. For this purpose, a system of planned and preventive repairs is being developed. By the time of carrying out maintenance of industrial equipment is divided into:
Daily, including inspection and keeping clean;
– Regulated, provided in the passport of the unit and performed seasonally or as it is used and consisting of oil change and quickly worn out parts, adjustment and inspection of work;
– Unregulated, caused by deviations detected during examination or during verification of indications of diagnostic systems.
The task of maintenance of industrial equipment and repair is to prevent failures and eliminate malfunctions. Work is carried out on the event when a breakdown is detected, in accordance with the regulations or the technical condition of the equipment. For various machines and assemblies, the frequency of repairs is calculated. Metal cutting machines are repaired every 8640 hours of operation, forging machines and machines with asynchronous engines 4320 hours, foundry electric furnace from 1440 to 2880 hours. At the same time, replacement of consumable and worn and failed parts is performed.
Background data
Repairs are planned and carried out on the basis of operational documents prepared according to GOST 2.601-2013 “Unified system of design documentation”. Operational documents”: technical passport or manual for operation, executive documentation (diagrams, drawings of the unit, its components and parts), cost estimates.
The passport contains information on how to carry out installation and maintenance of industrial equipment, terms and scope of work. When putting the machine or machine into operation, it is assigned an inventory number and a passport is entered into which data on the repairs carried out is recorded, a list of replaced parts is indicated.
Features and differences
According to the degree of complexity and scope of work, the repair is divided into:
– current, including the replacement of individual easily removed parts, liquids, lubricants and consumables;
Capital, which requires complete or partial dismantling of industrial equipment, any parts and components, including basic ones, are subject to replacement.
The most time-consuming and complex type of maintenance work is the dismantling of industrial equipment. It is performed for long-used machines with a high degree of wear, when the resource of most parts has expired. For disassembly, you will need a universal plumbing and assembly tool, specialized installation mechanisms that allow you to disassemble removable parts, cut bolts. Rigging of industrial equipment or heavy parts (hulls, stanins) is performed using power winches, waists, jacks, lifting mechanisms.
Timing and sequence of work
Work to maintain machines and machines in working condition involves the following operations and terms:
Before the start of the shift, the worker examines the machine, and after completing the work, puts it in order. As needed, the lubricant is replenished and minor repairs are carried out.
According to the passport, a schedule of bypassing and technical inspection is drawn up visually or with the use of control and diagnostic equipment. If necessary, partial dismantling, elimination of water and oil leaks is performed.
– In the appointed period based on the development of the machine, scheduled maintenance is carried out, including diagnosis, adjustment of mechanisms, lubrication, replacement of consumables and worn parts. If serious defects are detected, the operation of the unit stops until they are eliminated. When servicing industrial refrigeration equipment, the condition of the evaporator, oil separator, receiver is checked.
– Depending on the results obtained during maintenance and in accordance with GOST 21623-76 “System of maintenance and repair of equipment.” Indicators for assessing maintainability. Terms and definitions” is carried out ongoing repair, including the replacement of components and parts, the restoration of anti-corrosion coatings and linings, adjustment of joints.
During major repairs, the maximum resource recovery is performed, any parts of the unit are subject to replacement, the insulation and lining are completely or partially changed. If the work required dismantling, then the assembly of industrial equipment, reconciliation, centering and post-repair tests are performed.
The choice of type of repair affects the price of maintenance of industrial equipment. When making a decision, the guidelines and GOST 27.002-89 “Reliability in technology” are guided. Basic concepts. Terms and definitions.”
Special requirements
Support for the efficiency of equipment is carried out at all stages of operation. Maintenance is carried out during storage, operation and movement of industrial equipment. A missed malfunction can lead to a serious breakdown and disable the unit for a long time.
For industrial equipment of various types of work differ in volume, complexity and required qualification of the contractor. Electrical equipment is subject to special safety rules, caution is necessary when working in explosive and fire-prone rooms.
Why the service is necessary for the customer
In the operation of equipment requires knowledge of design and purpose. Only professionals during the maintenance of industrial equipment will conduct the necessary inspection and diagnostics and identify faults, will cope, if you need the design and manufacture of parts, construction and installation works.
Repair is completed by checking individual nodes and conducting acceptance tests. Executive documentation will be issued in the process. Only with professional performance of all stages will workable equipment, which will be put into operation without problems.
What is the uniqueness of our offer
In the asset of the company “Sintez TMK” a lot of implemented projects. The team with the necessary certificates and permits, engineers of builders, workers are ready to apply their experience, provide the necessary technical documentation. The advantage of this choice will be an integrated approach to solving the problem. You do not need to involve individual contractors, each of which is responsible only for its stage. Entrusting the performance of services for maintenance of technological equipment to one performer, you will get consistency of action and focus on the result, which guarantees compliance with the terms and quality of work.
Mistakes and problems. Possible and frequent.
Insufficient qualification of performers and negligence in the preparation and maintenance of equipment will lead to problems. If you run the system without testing, you can not guarantee the normal operation of the unit and the provision of operating parameters. Execution of works without RRP will increase the time and lead to increased costs. Without incoming control of project documentation, the quality of the equipment cannot be guaranteed.
Problems arise for objective reasons. Huge overall dimensions and weight of equipment and components complicate the service. To control and replace parts, special portal equipment, stationary GPM and car cranes will be required. For complex modern machines, the lack of technical documentation will cause difficulty.
In order to avoid mistakes and cope with possible problems, it is necessary to contact the services of professionals who are able to take into account possible risks and solve difficulties.
Regulatory instruments
GOST 18322-78 System of maintenance and repair of equipment. Terms and definitions”
GOST 21623-76 System of maintenance and repair of equipment. Indicators for assessing maintainability. Terms and definitions”
P 50-609-30-87 “Recommendations”. Operation and repair of equipment. Procedure for delivery for repair and acceptance from repair. General requirements”
GOST 2.601-2013 Unified system of design documentation. Operational documents”
GOST 27.002-89 “Reliability in technology”. Basic concepts. Terms and definitions”