1. Purpose and structure of the RMS plant

The purpose of the RMS of the plant is the organization of a complex of works for the operation, maintenance and repair of the main technological and mechanical equipment, as well as the management of this complex of works.

The structure of the RMC of enterprises consists of three forms of organization of the repair service:

decentralized;

Centralized;

Mixed.

The decentralized form is characterized by the fact that repairmen and material and technical means are dispersed among technological shops, in which they independently organize and carry out repairs of their equipment.

Advantages: high mobility, efficiency of the beginning of repair.

Disadvantages: - the need for a large machine park and production facilities.

The centralized form is characterized by the fact that all repair personnel and all material and technical means are concentrated in other centralized work shops, divisions, and repair organizations.

Advantages: - high quality of repairs.

Disadvantages: - high cost of repairs.

A mixed form is a combined form that combines both of the above forms of repair work. With such

system of work, in addition to the centralization of the mechanical service outside the workshop, repairmen work in the workshop itself and have a repair and mechanical workshop, with a small machine park, and a technical archive.

Dignity: - repair is carried out by repairmen of shop.

Maintenance and repair is organized by the mechanical repair service of the plant, which is headed by the OGM.

For this workshop, we accept a mixed form.

2. Appointment and structure of the OGM of the enterprise.

Appointment of OGM

1) Organization of work on the operation, maintenance and repair of equipment in the shops of the enterprise.

2) Coordination of the activities of the shops and services of the plant for the preparation of annual and monthly PPR schedules.

3) Development of measures for the implementation of repairs and control of their implementation.

OGM activities

The activities of the OGM include the processing of requests for repairs, applications for spare parts, as well as the execution and production of orders and work orders for the manufacture, and the purchase of parts and spare parts. The OGM is headed by the chief mechanic, who directly reports to the chief engineer of the enterprise.

The structure of the enterprise's OGM

3. Form of repairs at the enterprise

There are five options for repairing the main and auxiliary equipment:

1) Factory repair;

2) Repair at a repair plant;

3) Repair by special repair organizations;

4) Repair in the RMC of the plant;

5) Repair by the RMC of the shop.

4. Purpose and structure of the RMS shop

The workshop mechanic is at the head of the RMS of the workshop, who manages the repairs carried out in the workshop, and also monitors the condition of the workshop equipment. Subordinate to the shop mechanic are: locksmiths, welders who carry out minor repairs.

The purpose of the workshop is to carry out all types of planned equipment repairs, as well as unplanned ones. The repair service must always work efficiently and smoothly, avoiding equipment downtime, which can lead to material losses.

The structure of the mechanical repair service of the shop.

5. Calculation of the number of workshop repairmen

The calculation is made according to the following formula

where: K cn - coefficient of the payroll,

K cn \u003d 1.4 ÷ 1.8; accept K cn = 1.4;

F n - the nominal annual fund of working hours of one repairman, F n = 2002 h;

K m - coefficient of mechanization of work, K m =1.3;

K n - coefficient of fulfillment of the norms, K n =1.2;

Total labor costs for repairs and inspections of all workshop equipment, including auxiliary equipment and their quantity,

N 1 -τ | +n 2 ∙τ 2 +... + n m -τ n, (62) where:

n m - the number of machines of the same type;

τ n - laboriousness of equipment repairs, average annual (person ∙ hour);

for small businesses

τ = τ then ∙τ t ∙τ k; (63)

13262 hours - according to practice.

According to the calculation, Ch cn \u003d 5.8. We accept H cn \u003d 6.

6. Number of locksmiths on duty

The duties of the on-duty locksmith include the maintenance of equipment. If a mechanical equipment failure occurs on a shift, the locksmith on duty is the first to repair the failure.

The number of locksmiths on duty is determined by the formula:

where K d is the coefficient for accounting for the number of locksmiths on duty, K d \u003d 0.2.

The remaining indicators are similar to those given when calculating the number of workshop repairmen.

We take the number of locksmiths on duty equal to 1, i.e. 1 locksmith per shift.

5.6. Types, methods and systems of repairs in the workshop

5.6.1. Types of repairs

In non-ferrous metallurgy, there are two types of repairs, current (T) and capital (K).

During the current repair, the machine is partially disassembled into components and parts, individual parts and components are replaced or restored, the mechanisms for their regulation are revised, the lining is replaced or restored, and the machine is tested.

If the machine has parts with different service life, then two routine repairs are carried out.

Current repairs, depending on the capacity of the enterprise, are carried out either by shop, factory RMS, or by special repair teams.

Current repairs are carried out in accordance with the scheduled preventive maintenance schedules. The cost of carrying out current repairs is attributed to the shop cost.

During the overhaul, the machine is completely disassembled into parts, cleaning, repair of basic parts, replacement or restoration of parts, assembly, adjustment, idling and under load testing. Depending on the capacity of the enterprise and the type of equipment, this repair is carried out by the workshop, the enterprise, or with the involvement of special repair enterprises. Capital repairs are financed from depreciation charges. It is carried out according to the PPR schedules.

5.6.2. repair methods.

There are three types of repair methods:

Individual,

Impersonal,

Mixed.

1.Individual - with this method, worn parts are removed from the repaired machine and sent to the restoration workshops. After the parts are installed in the same machine. This method is used in small enterprises.

2. Impersonal - with this method, worn parts are removed from the repaired machine and sent to the restoration workshops, and either new or previously restored parts taken from the spare parts warehouse are installed in the machine. It is used in enterprises where large interruptions in the operation of technological lines are unacceptable, as well as in enterprises of high power.

This method has disadvantages, there are two of them:

The so-called "mortification of capital";

The need for additional space for storing parts and
nodes. There are two types of "impersonal" repair method:

a) MANPADS - periodic replacement of the repair kit;

b) Aggregate-nodal method.

3. A mixed method is a combination in certain proportions of individual and “impersonal methods.

5.7. Repair systems

Three systems of planned preventive repairs are used:

Post-examination;

Standard PPR;

Periodic system PPR.

1. Post-inspection - the PPR system provides for a periodic (once a month) by the mechanic of the workshop equipment, during which he concludes that repairs are necessary (used at low-capacity enterprises).

2.Standard PPR - consists in the use of a designated resource, after which the equipment, despite its technical condition, is replaced or repaired. It is used in cases where a possible failure can lead to human casualties or large material losses.

3. Periodic system - it is associated with repairs according to the PPR schedule. It is used at enterprises with a full load of equipment (around the clock).

We accept an individual repair method and a periodic PPR system.

5.8. PPR calculation

The calculation of the PPR schedule is carried out according to the methodology proposed in the "Regulations on the PPR ...".

The initial data for the calculation are the standards for the frequency and complexity of types of repairs, from the "Regulations on the PPR ...". Initial data are given in Table 5.1.

Table 5.2

PPR schedule.

5.5.1. Factory repair

It consists in cleaning the equipment, packing it in a special container and after sending it to the manufacturer.

At the factory, the equipment is unpacked, then it is disassembled into components and parts, and the parts are troubleshooted. Unusable parts are sorted out, worn parts are restored. Then the car is assembled, it is started at idle (running in). Then it is packed in the same container and sent to the consumer.

Advantages:

a) replacement of worn parts with parts with the same tolerance fields;

6) repairs in a shorter time;
c) higher quality of repair.
disadvantages: high repair cost.

5.5.2. Repair at a repair plant

The repair plant is usually located near enterprises with the same type of equipment, as well as equipment with similar technological features. This plant is equipped with the necessary machine park, technological park, tools and fixtures, access roads, etc.

There are two options for equipment repair with the involvement of repair plants:

1) When the repaired equipment is sent for repair directly to the factory. At the factory, the equipment is unpacked, disassembled into units and parts, equipment troubleshooting is carried out, worn parts are restored or replaced with new ones. The machine is assembled, run-in is performed, and after the equipment is sent to the consumer.

Disadvantage: poor workmanship compared to the manufacturer.

2) The repair plant sends specialists - repairmen to the enterprise where the repair is carried out. At the same time, the enterprise provides these specialists with the necessary tools, working conditions, materials, and in some cases, locksmiths and welders.

5.5.3. Special repair teams (contractors)

These are organizations that have high-class engineers and repairmen in their staff. They are provided with the necessary equipment for repairs of any complexity. The advantages include the high quality of repairs carried out in a short time, and the disadvantages are the high cost of repairs.

5.5.4. By the forces of the RMC plant

The enterprise organizes a mechanical repair shop equipped with the necessary machine park, fixtures and tools, and

as well as repair sites. RMCs are staffed with the necessary staff of repair personnel.

Their work (the work of the RMC) is built on the PPR graphs. According to this schedule, all types of inspections and repairs of the plant are carried out, subordinate to the RMC to the chief mechanic of the plant.

5.5.5. By the forces of the RMS workshop

The workshop has a certain staff of locksmiths performing current daily work. For the period of repair, a repair team is allocated from this state, headed by a foreman. The remuneration of the members of the repair team is either piecework or piecework - bonus. At the end of the repair, the repairmen perform daily routine work. The advantage is the stimulation of the work of repairmen, and low staff turnover.

5.11. Lubrication facilities of the workshop

The main task of the lubrication service is to provide reliable and economical lubrication at all stages of the equipment life.

The organization of the lubrication economy in the workshop should be based on the certification of equipment with the compilation of maps and tables of lubrication.

Certification covers all technical, lifting and transport equipment and mechanisms, consumers of lubricants. On the basis of lubrication maps and tables, calculations are made of the need for lubricants by type and brand, based on consumption per shift, per month and throughout the year. In accordance with consumption standards and lubrication tables, the required amount of lubricants for each piece of equipment is determined. Calculations of the need for lubricants performed by mechanics of workshops and other manufacturing enterprises, verified and summarized in the OGM, serve as the basis for drawing up relevant applications. The arrival, storage and delivery of lubricants to production sites is carried out by employees of the warehouse of lubricants of the workshop.

5.11.1 Application for fuel

Table 5.3

Application for fuel

5.12. Locksmith's workplace

The layout of the mechanics' workplace and the arrangement of auxiliary equipment is shown in Fig. 16.

Scheme of a locksmith's room

1 - vertical drilling machine;

2- grinding machine;

3- cabinet for storing tools and inventory;

4- lathe;

5- metal table

6.7- workbench

5.13. Workshop warehouse

There are three types of warehouses:

1) Open warehouses;

2) Closed not heated;

3) Closed heated.

This workshop has an open warehouse, which is protected from the effects of precipitation by means of a canopy. This warehouse stores parts and components of machines, as well as various types of consumables that are not afraid of precipitation. Also in the workshop there is a closed warehouse where equipment, parts and assemblies are stored, which are afraid of direct exposure to precipitation and sunlight. Consumables such as bearings are stored in special cabinets with constant ambient temperature.

5.14. Work permit for repairs

Enterprise, shop _________________________________________________________________

Work permit No. _____

To perform high-risk work

1. Foreman of works ______________________________________________________ (enterprise, shop, position, surname, I, O.)

2. Allowed to perform __________________________________________________

(place of work, name of equipment, summary of work)

3. D lowering to work _____________________________________________________

(position, surname, I, O.)

4. Measures to ensure the safety of work:

4.1 Stop__________________________________________________________________

(stop location, position)

4.2. Disable _______________________________________________________________

(knife switch, gate valve, line, etc., remove the tag)

4.3. Install _______________________________________________________________

(short circuit, dead end, plugs, signal lamps, etc.)

4.4 Take a sample for air analysis _____________________________________

4.5. Protect _________________________________________________________________

(work area, hang out posters)

4.6. Provide for safety measures when working at heights and in wells _____________

_____________________________________________________________________________

4.7. Warn _____________________________________________________________

(drivers of neighboring cranes and cranes of adjacent spans with a signature in the logbook)

______________________________________

4.8 Warn safety measures at railway tracks ______________________

______________________________________________________________________________

(installation of signs, posters, fences, dead ends, etc.)

4.9. Specify routes to the place of work _____________________________________________

(attach diagram if necessary)

4.10. Additional activities _______________________________________________

______________________________________________________________________________

5. Work permit issued by _______________________________________________________________

(position, full name)

6Measures completed:

7Agreed: the head of the shift (section) _________________________________________

_____________________________________________________________________________

(surname, signature)

7.1. __________________________________________________________________________

(position name, signature)

8 The measures have been taken, the safety of work has been ensured, the foreman has been acquainted and instructed with the working conditions, I permit permission - allowing to work _____________________________________________________________________________

9Familiarized with the working conditions and instructed, checked the preparation, accepted the workplace - foreman ______________________________________________

(position, surname, signature, date, time)

________________________________________________________________________________________________________________

1 The work is finished, the work permit from the foreman accepted ______________________

___________________________________________________________________________

(date, time, position, surname, signature of the applicant)

5.15. The project of the organization of work during the repair of the machine

When preparing the repair of large and complex equipment, a work organization project (WOR) is drawn up, which is developed by the executing organization and agreed with the customer.

The project for the organization of repairs should provide for the technical means of mechanization of the work to be performed, the composition and qualifications of the repair personnel. Organization of receipt, delivery and storage of components and parts of equipment. Organization of repair and installation sites and sites at the work site, as well as measures for the safety of their implementation.

POR regulates the procedure for conducting and measures to ensure the operations of the preparatory, dismantling and recovery-assembly periods.

5.16. Calculation of the operational overhaul schedule

1) At the first stage, it is necessary to write out from the "standard norms ..." a list of all repair operations performed, indicating the number of nodes, the complexity of the operations and the category of repairmen.

2) Determine the approximate number of the brigade to perform repair operations according to the formula:

H k \u003d τ k / t K \u003d 25.4 / 8 \u003d 3.175 people. (65)

We accept the nearest value - the composition of the brigade 3 people: locksmiths of 3,4,5 categories,

where τ to - normative complexity of performing one repair, man-hour;

t K - repair time, hour

3) Rules for scheduling:

There must be a strict alternation of operations;

Repairmen must move from one operation to another without interruption;

There should be the same number of repairmen on each repair day;

Observe the logical, from the point of view of safety, operations;

Repairmen should not interfere with each other.

4) The length of the segment on the graph is determined by the formula:

T 0 \u003d (τ 1 + τ 2 + ... + τ n) / n rem (66)

where τ 1 , τ 2 , τ n - the complexity of the operation, indicated on the graph by one segment, man-hour;

Prem - the number of repairmen on this operation, people.

T o1 \u003d 0.6 / 3 \u003d 0.2 hour;

T o2 \u003d (0.1 + 0.5) / 1 \u003d 0.6 hour;

T o3 \u003d (0.8 + 2.0) / 2 \u003d 1.4 hours;

T o4 \u003d 0.8 / 1 \u003d 0.8 hour;

T o5 \u003d (0.5 + 0.5) / 2 \u003d 0.5 hour;

T o6 \u003d 0.5 / 1 \u003d 0.5 hour;

T o7 \u003d 0.6 / 1 \u003d 0.6 hour;

T o8 \u003d 5.0 / 2 \u003d 2.5 hours;

T o9 \u003d (1.5 + 0.4) / 1 \u003d 1.9 hours;

T o10 \u003d 3.0 / 3 \u003d 1 hour;

T o11 \u003d (0.6 + 1.2) / 2 \u003d 0.9 hour;

T o12 \u003d 0.9 / 1 \u003d 0.9 hour;

T o13 \u003d (0.8 + 0.6 + 0.8 + 0.2) / 3 \u003d 0.8 hour;

T o14 \u003d 2.0 / 3 \u003d 0.67 hours;

T o15 \u003d 1.5 / 3 \u003d 1.5 hour

5) When connecting to the performance of repair operations included in the formula (5.11), other repairmen, the length of the segment is adjusted.

6) When repairmen switch from one operation to another, expression (5.11) is corrected.

7) If repairmen who are not related to the activities of the workshop’s mechanical repair service are involved in the performance of certain operations, then a separate line is allocated in the operational schedule for these types of work. The labor intensity of performing the work of these workers is not taken into account in (5.10).

8) If during the repair of equipment a large amount of welding work is required, then gas-electric welders are involved in repairs. The labor intensity of the work of gas-electric welders is not taken into account in expression (5.10). If the volume of welding work is not large, then these operations can be performed by locksmiths of 4 and 5 categories. The labor intensity of work in this case is taken into account in expression (5.10).

Table 5.4

List of defects

Table 5.5

List of wearing parts

We accept d=M20

5.3 Equipment lubrication.

Lubricants according to their composition are divided into mineral, vegetable, animal and synthetic.

Oils of mineral origin have received the widest application at non-ferrous metallurgy enterprises.

In the considered wet grinding ball mill, the following components are lubricated: a gearbox, a roller support housing, roller bearings of a support roller, a drive, a gear train. The gearbox is lubricated by dipping the gears in oil.

The lubrication of the tungsten compartment equipment is carried out by pouring liquid oils directly into the bearing stations of the mill and by injection into the bearing assemblies of crushers, elevators and bearing stations of furnaces and mills.

Description of oils. Oils used to lubricate the equipment of the grinding and furnace section of the tungsten department, the following types of oils are used: 1) industrial oil I-40 is used to lubricate rollers and support stations 2) thick lubricants are used to lubricate bearing assemblies: grease, cyatim-203, grease 1-13 and lithol. These types of lubricants are used in accordance with the operating conditions (high temperature and dustiness).

Lubrication is carried out daily before starting work. Lubricant consumption is determined by the upper filling level and ranges from 8-10 liters of oil 200-250 gr. thick lubricants. Disadvantages: liquid oils do not have sufficient consistency due to the poor quality of their manufacture, it has a very low consistency coefficient, which leads to premature wear of rubbing surfaces.

To lubricate gears, a lubricant should be used that can hold the teeth on the surface for a long time and create a sufficiently strong oil film that protects metal surfaces from contact.

In accordance with the rules established at the JSC Pobedit plant, G.S.M. are brought by the workshop from the central warehouse of G.S.M. Storage is carried out in fireproof, ventilated and separately spaced from the main areas. Receipt is carried out directly according to the invoices of the recipient's shop. Accounting for lubricants is carried out according to the approved list of consumption G.S.M. The deposits of pollution and clogging of the crankcases formed as a result of the operation of the machine mechanisms must be renewed and cleaned of the crankcase from old grease and stored in a container intended for this and transported to a central collection point for treated oils for regeneration.

For lubrication, industrial oil 45 is possible according to GOST 1707-51. Roller bearings are lubricated with TsIATIM 203 grease according to GOST 8773-73.

Table 5.1

Lubrication costs per year.