Permyakov Artyom

Introductory part

Introduction

    Any productions are realised by use of the technical objects differing among themselves is constructive, manufactured production, modes and working conditions, a technological level and age. The enterprises also differ the big variety of engineering procedures, production volumes, structure and equipment structure. Use technical юбъектов as required within certain service life is accompanied by fulfilment of two kinds of problems: the prevention (preventive maintenance) of pathological processes of damageability (maintenance service) and restoration of their working properties by replacement of the worn out constituents (repair).
        the Decision of these problems is carried out specialised on kinds of works and the equipment by the services forming system of maintenance service and repair (MSaR).

Work urgency

    The urgency of a theme of research is caused by the following:
    • insufficient disclosing of organizational potential of management by maintenance service and repair of the equipment of rolling shops;
    • necessity of theoretical judgement of the accumulated domestic and foreign experience and deeper studying Features of strategy of maintenance service and repair of the equipment of rolling production.
    In the domestic literature the great attention is given studying of the questions connected with management by maintenance service and repair of the equipment. Theoretical bases of essence, problems and the importance service for production work effectivization are presented in works of such known Russian scientists as R.Akberdin, V.Grebenik, A.Pronikov, V.Sedush, V.Semenov etc. Works of scientists of A.Aleksandrova, A.Bondarenko, R.Makarova, A.Myntsova, V.Novikova, I.Tararychkina, A.Shkumata are devoted the general questions of monitoring and equipment diagnostics. Bases of strategy of maintenance service and equipment repair are considered in manuals both domestic, and foreign authors: A.Nazarycheva, K.Norta, D.Kottsa, etc.
    The analysis of materials concerning management of maintenance service and repair of the metallurgical equipment has shown that problems of working out and a scientific substantiation of strategy of maintenance service and repair of the equipment for conditions of separate shop have appeared are not investigated enough.

The purpose and work problems

    Thus, it is obvious that existing system ToiR is imperfect and based on methods of planning which are subject to a number of subjective factors of an estimation of a technical condition of the equipment.
        Proceeding from it, the purpose of the further researches is: working out of regulations of maintenance service and the repairs, based on strategy of realisation of repairs on a condition with the maximum use of a resource on an example of the combined reducer of a rolling cage № 9 camps 150 Open Societies "ММZ".
    Proceeding from the work purpose it is possible to allocate following problems at work realisation:
        • to advance influence of various factors on change of a resource of work of the equipment;
        • to advance how probably to calculate a residual resource;
        • to conduct research of interaction of contact surfaces;
        • to advance diagnosing parametres.

Theoretical part

System ToiR. The basic terms and development history

        For complete and qualitative research we will advance used in a science and the technician the terms concerning concept of system ToiR:
        1. System of maintenance service and engineering repair - set of the interconnected means, the maintenance service and repair documentation and the executors necessary for maintenance and restoration of quality of items, entering into this system.
        2. Maintenance service - a complex of operations or operation on maintenance of working capacity or serviceability of an item at proper use, expectation, storage and transportation.
        3. Repair - a complex of operations on restoration of serviceability or working capacity of items and restoration of resources of items or their constituents.
        System MSaR development is caused by development of engineering procedure, designs of the equipment and administrative structure at the enterprises. System development can be divided into some stages:
        1st stage – with occurrence of metallurgical production there was a strategy of emergency repairs which provides realisations of repairs after equipment failure. This stage is characterised by low qualification of the workers taken by repair, absence of any repair documentation.
        2nd stage – occurrence in the forties XX centuries of strategy of scheduled preventive maintenance that has been caused by planned economy formation in the USSR.[2]
        3rd stage - on border of 70-80th years the equipment though also expensive, bulky and inconvenient with the modern point of view, but allowing to carry out вибромониторинг not only the core, but also auxiliaries on the basis of the frequency analysis has found application in the industry mobile and portable виброизмерительная. It has predetermined occurrence of new strategy MSaR – repairs on a technical condition. [3]
        4th stage – modern development of system MSaR. This stage is characterised by occurrence and development of strategy of the proactive service based on extension of a between-repairs resource.
    Thus it is possible to draw a conclusion that the system MSaR in ferrous metallurgy is a part of the enterprise (can be allocated in separate or consist in its structure) which has the appointment (maintenance of an efficient condition of the equipment), methods and methods of achievement of objects in view, the manpower reserves (line fault service), a certain set of adaptations and the instruments, the certain documentation, realises the problems in complete life cycle of the equipment, beginning from its introduction in operation before writing off.

Maintenance service and repair strategy

        For deeper understanding of system THAT and Р is necessary to consider system strategy. Such strategy at present exists four:
        • jet,
        • scheduled preventive,
        • strategy of repair according to a technical condition,
        • the proactive.
        Jet maintenance service - such method of service at which repair or equipment replacement is made only in that case when it fails or produces the resource. Jet service has following defects: possibility of unscheduled downtimes because of sudden failures of the equipment both expensive and long repair because of gravity and extensiveness of defects. Besides, there is a probability of sudden failure of several various units simultaneously owing to what necessity for repair work can exceed line fault service possibilities.
        Scheduled preventive maintenance service - such method of the service which basis is planned periodic realisation of preventive works of various volume on the equipment, i.e. drawing up and observance of the schedule of fulfilment through strictly certain intervals of time of works on a preventive maintenance (flowing, to average or capital). Dignity of such method, in comparison with jet service, the slashing of probability of sudden failure of the equipment is. Defect according to plan - preventive maintenance is realisation of "excessive" repairs, i.e. repairs of actually serviceable equipment, and, as consequence, excessive growth of working costs.
        Achievements in working out контрольно - the measuring equipment have ensured possibility not only to reveal a condition of the unit by measurement of some its technical parametres, but also on the basis of the analysis of changes of the measured parametres to predict necessity and to plan terms of realisation of repair, i.e. to carry out repairs only those units where it is necessary. Such kind of service is called as "precautionary", or service on an actual technical condition. Dignity of such method of service is minimisation of repair work (an exception of repair of without defects knots) and increase on 25... 40 % of a between-repairs resource in comparison with scheduled preventive maintenance service . The situation when necessity for realisation of repair work on several units simultaneously will exceed line fault service possibilities can be serious defect of such kind of service.
     Proactive maintenance service - the approach directed on decrease of total amount of required maintenance service and maximisation of service life of the equipment (i.e. in an ideal - creation of the "eternal" unit which is not requiring maintenance service) by regular removal of sources of defects, leading to premature damage. In other words, by results of generalisation of the most often meeting defects revealed in the course of work of the equipment, the analysis and definition of the reasons of their occurrence and influence on a between-repairs interval is carried out, and then measures on bar of claim by lapse of time of occurrence of these defects are taken. In particular, the constant analysis of work of repair staff is made and defects of work of this or that team, shown on group of units (for example, poor-quality assemblage, centering or balancing), the analysis of work of repair production with revealing of defects of repair technologies (for example, production processes of bearings of sliding), the equipment analysis (for example, absence of equipment on heating of bearings качения emerge at installation), constructive changes (for example, application of abrasive resistant materials) etc. [3,4]

The equipment of a wire camp 150

        The continuous wire camp consists of 13 horizontal cages , 4 horizontal and 4 vertical cages console type. Cages are established consistently in five groups: draught, 1st intermediate, 2nd intermediate, fair with the general drive (the fair block) and additional two cages with the general drive for realisation supervised proskating rinks. A proskating rink it is led in two threads in draught and 1 intermediate groups of cages and in one thread – in cages 2 intermediate groups, wire and низкотемпературного blocks. The scheme of an arrangement of the basic process equipment of a camp is shown in drawing 1.
        The maximum speed proskating rinks – 120 km/s, the settlement worker – from 23 to 110 km/s depending on прокатываемого a profile.
    

Practical part

The description of a course of experiment

    The practical part of finale works assumes experiment realisation. As at present there is a process of a writing of work I can state only directions of realisation of experiment.
        It is planned to use physical modelling at realisation of tests. The matter is that key parametre of working capacity of details of the combined reducer is their technical condition. And for equipment statusing it is necessary to advance parametres and methods of valuation. In this case a main method of diagnosing is visual survey of the equipment at realisation of surveys or simple measuring devices.
        Also it is necessary classificatied all knots of the mechanism on interaction of contacting surfaces. It is possible to offer the following classification: carving connections, bearings, sliding bearings, tooth gearings etc.
        For each group of details it is necessary to establish controllable parametre of an estimation of a technical condition. For example, for bearings качения - a backlash, for tooth gearings - a contact stain (drawing 2).        
The data received as a result of realisation of experiment will be a basis for appointment of surveys and repairs of the equipment of a camp 150.     

Final part

In a final part of work regulations of realisation of maintenance service and repairs of the equipment of a camp 150 which can form the basis for drawing up of the new standard documentation in the field of MSaR will be developed.

The list of sources

    1. ГОСТ 18322-78 «Система технического обслуживания и ремонта техники. Термины и определения»
    2. Васильев В.А., Васильев А.В. Пособие по ремонту металлургического оборудования: На опыте организации ремонтной службы Ждановского металлургического завода им. Ильича., - Донецк, 1979г., 120с.
    3. Ширман А.Р., Соловьёв А.Б. Практическая вибродиагностика и мониторинг состояния механического оборудования.- М, 1996г.,276с.
    4. Ловчиновский Э.В. Реорганизация системы технического обслуживания и ремонта оборудования предприятия., 2005 г.
    5. Организация технического обслуживания металлургического оборудования. В.Я. Седуш, Г.В. Сопилкин, В.З. Вдовин и др. – К.,1986 г.,124с.
    6. В.Д. Плахтин. Теротехнология в металлургии. – М., 1979 г., 84с.
    7. Королев А.А. Механическое оборудование прокатных цехов черной и цветной металлургии. – М.: Металлургия, 1976. – 544 с.
    8. http://www.prostoev.net
    9. http://www.ifsrussia.ru/publmckinsey2.htm
    10. http://cert-food.narod.ru/new_page_3.htm