Job responsibilities Such employees as a mechanic are very diverse. They depend on the specifics of the equipment being serviced. However, in any case, the main goal of performing plumbing work remains to ensure uninterrupted operation and premature failure of subordinate mechanisms, machines, machine tools and other mechanisms.
Determining the list of tasks performed by a mechanic and his level of qualifications
Unambiguously answer the question of what is included in the job responsibilities of a plumbing specialist. It depends on many nuances. The key ones are the nature of the equipment being serviced and the degree of qualification of the employee.
It is generally accepted to distinguish among locksmiths. Their assignment occurs from least to greatest, where the first category means the presence of basic knowledge and skills, and the sixth - high level training and professionalism. An important role in determining the qualifications of a specialist is played by his work experience, since it is one of the main sources of acquiring plumbing skills. Basic knowledge is acquired during secondary specialized education.
According to the available categories, it is customary to differentiate the list of tasks performed by specialists. They are determined on the basis of a unified tariff and qualification directory of jobs and professions. So, with the 1st qualification category, a mechanic, according to ECTS, is allowed to prepare equipment, select lubricating fluids, work with screws, bolts and other connections. A 2nd category repairman is allowed to dismantle simple components and assemblies, repair them and diagnose them. In accordance with the assigned qualification category ECTS specifies a list of operations performed and requirements for a specialist.
The main areas of plumbing are industrial equipment and technological installations, instrumentation and automation. It is also worth highlighting the systems that are serviced by workers at this level. These include thermal, plumbing and ventilation systems. Repairers of ship mechanisms and equipment deserve special attention, since their job responsibilities are related to the repair and debugging of complex mechanisms of steam and hydraulic machines.
The tasks and operations performed during the work activity of each repairman have their own specifics. But regardless of the direction of activity, the main task remains to ensure accident-free and efficient work subordinate equipment.
Functionality of a fitter
Mechanical assembly specialists install components and assemblies and complex technological equipment.
Job responsibilities include the following operations:
- work on grinding in, as well as scraping mating surfaces;
- fitting of parts and assemblies of machines and mechanisms;
- balancing components and parts in a static and dynamic way;
- troubleshooting equipment and correcting assembly errors.
MSR mechanic usually works with industrial equipment of varying complexity. The degree of uniqueness of the equipment to which a specialist is allowed to perform work is determined by his qualification level.
Job responsibilities of an instrumentation mechanic
This specialty involves the repair and maintenance of precision control measuring instruments and automation. To obtain the position of a control and automation fitter, it is enough to have a secondary specialized education and a medical examination to determine the ability to perform job duties.
Includes execution next works and operations:
- carrying out work on timely repair and maintenance of instrumentation and automation in accordance with the assigned category and functionality established by ECTS;
- ensuring proper operation of alarm and interlock systems;
- preventing premature failure of entrusted equipment;
- control over its correct operation.
Functionality of a mechanic for repairing technological installations
RTU mechanic must have a secondary specialized education. The list of knowledge and skills of specialists of this specification includes the basics of plumbing, design features of equipment, processed metals and permissible loads on them.
The list of job responsibilities includes the following work and operations:
- repair and maintenance of components and assemblies, machines and mechanisms, fittings and pipelines;
- preventing premature failure of this equipment;
- control over its correct operation;
- testing of machines and mechanisms.
Functionality of a mechanic for servicing heating networks
The jurisdiction of specialists in this area includes pipelines and equipment for hot and cold water supply at the enterprise. The work site is the location of the heating main.
Heating network maintenance mechanic must perform the following functions:
- operations for maintenance and repair of heating networks, hot and cold water supply pipelines;
- control shut-off valves and pipelines;
- pressure control in the pipeline system;
- selection and implementation of a suitable operating mode thermal equipment in accordance with climatic conditions;
- preventing premature wear of pipelines and heating networks, monitoring their condition.
Responsibilities of an emergency repair mechanic
AVR mechanic performs renovation work plumbing and sewerage equipment. He is directly subordinate to the head of the department. Qualifications are assigned in accordance with ECTS and are confirmed annually.
The job responsibilities of an emergency repair mechanic include performing the following operations:
- removing blockages and cleaning sewer pipes;
- installation and dismantling of water pipes, cutting them;
- heating of water supply networks;
- produces emergency repair plumbing and sewer networks and much more.
Professional tasks of a ventilation mechanic
As with other areas of metalworking work, the task of the workers at this level is to debug and ensure continuous operation of the equipment under their jurisdiction, namely ventilation systems.
In functionality ventilation mechanic includes the following work:
- monitoring the condition of the enterprise’s ventilation systems;
- installation and dismantling of relevant parts and ventilation equipment;
- ensuring timely repair of failed mechanisms;
- carrying out the prevention of premature wear of ventilation systems and preventing this.
Responsibilities of a ship's fitter
This specialization has qualification categories and corresponding functionality, which are determined by ECTS. Ship fitter performs installation and dismantling of equipment, alignment and installation of units and components, repair and maintenance operations. The list of work performed also includes:
- installation and dismantling operations for marine diesel engines;
- their repair and maintenance;
- carrying out repairs and preventative work to prevent breakdowns of electrical equipment and steam engines;
- repair and debugging of individual parts and components of hydraulic and steam machines.
For the most part, employees of this specialization are divided into teams that perform separate, predetermined operations. At the same time, each employee must be ready to move to another area of work within the framework of his professional qualifications.
Requirements for metalworkers
Among there are qualification categories. According to ECTS, they have their own functional tasks and requirements. Specialists in this field confirm the degree of their professionalism through annual certification.
Plumbing specialists belong to the category of workers and report directly to the head of their department or workshop. In addition to direct job responsibilities, the functionality of a mechanic includes carrying out direct instructions from the head of the department regarding production activities. Also, compliance with the norms and standards of labor organization established at the enterprise, compliance with technological and fire safety.
The availability of the required knowledge and skills is determined by the nature of the work performed and the qualification category. Skills must be sufficient to perform assigned production tasks. If necessary, a specialist can perform repair and maintenance work on more complex equipment than is provided for by its category. This may be subject to supervision by a more qualified repairman.
Regardless of direction labor activity, a mechanic can increase his professional qualifications. This will help ensure better quality work and achieve promotion to department head or mechanical engineer.
This job description has been automatically translated. Please note that automatic translation is not 100% accurate, so there may be minor translation errors in the text.
Preface to the job description
0.1. The document comes into force from the moment of approval.
0.2. Document developer: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
0.3. The document has been approved: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
0.4. Periodic verification of this document is carried out at intervals not exceeding 3 years.
1. General Provisions
1.1. Job title "Repairman" technological installations 4th category" belongs to the category "Workers".
1.2. Qualification requirements: complete general secondary education. Vocational and technical education. Training. Work experience as a mechanic in the repair of technological installations of the 3rd category for at least 1 year.
1.3. Knows and applies in practice:
- structure, operation, maintenance and repair procedures auxiliary equipment, gas communications, technological fittings;
- instructions from manufacturers and instructions for operation and maintenance of equipment and fittings, instructions on labor protection by profession and type of work;
- procedure for the safe performance of hazardous gas and hot work;
- purpose, installation of complex equipment;
- technical specifications for repair, testing, adjustment and delivery of equipment that is being repaired;
- basics of preventative maintenance;
- system of tolerances and fits, qualities and roughness parameters;
- methods of marking and processing various simple parts;
- arrangement of lifting mechanisms and rules for their use;
- basics of loading and unloading operations.
1.4. A mechanic for the repair of technological installations of the 4th category is appointed to the position and dismissed from the position by order of the organization (enterprise/institution).
1.5. A mechanic for the repair of technological installations of the 4th category reports directly to _ _ _ _ _ _ _ _ _ _ .
1.6. A mechanic for the repair of technological installations of the 4th category supervises the work of _ _ _ _ _ _ _ _ _ _ .
1.7. A mechanic for the repair of technological installations of the 4th category during absence is replaced by a person appointed in the prescribed manner, who acquires the appropriate rights and is responsible for the proper performance of the duties assigned to him.
2. Characteristics of work, tasks and job responsibilities
2.1. Disassembles, repairs, assembles complex installations, machines, apparatus, pipelines and fittings using lifting mechanisms.
2.2. Conducts metalworking processing parts according to 7-10 qualifications (2-3 accuracy class).
2.3. Removes and installs operating and control safety valves from tank equipment.
2.4. Tests, adjusts and returns equipment after repair.
2.5. Manufactures complex devices for assembling and installing equipment that is being repaired.
2.6. Prepares defect reports for repairs.
2.7. Knows, understands and applies current regulations relating to his activities.
2.8. Knows and complies with the requirements of regulations on labor protection and environment, complies with the standards, methods and techniques of safe work performance.
3. Rights
3.1. A 4th grade process plant repairman has the right to take action to prevent and eliminate cases of any violations or inconsistencies.
3.2. A mechanic for the repair of technological installations of the 4th category has the right to receive all social guarantees provided for by law.
3.3. A mechanic for the repair of technological installations of the 4th category has the right to demand assistance in the performance of his official duties and the exercise of his rights.
3.4. A mechanic for the repair of technological installations of the 4th category has the right to demand the creation of organizational and technical conditions necessary for the performance of official duties and the provision necessary equipment and inventory.
3.5. A mechanic for the repair of technological installations of the 4th category has the right to get acquainted with draft documents relating to his activities.
3.6. A mechanic for the repair of technological installations of the 4th category has the right to request and receive documents, materials and information necessary to fulfill his job duties and management orders.
3.7. A mechanic for the repair of technological installations of the 4th category has the right to improve his professional qualifications.
3.8. A mechanic for the repair of technological installations of the 4th category has the right to report all violations and inconsistencies identified in the course of his activities and make proposals for their elimination.
3.9. A mechanic for the repair of technological installations of the 4th category has the right to familiarize himself with documents defining the rights and responsibilities of the position held, and criteria for assessing the quality of performance of job duties.
4. Responsibility
4.1. A mechanic for the repair of technological installations of the 4th category is responsible for failure to fulfill or untimely fulfillment of the duties assigned by this job description and (or) non-use of the granted rights.
4.2. A mechanic for the repair of technological installations of the 4th category is responsible for non-compliance with the rules of internal labor regulations, labor protection, safety precautions, industrial sanitation and fire protection.
4.3. A mechanic for the repair of technological installations of the 4th category is responsible for the disclosure of information about an organization (enterprise/institution) related to a trade secret.
4.4. A mechanic for the repair of technological installations of the 4th category is responsible for failure to fulfill or improper fulfillment of internal requirements regulatory documents organization (enterprise/institution) and legal orders of management.
4.5. A mechanic for the repair of technological installations of the 4th category is responsible for offenses committed in the course of his activities, within the limits established by the current administrative, criminal and civil legislation.
4.6. A mechanic for the repair of technological installations of the 4th category is responsible for causing material damage to an organization (enterprise/institution) within the limits established by the current administrative, criminal and civil legislation.
4.7. A mechanic for the repair of technological installations of the 4th category is responsible for the unlawful use of the granted official powers, as well as their use for personal purposes.
5. Examples of work
5.1. Devices air cooling- disassembling the gearbox.
5.2. Devices column type- repair, assembly internal devices, removal and installation of covers, heads.
5.3. Heat exchangers - assembly.
5.4. Granulators, crystallizers, mixers, filters - disassembly, repair, assembly.
5.5. Piston compressors - disassembly, repair and assembly of crankshaft cylinders, crosshead assembly, valves, pistons.
5.6. Centrifugal compressors - disassembling the rotor, repairing bearings and gear couplings.
5.7. Centrifugal, double-casing and multi-stage pumps with more than four impellers - disassembly.
5.8. Tubular furnaces - replacement of pipes.
5.9. Reactors - replacing the lantern, removing the heads, removing and installing the zone thermocouple pocket, assembling the seal assembly and coupling connections.
5.10. Gearboxes - repair, assembly, regulation.
1. General requirements security
1.1.K independent work Persons at least 18 years of age who have undergone a preliminary medical examination upon entry to work are allowed to work as a mechanic for the repair of technological installations, as well as:
- induction training;
- fire safety instruction;
- initial training at the workplace;
- electrical safety training in the workplace
1.2. A mechanic for repairing technological installations must:
- undergo repeated training on occupational safety in the workplace at least every three months;
- undergo unscheduled and targeted briefings;
- pass a knowledge test according to the rules of the device and safe operation lifting mechanisms;
- undergo a sanitary medical examination in accordance with Order of the Ministry of Health of the Russian Federation No. 90 dated March 14, 1996 and Order of the Ministry of Railways dated July 7, 1987 No. 23 c;
- perform only the work that is part of his duties;
- .use safe methods labor;
- comply with the requirements of prohibitory, warning, directional and prescriptive signs and inscriptions and signals given by train compilers and vehicle drivers;
- Be extremely careful in traffic areas.
1.3 A mechanic for repairing technological installations must know:
- the effect on humans of dangerous and harmful production factors that arise during work;
- general arrangement of technological installations;
- alarm signals installed on the PPP and the location of the devices for giving them;
- rules for the design and safe operation of lifting mechanisms;
- requirements for industrial sanitation, electrical safety and fire safety;
- location of first aid kits;
- internal labor regulations established at the enterprise;
- requirements of this instruction, instructions on fire safety measures, instructions on electrical safety;
- prescription of personal protective equipment;
- instructions for signaling on Russian railways;
- regulations on discipline of railway transport workers;
- rules and regulations on labor protection, safety and industrial sanitation;
- instructions for maintenance of railcar equipment;
- be able to provide first aid to victims, use fire extinguishing equipment, and call the fire department if a fire occurs.
1.3. A mechanic for repairing technological installations in his work must be guided by the following requirements:
These instructions;
Federal Law “Transport Charter of the Railways of the Russian Federation”;
Rules technical operation Railways of the Russian Federation (PTE);
Instructions for signaling on Russian railways;
Regulations on discipline of railway transport workers in the Russian Federation.
1.4. While working, a mechanic repairing technological installations may be exposed to the following dangerous factors.
Objects and tools falling from heights.
Increased or decreased temperature.
Increased humidity and air mobility in the working area.
Increased noise and vibration levels
Moving vehicles, mechanisms, rolling stock.
Insufficient lighting at night.
1.5. A mechanic for repairing technological installations must use the following personal protective equipment:
Cotton suit, acid-proof gloves, boots, goggles.
In winter additionally:
The jacket is insulated.
1.6. A mechanic who repairs technological installations must comply with the following fire safety requirements:
Smoking only in designated areas;
Do not approach the gas welding machine with an open flame, gas cylinders flammable liquids, gas liquids and painting chambers;
Do not touch oxygen cylinders with hands contaminated with oil;
Know and be able to use primary fire extinguishing equipment.
1.7 Personal clothing and workwear must be stored separately in lockers and a dressing room. It is prohibited to take protective clothing outside the enterprise.
1.8 You should eat food only in canteens, buffets or specially designated rooms with appropriate equipment. Before eating, you should wash your hands thoroughly with soap.
1.9. While on railway tracks The locksmith must comply with the following requirements:
Railway tracks pass only in designated places, marked with “Service Passage” signs, walk along the path only along the side of the road;
Cross tracks only at right angles, after making sure that there is no locomotive moving at a dangerous distance in this place;
Cross the track occupied by rolling stock only using the transition platforms of the cars;
Walk around groups of cars no closer than 5 m from the automatic coupler;
Walk between uncoupled cars if the distance between them is at least 10 m;
When getting off the car, hold on to the handrails and position yourself facing the car, having previously inspected the place where you got off and made sure that the handrails and steps are in good condition, as well as the absence of moving stock on the adjacent track;
Pay attention to traffic lights;
Do not cross paths in front of moving trains;
Sit on and get off the steps of carriages while moving;
Climb under carriages;
step on electric wires and cables;
Touch broken wires;
Climb onto the roof of a car located under the overhead wire;
Move closer than 2 m to live parts of the contact network.
1.10. When leaving the track from the heating room, as well as from buildings that impair the visibility of the track, you must first make sure that there is no train moving along it.
1.11.For failure to comply with the safety requirements set out in these instructions, the mechanic is liable in accordance with current legislation.
2. Safety requirements before starting work
2.1. Before starting work, a mechanic repairing technological installations must:
Put on proper overalls and safety shoes and put them in order;
Tuck in the loose ends of the clothing so that it does not hang down;
Establish the sequence of operations;
Inspect your workplace, check the condition of racks and pallets;
Check the availability and serviceability of tools, measuring instruments, templates, as well as their availability on racks and repair installations of spare parts and materials;
Check the operation of the electric hoist and the serviceability of the limit switches;
Check the availability of fire fighting equipment;
Check the serviceability of ladders and bridges and ensure their reliable installation;
Make sure that workplace lighting is reliable.
3. Safety requirements during operation
3.1 Each machine, machine tool, unit, stand must have technical certificate. Non-standard equipment must have circuit diagrams. New or installed equipment should be put into operation only after its acceptance by a commission chaired by the chief or chief engineer.
3.2. Equipment intended for the repair of cars, their components and parts must be kept in good condition, placed in places provided for by the technological process, and not interfere with work, free passage and passage.
3.3. All technological equipment must have operating instructions containing safety requirements for maintenance.
3.4. Technological equipment, which can serve as a source of danger for workers, the surface of fences and other protective devices, and fire equipment must be painted in signal colors.
3.5. Electrical equipment, as well as equipment and mechanisms that may be energized, must be grounded.
3.6. Lifting mechanisms and lifting devices (slings, traverses, grips) must be operated and tested in accordance with the Rules for the Design and Safe Operation of Load-Lifting Cranes.
3.7. Heat-consuming installations, steam pipelines and hot water must be operated in accordance with the Rules for the operation of heat-consuming installations.
3.8. Equipment (machines, mechanisms, presses) must be installed on foundations, carefully leveled and secured. It is necessary to have convenient passages to equipment for inspection, lubrication and maintenance.
3.9. The vice on workbenches must be in full working order, stable and at a height convenient for work.
3.10. Jacks must have a load capacity designation, inventory number, and the date of the next test. Periodic technical inspection of jacks must be carried out at least once every 12 months. Current Maintenance jacking should be carried out every 10 days.
3.11. After any type of repair of a car repair installation, all fixtures and devices must be run in and tested under operating loads, as well as adjustment of all components and parts. After scheduled repairs, commissioning of the car repair unit must be carried out by the site foreman.
3.12. Washing machines used in preparing cars for repairs for external and internal washing of cars, as well as for washing bogies, wheel sets, bearings and other car parts, must be equipped with devices for cleaning, reuse and disposal Wastewater, mechanized removal of sludge and debris.
3.13. The management of the depot and VET must provide workers with working, properly sharpened tools. The faulty tool must be removed and replaced.
3.14. Devices must be convenient to use, easy to install, secure in working position and easy to remove. The operation of devices should not create unnecessary stress for the employee. physical strength, applications special means and may not be accompanied by increased levels of noise and vibration.
3.15.Manual power tool must be in good order and grinding machines have protective covers.
3.16. Hand tool and devices for daily use must be secured for individual or team use.
3.17. To carry tools, if required by working conditions, each worker must be given working manual drawers or bags.
3.18.Spray guns, hoses, handles of brushes, spatulas, knives and other painting tool should be cleaned and rinsed of residues at the end of the shift paint and varnish materials and put it in a storage room or other specially equipped place.
3.19. Using ladders and stepladders, they must be accounted for, numbered and have signs indicating that they belong to a specific area. The depot and technical maintenance department must keep a log of ladders and stepladders indicating the timing of their tests.
3.20. Special mobile carts used for painting works, must be kept in full working order and ensure the safety of work. Platforms for mobile carts must be fenced on three sides with railings at least 1 m high with transverse or longitudinal connections and have a continuous perimeter fence at a height of at least 150 mm from the floor. When not in use, the trolleys of mobile platforms must be securely fastened.
3.21. Wash water when washing cars, bogies, wheel sets, bearings and other parts must be collected and rendered harmless.
4. Safety requirements in emergency situations
4.1. When repairing technological installations in a depot, the following emergency situations may arise:
Ignition that could lead to fire;
Fall of a car raised on jacks or placed on jackstands.
4.2. Whenever emergency situation the mechanic is obliged to stop work, immediately inform the foreman and then follow his commands.
4.3. When eliminating an emergency situation, it is necessary to act in accordance with the approved emergency response plan.
4.4. In the event of a fire that could lead to an explosion, you must:
Immediately notify the fire department;
Proceed to extinguish the fire;
Organize the evacuation of people;
Organize a fire department meeting.
4.5. When electrical equipment catches fire, use only carbon dioxide or powder fire extinguishers.
4.6. In the event of injury or illness, a mechanic repairing technological installations must stop working, notify the foreman and go to the first aid station.
5. Safety requirements after completion of work
5.1. Upon completion of the work, the mechanic must:
Tidy up the workplace;
Place tools, equipment and accessories in a specially designated place;
Collect used cleaning material in metal boxes with a tight-fitting lid;
Take off your overalls and put them in the closet.
5.2. If necessary, wash contaminated workwear.
5.3.After work or in cases of contamination of body parts, take a shower.
5.4. About all violations production process the mechanic must inform the foreman.
I APPROVED
CEO
Last name I.O. ________________
"________"_____________ ____ G.
1. General Provisions
1.1. A repairman belongs to the category of workers.
1.2. A repairman is appointed to a position and dismissed from it by order general director on the recommendation of the chief engineer/site manager.
1.3. The repairman reports directly to the chief engineer/site manager.
1.4. During the absence of a repairman, his rights and responsibilities are transferred to another official, as announced in the organization order.
1.5. A person who meets the following requirements is appointed to the position of repairman: primary vocational or secondary vocational education, work experience in the relevant field for at least a year.
1.6. A repairman must know:
- technological processes manufacturing of products;
- kinematic and electrical circuits serviced machines;
- design and rules for using complex instrumentation and instruments;
- design features universal, special devices and other equipment;
- ways to install the tool;
- enterprise standards and methodological instructions for quality as they relate to its activities.
1.7. A repairman is guided in his activities by:
- legislative acts of the Russian Federation;
- Charter of the organization, internal labor regulations, others regulations companies;
- orders and instructions from management;
- this job description.
2. Job responsibilities of a repairman
A repairman performs the following job duties:
2.1. Performs timely repairs of production site equipment.
2.2. Conducts scheduled preventive maintenance (PPR) of equipment according to the PPR schedule.
2.3. Identifies the causes of premature wear of equipment, takes measures to prevent and eliminate them.
2.4. Repairs technical equipment and carries out minor repairs to components and mechanisms of machine tools.
2.5. Keeps records of existing equipment (mandrels, fixtures, etc.) and orders spare parts in a timely manner.
2.6. Performs operations related to setting up machines.
2.7. Treats equipment and accessories with care and maintains it in working condition and cleanliness, does not leave operating equipment unattended.
3. Rights of a repairman
A repairman has the right:
3.1. Require the administration to ensure labor protection, safety and fire safety rules.
3.2. Require the provision of protective clothing in accordance with current standards.
3.3. Submit proposals for improvement of work related to the responsibilities provided for in these instructions for consideration by management.
4. Responsibility of the repairman
The repairman is responsible for:
4.1. For failure to perform and/or untimely, negligent performance of one’s official duties.
4.2. For failure to comply with current instructions, orders and regulations on maintaining trade secrets and confidential information.
4.3. For violation of internal labor regulations, labor discipline, safety and fire safety rules.
Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Part No. 1 of Issue No. 36 of ETKS
Issue approved by Resolution State Committee USSR on labor and social issues and All-Union Central Council of Trade Unions dated June 7, 1984 N 171/10-109
(as amended by the Resolutions of the State Committee for Labor of the USSR, the Secretariat of the All-Union Central Council of Trade Unions dated 02/03/1988 N 51/3-69, dated 08/14/1990 N 325/15-27, Ministry of Labor of the Russian Federation dated 11/21/1994 N 70, dated 07/31/1995 N 43)
Technological installation repairman
§ 46. Mechanic for repair of technological installations of the 2nd category
Characteristics of work. Disassembly, repair, assembly and testing of simple components and mechanisms of machines, apparatus, pipelines, fittings. Repair of simple installations, units and machines, as well as of medium complexity, under the guidance of a more highly qualified mechanic. Metalworking of parts according to 12 - 14 qualifications (5 - 7 accuracy classes). Washing, cleaning and lubricating parts. Marking and drilling holes on flanges. Straightening, filing and threading of pipes. Manufacturing simple devices for assembly and installation of equipment being repaired.
Must know: design, purpose and principle of operation of individual devices and components of the equipment being repaired; operating conditions of the equipment being serviced; basic locksmith techniques; general rules of welding and soldering; rules for testing small diameter pipelines; basic concepts about tolerances and fits, qualifications, classes of accuracy and purity of processing; purpose and rules for using devices and tools; pipe marking techniques; drawing elements; rules for the use of oils, detergents and lubricants.
Work examples
1. Hatch covers for machines and apparatus - removal and installation.
2. Fences - removal and installation.
3. Gaskets - manufacturing.
4. Heat exchangers of the “pipe in pipe” type - disassembly.
5. Cooling and lubrication system pipes - cleaning.
6. Gas injectors - revision.
§ 47. Mechanic for repair of technological installations of the 3rd category
Characteristics of work. Disassembly, repair, assembly and testing of medium complexity components and mechanisms of machines, apparatus, pipelines, fittings. Repair of medium complexity installations, assemblies and machines, as well as complex ones under the guidance of a more highly qualified mechanic. Metalworking of parts according to 11 - 12 qualifications (4 - 5 accuracy classes). Dismantling and assembling piping of devices, pumps, compressors. Production of medium complexity devices for assembly and installation of equipment being repaired.
Must know: design and principle of operation of the equipment and fittings being repaired; technical specifications for pipes; profile steel, fastening materials; basics of welding; properties of welded metals; rules for laying pipelines; equipment operation rules; fundamental technological scheme and communication diagram of the serviced installation; tolerances and landings; qualities and roughness parameters.
Work examples
1. Fittings low pressure- removal, repair, installation.
2. Compressors - disassembling and removing valves, oil seals, oil deflectors, crossheads, bearings, valve covers and cylinders.
3. Oil pumps, lubricators - disassembly, repair.
4. Piston, plunger, centrifugal and gear pumps, disassembly and repair.
5. Oil seals - packing.
6. Pipelines and apparatus for the cooling and lubrication system of compressors and pumps - disassembly.
7. Furnace pipes, plates and inter-plate space of columns, tubes and inter-tube space of heat exchangers, tubes of refrigerator condensers - cleaning from coke and deposits.
§ 48. Mechanic for repair of technological installations of the 4th category
Characteristics of work. Dismantling, repair, assembly of complex installations, machines, apparatus, pipelines and fittings using lifting mechanisms. Metalworking of parts according to 7 - 10 qualifications (2 - 3 accuracy classes). Removal and installation of working and control safety valves from capacitive equipment. Testing, adjustment and handover of equipment after repair. Manufacturing of complex devices for assembly and installation of repair equipment. Preparation of defect reports for repairs.
Must know: purpose, arrangement of complex equipment; technical conditions for repair, testing, adjustment and delivery of equipment being repaired; basics of preventive maintenance; system of tolerances and fits, qualities and roughness parameters; methods for marking and processing simple various parts; arrangement of lifting mechanisms and rules for their use; basics of rigging; rules for checking repaired and assembled components and devices.
Work examples
1. Air coolers - disassembling the gearbox.
2. Column-type devices - repair, assembly of internal devices, removal and installation of covers and heads.
3. Heat exchangers - assembly.
4. Granulators, crystallizers, mixers, filters - disassembly, repair, assembly.
5. Piston compressors - disassembly, repair and assembly of cylinders, crankshaft, crosshead assembly, valves, pistons.
6. Centrifugal compressors - disassembling the rotor, repairing bearings and gear couplings.
7. Centrifugal, double-casing and multi-stage pumps with more than four impellers - disassembly.
8. Tubular furnaces - replacement of pipes, twins.
9. Reactors - replacing the lantern, removing the heads, removing and installing the zone thermocouple pocket, assembling the seal assembly and coupling connections.
10. Gearboxes - repair, assembly, adjustment.
§ 49. Mechanic for repair of technological installations of the 5th category
Characteristics of work. Dismantling, repair, assembly of particularly complex installations of machines, apparatus, units, pipelines, fittings using mechanisms and delivery after repair. Metalworking of parts and assemblies according to 6 - 7 qualifications (1 - 2 accuracy classes). Disassembly, repair and assembly of components and equipment in conditions of intense and dense landings. Technical examination of equipment.
Must know: structure and design features of complex equipment; technological sequence and organization of labor during repair, assembly, installation of equipment; all types of materials used in repairs; methods for determining premature wear of parts; static and dynamic balancing of machines; geometric constructions with complex markings; methods for restoring worn parts; methods for repairing equipment and equipment operating under high pressure.
Work examples
1. Apparatuses - repair of housing (not requiring heat treatment), checking plates for bubbling.
2. Shut-off, safety and control valves - disassembly, repair, grinding in, assembly and adjustment.
3. Ventilation ducts - assembly.
4. Blowers, gas blowers and superchargers - repair, testing.
5. Compressors, pumps - scraping of bearing shells and other machine parts, repair of safety and check valves.
6. Piston compressors - adjustment and commissioning.
7. Gas engine compressors - repair.
8. Refrigerator condensers - removal and installation of sections.
9. Ball mills, roller mills, crushers, screens, smoke exhausters, granulators - major renovation, test, passing.
10. Centrifugal, double-casing and multi-stage pumps with more than four impellers - repair, assembly, commissioning.
11. Tubular furnaces - control, pipe rejection.
12. Reactors - repair.
13. Heat exchangers (raw materials) for hydrotreating, catalytic reforming, hydrocracking and other over 200 atm repairs.
14. Centrifuges - repair.
§ 50. Mechanic for repair of technological installations of the 6th category
Characteristics of work. Repair, installation, dismantling, assembly, testing and adjustment of particularly complex unique installations, devices, machines and units using mechanisms. Identification and elimination of defects during equipment operation and during inspection during repairs. Accuracy and load testing of repaired equipment.
Must know: design features of particularly complex equipment; technical conditions for repair, testing and commissioning of particularly complex unique equipment; metal technology; methods for restoring particularly complex and critical components; permissible loads on working parts, components and mechanisms of equipment; equipment maintenance and repair systems.
Work examples
1. Air coolers - assembly and alignment of the gearbox.
2. Drum vacuum filter - replacement of intermediate bearing shells, repair of the faceplate, adjustment of the cam head, commissioning.
3. Granulators - sorting of parts, repair and assembly of the drive head, stopper, alignment of the main drive electric motor, alignment of the knife support.
4. Centrifugal compressors - repair of labyrinth seals and rotor; rotor balancing, alignment, assembly.
5. Gas engine compressors - fitting, adjustment, testing.
6. Waste heat boilers - major repairs, hydraulic tests. Lens Pipe Seals high pressure(700 - 2500 atm) - repair.
7. Tubular furnaces - testing (hydraulic or pneumatic) of the coil.
8. Reactors - vessel repair, hydraulic testing.
9. Catalytic cracking reactors - replacement of the stuffing box, lens compensator and straight section of the pressure riser, separation plate glass, side pipes and outlet manifold.
10. Catalytic reforming and hydrotreating reactors - repair and assembly of the glass, distribution devices, pocket of zonal thermocouples.
11. Reactors with a stirrer - installation of a stirrer and bottoms in a high-pressure reactor, alignment and assembly of coupling connections, hydraulic testing.
12. Catalytic cracking regenerators - replacement of the coil, defective areas, distribution grid, production of an air box, replacement of defective areas.
13. Planetary gearboxes and with a complex tooth profile - assembly.
14. Heat exchangers (raw materials) for hydrotreating, catalytic reforming, hydrocracking and other installations over 200 atm, assembly, testing.
15. High-pressure pipelines for any liquids and gases, as well as pipelines of reactor units of catalytic reforming, hydrotreating, hydrocracking installations - repair, assembly.
16. Steam turbines - checking the gap between the blades, housing, rotor; repair and establishment of gaps in diaphragm seals, stuffing box seals, thrust and support bearings, alignment, adjustment.
17. Turbochargers - overhaul and delivery.
18. Centrifuges - pressing on clutch couplings, aligning shafts, pressing out and assembling the mechanical seal housing, disassembling and assembling probes, scraping bearings, bushings, sorting parts, commissioning.
§ 50a. Technological installation repairman, 7th category
(introduced by Decree of the Ministry of Labor of the Russian Federation dated July 31, 1995 N 43)
Characteristics of work. Adjustment and comprehensive setup of complex technological complexes, combined and large-scale installations. Maintenance and diagnostics, including vibration diagnostics of machinery during operation and during repairs. Load testing and adjustment of particularly complex mechanisms and repaired equipment. Maintaining technical documentation for the operation and repair of equipment, participation in the commissioning of complex technological complexes and installations. Management of lower skilled workers.
Must know: methods for setting up complex technological complexes and installations; design features of particularly complex equipment; technical documentation for repair, testing and commissioning of particularly complex equipment; metal technology; system of admissions and landings; modern methods of restoring parts and assemblies - plasma spraying, the use of metal plastics and others; system of scheduled preventive maintenance of equipment at oil refineries.
