Characteristics of the work. Repair, installation, dismantling, testing, regulation and adjustment of complex equipment, units and machines and delivery after repair. Mechanical processing of parts and assemblies according to 6 - 7 qualifications. Disassembly, repair and assembly of components and equipment in conditions of intense and dense landings.
Must know: design features repaired equipment, units and machines; technical specifications for repair, assembly, testing and adjustment and for the correct installation of equipment, units and machines; technological process of repair, assembly and installation of equipment; rules for testing equipment for static and dynamic balancing cars; geometric constructions with complex markings; methods for determining premature wear of parts; methods for restoring and strengthening worn parts and applying a protective coating.
Work examples
1. Automatic multi-spindle turret lathes, copying machines, jig boring machines, gear planing and roll lathes - average repair, installation, adjustment, accuracy testing, start-up and commissioning.
2. Units high pressure(synthesis columns), separators, evaporators, water condensers, refrigerators - current and medium repairs.
3. Distillation and distillation devices - major renovation.
4. Apparatuses, high-pressure gas pipelines - inspection, repair and testing.
5. Complex film projection devices and developing machines - average repair.
6. Oxygen and argon equipment for open-hearth furnaces - repair, maintenance.
7. Gas blowers - overhaul and testing.
8. Vacuum drying and ironing rollers - repair and adjustment.
9. Gearboxes of semi-automatic lathes - assembly and switching with mutual fitting of splined rollers and gears.
10. Oxygen booster compressors - major repairs.
11. Lifting machines - repair, adjustment and leveling of crane tracks.
12. Machines for sorting letters - repair.
13. Charging machines for open hearth furnaces - complete renovation with replacement of the shaft, adjustment of all mechanisms.
14. Loading machines - inspection of the movement and rotation mechanism, disassembly, assembly, alignment and replacement of parts.
15. Automated washing machines - repair and adjustment.
16. Mills, screens, drying drums - overhaul, testing, adjustment and delivery.
17. Hydraulic feed mechanisms of metalworking machines - repair and adjustment.
18. Mechanisms of hydraulic pipelines of machine tools - repair, assembly, adjustment.
19. Vacuum and fore-vacuum pumps - major repairs.
20. Blast furnaces - installation of an inclined bridge.
21. Reactors - repair.
22. Gearboxes for rotary kiln cranes and differential gearboxes for rolling mills - inspection, repair.
23. Robots and manipulators with program control with a repair complexity category of up to 20 units. - major repairs, adjustment.
24. Deep drilling rigs - repair.
25. Gear grinding, gear shaping, gear planing machines with complex curved guides - checking for accuracy.
26. Computer controlled machines - testing for rigidity.
27. Volumetric turbodrills, geared, jet-turbine, high-torque, with precision casting turbines - repair, assembly, installation, regulation, testing.
28. Vacuum evaporation units - disassembly, repair, assembly.
29. Cylinders, main and connecting rod bearings - check after running in and final fastening of all connections.
30. Economizers, steam superheaters, compressor and blower units - major repairs, delivery after testing.
31. Electric and ore-smelting furnaces - checking the alignment of the lifting screws, conveyor and fit of the furnace body on all four columns.
Introduction
This edition of the Unified Tariff and Qualification Directory of Work and Professions of Workers (ETKS) was developed on the basis of the previously existing ETKS, issue 2, approved by Resolution of the State Committee for Labor of the USSR and the Secretariat of the All-Union Central Council of Trade Unions dated January 16, 1985 N 17/2-54. Its development was caused by changes in production technology, the increasing role and scientific and technological progress in production activities and, on the basis of this, increased requirements for the level of qualifications, general education and special training of workers, quality, and competitiveness of products in the domestic and foreign markets; as well as changes in the content of labor.
The categories of work are established according to their complexity without taking into account working conditions (with the exception of extreme cases that affect the level of complexity of work and increase the requirements for the qualifications of the performer).
The tariff and qualification characteristics of each profession have two sections. The section "Characteristics of work" contains a description of the work that the worker must be able to perform.
The section “Must know” contains # the basic requirements for the worker in relation to special knowledge, as well as knowledge of regulations, instructions and other guidance materials, methods and means that the worker must use.
In tariff qualification characteristics akh provides a list of jobs that are most typical for this category of worker’s profession. This list does not exhaust all the work that a worker can and should perform. The administration can develop and approve in agreement with the trade union committee or other authorized employees representative body an additional list of works corresponding in complexity to those contained in the tariff and qualification characteristics of the professions of workers of the corresponding categories.
In addition to the work provided for in the section "Characteristics of work", the worker must perform work on the acceptance and delivery of shifts, cleaning the workplace, devices, tools, as well as maintaining them in proper condition, maintaining established technical documentation.
Along with the requirements for theoretical and practical knowledge contained in the section, the worker must know: rules and regulations on labor protection, industrial sanitation and fire safety; rules for using personal protective equipment; requirements for the quality of work (services) performed; types of defects and ways to prevent and eliminate them; industrial alarm; requirements for the rational organization of labor in the workplace.
A worker of higher qualifications, in addition to the work listed in his tariff and qualification characteristics, must be able to perform work provided for by the tariff and qualification characteristics of workers of lower qualifications, as well as supervise workers of lower grades of the same profession. In this regard, the work listed in the tariff and qualification characteristics of professions of lower grades is, as a rule, not included in the characteristics of higher grades.
The general provisions of the Unified Tariff and Qualification Directory of Work and Professions of Workers are included in the ETKS,
Explanatory note
This program is compiled in accordance with the requirements of ETKS and is intended for individual and team training of workers in the profession of mechanic - repairman of 2-3, 4-5.6 categories.
Theoretical training for mechanics - repairmen of the 2nd, 3rd category is designed for 120 hours, for mechanics - repairmen of the 4th, 5th category - for 60 hours, for mechanics - repairmen of the 6th category - 30 hours.
Practical training is designed for 60 days for mechanics - repairmen of the 2nd, 3rd category, for 30 days for mechanics - repairmen of the 4th, 5th category and 28 days for mechanics - repairmen of the 6th category. The goal of the program is to provide the necessary knowledge on the program for individual and team training of mechanics and repairmen, according to the approved “List of Professional Training Professions” and the annex to the Order of the Ministry of Education of the Russian Federation dated October 29, 2001. No. 3477.
By the end of the training, each student must be able to perform all the work provided curriculum and qualification characteristics, in compliance technical requirements and time standards established in production.
To conduct theoretical knowledge, highly qualified engineering and technical workers with experience in theoretical training frames.
Throughout the entire educational process Special attention it is necessary to pay attention to safety issues, industrial sanitation and fire prevention measures.
Profession - repairman Qualification - 2nd category
Characteristics of the work:
Disassembly, repair, assembly and testing of simple components and mechanisms of equipment of units and machines, as well as of medium complexity, under the guidance of a more highly qualified mechanic.
Should be able to:
1. Carry out metalworking of parts according to 12 - 14 qualifications.
2.Rinse, clean, lubricate parts and remove spills.
3.Perform work using pneumatic, electric tools and on drilling machines.
4. Scraping parts using power tools
5. Manufacturing simple devices for repair and assembly.
6. Comply with the requirements of labor protection rules
Must know:
1.Basic techniques for performing work on disassembling, repairing and assembling simple components and mechanisms, equipment, assemblies and machines.
2. Purpose and rules for using plumbing and control and measuring tools.
3.Basic mechanical properties processed materials.
4. Basic concepts about tolerances and fits, qualities and roughness parameters. 5.Name, marking and rules for using oils, detergents, metals and lubricants. 6. Instructions and regulations on labor protection:
P-OT “Fall protection”
Work examples:
1. Bolts, nuts, studs - filing, thread fitting, changing them and fastening them.
2. Shut-off valves for air, oil and water - installation to suit the location.
3. Piston pumps - repair, installation.
4. Gaskets - manufacturing.
Profession: repairman. Qualification - 3rd category.
Characteristics of the work:
Disassembly, repair, assembly and testing of medium complexity components and mechanisms of equipment, units and machines, as well as complex ones under the guidance of a more highly qualified mechanic.
A 3rd category repairman must be able to:
1 Carry out metalworking of parts according to qualifications II-I2.
2 Repair lined equipment and equipment made from protective
materials.
3 Perform marking, straightening and bending, chopping, cutting, filing, drilling, countersinking,
scraping.
4 Comply with the requirements of labor protection rules.
A 3rd category repairman must know:
1 Design of the equipment being repaired.
2 Purpose and interaction of main components and mechanisms.
3 Technological sequence disassembly, repair and assembly of equipment.
4 Technical conditions for testing the adjustment of components and mechanisms.
5 Basic properties of processed materials.
6 Construction of universal devices and medium-complexity instrumentation
tool.
7 Tolerances and fits, qualities and roughness parameters.
8 Instructions and regulations on labor protection:
IOT "At cold processed parts on metal-cutting machines."
IOT “For mechanics installing and repairing mechanical equipment. equipment."
IOT “Working with portable hand-held power tools, electric manual machines and portable lamps"
IOT “Working with abrasive tools”
P-OT “Regulations on the procedure for workers to act in emergencies”
P-OT “Fall protection”
P-OT “Procedure for disconnecting, blocking and locking energy, posting warning tags and checking”
Program " Safety fences equipment"
Work examples:
1. The details are simple; stripping, filing, manual threading, reaming holes.
2. Lathes; complete repair of longitudinal and transverse slides, calipers.
3. Housings and frames are complex; manufacturing.
4. Steady rests - repair.
5. Liners and bearings - cutting out lubrication grooves.
Qualification characteristics
Profession: repairman. Qualification - 4th category
Characteristics of the work of a 4th category repairman:
Disassembly, repair, assembly and testing of complex and particularly complex components and mechanisms. Mechanical processing of parts and assemblies of 7-10 quality.
A 4th category repairman must be able to:
1. Repair, dismantle, test, adjust, adjust complex equipment and
delivery after renovation.
2. Manufacture complex devices for repair and installation.
Z. Draw up defective statements for repairs. 4.Comply with the requirements of labor protection rules.
A 4th category repairman must know:
1. Construction of the equipment being repaired.
2. Rules for regulating machines.
3. Methods for eliminating defects during the repair process.
4 Design, purpose and rules for using complex instrumentation.
5. Methods for marking and processing simple various parts.
6. System of tolerances and fits, qualities and roughness parameters.
7. Basic provisions of preventive maintenance and equipment.
8. Instructions and regulations on labor protection:
IOT “When cold processing of parts on metal-cutting machines.”
IOT “For mechanics installing and repairing mechanical equipment. equipment."
IOT “Working with portable hand-held power tools, electric hand-held machines and portable lamps”
IOT “Working with abrasive tools”
P-OT “Regulations on the procedure for workers to act in emergencies”
P-OT “Fall protection”
P-OT “Procedure for disconnecting, blocking and locking energy, posting warning tags and checking”
Equipment Safety Guard Program
Work examples:
1. Gearboxes and feeds of metalworking machines - assembly, adjustment
2. Die casting machines - repair.
3. Metal-cutting machines - major repairs, adjustment.
4. Gearboxes of rotary kilns - repair.
5. Shut-off valves - inspection, repair, installation.
Qualification characteristics:
Profession: repairman. Qualification - 5th category
Characteristics of the work of a 5th category repairman:
Dismantling, repair, installation, testing and adjustment of particularly complex equipment.
A 5th category repairman must be able to:
1. Carry out metalworking of parts and assemblies according to 6-7 qualifications.
2. Disassemble, repair, assemble equipment components in tense and dense conditions
landing
A 5th category repairman must know:
1. Design features of the equipment being repaired.
2.Specifications for repair, assembly, testing, adjustment and correct installation
equipment.
Z.Rules for testing equipment for static and dynamic balancing of machines.
4. Geometric constructions with complex markings.
5. Methods for determining premature wear of parts.
6. Instructions and regulations on labor protection:
IOT “When cold processing of parts on metal-cutting machines.”
IOT “For mechanics installing and repairing mechanical equipment. equipment."
IOT “Working with portable hand-held power tools, electric hand-held machines and portable lamps”
IOT “Working with abrasive tools”
P-OT “Regulations on the procedure for workers to act in emergencies”
P-OT “Fall protection”
P-OT “Procedure for disconnecting, blocking and locking energy, posting warning tags and checking”
Equipment Safety Guard Program
Work examples:
1. Automatic turning-turret multi-spindle, copying, jig-boring,
Gear planing machines - average repair, installation, adjustment, accuracy testing, start-up and
commissioning.
2.Speed boxes for semi-automatic lathes - assembly and switching with mutual fit
splined rollers and gears.
3. Hydraulic feed mechanisms of metalworking machines - repair and adjustment.
4. Gear-shaping and gear-planing machines with complex curved guides -
checking for accuracy.
5. Machines with program control - testing for rigidity.
Qualification characteristics
Profession: repairman. Qualification - 6th category
Characteristics of the work of a mechanic-repairman of the 6th category:
Repair, installation, dismantling, testing and adjustment of particularly complex, large-sized, unique equipment.
A 6th category repairman must be able to:
1. Identify and eliminate defects during equipment operation and during in-process inspection
repair.
2. Check repaired equipment for accuracy and load test it.
3. Comply with the requirements of labor protection rules.
A 6th category mechanic/repairman must know:
1. Design features, kinematic and hydraulic diagrams of the repaired
equipment.
2.Methods of repair, assembly, installation, accuracy testing and testing of repaired
equipment.
3. Permissible loads on working parts, components, equipment mechanisms and preventive
measures to prevent breakdowns, corrosive wear and accidents.
4. Instructions and regulations on labor protection:
IOT “When cold processing of parts on metal-cutting machines.”
IOT “For mechanics installing and repairing mechanical equipment. equipment."
IOT “Working with portable hand-held power tools, electric hand-held machines and portable lamps”
IOT “Working with abrasive tools”
P-OT “Regulations on the procedure for workers to act in emergencies”
P-OT “Fall protection”
P-OT “Procedure for disconnecting, blocking and locking energy, posting warning tags and checking”
Equipment Safety Guard Program
Work examples:
1. Automatic multi-spindle lathes - cap. repair.
2. Jig boring machines - restoration of coordinates.
3. Machines with program control - checking for accuracy, restoring coordinates, repairs,
trial.
4. Electric pulse machines - repair.
Thematic plan and theoretical training program:
| Themes |
Number of hours |
|||
| 1 | Introduction | |||
| 2 | Safety precautions, industrial sanitation and fire safety | |||
| 3 | Plumbing | |||
| 4 | Basics general technology | |||
| 5 | Tolerances, landings | |||
| 6 | Reading blueprints | 2 | ||
| 7 | Instrumentation and measurement technology | 8 | ||
| 8 | Information from technical mechanics | |||
| 9 | Information from electrical engineering | |||
| 10 | Technological process for repairing industrial equipment | |||
| 11 | Mechanization and automation of production | |||
| 12 | Qualifying exam | |||
| TOTAL: | ||||
Theoretical training program
Topic 1. Introduction
Basic information about production and workplace organization. Familiarization with qualification characteristics and training program.
Topic 2. Hazard-free technology, industrial sanitation and fire safety.
Responsibilities of workers in the field of labor protection. Production technology. Requirements for the workplace, equipment, hand tools.
Safety rules for cold working of metals. Safety precautions before starting work, during work, after finishing work. Accidents and analysis of injury cases. Responsibility.
Electrical safety. Electric shock hazard. Cases of damage to el. electric shock Methods for freeing the victim from the effects of email. current and first aid. Basic rules for the design and operation of equipment. Safe voltage. Procedures for disconnecting, blocking and locking out energy, and posting warning tags.
Industrial sanitation. Tasks of industrial sanitation. Occupational diseases and their main causes. Prevention of occupational diseases. Basic preventive and protective measures. Personal protective equipment, personal hygiene. Self-help and first aid in case of accidents. Medical and sanitary services for workers at the enterprise.
Work at height. Purpose, types of equipment and fall protection. Requirements for personal protective equipment against falls: carabiners, slings, webbing belts. Application, control methods. Documentation drawn up when organizing work at height.
Instructions for accessing confined spaces, performing work in them and conducting rescue operations. Regulation of entry into the ZP, practice of conducting work in it. Drawing up a work order for high-risk work.
Procedure for reporting and reporting an incident.
Fire prevention measures. The main causes of fires in workshops and on the territory of the enterprise.
Fire prevention measures. The use of open fire is prohibited. Fire stations, fire protection, fire-fighting devices, devices, alarms. Chemical fire extinguishing agents and rules for their use. Rules of behavior when staying in fire-hazardous places during fires. The procedure for workers to act in the event of an alarm, actions in an emergency.
Topic 3 Plumbing
Planar markings.
Purpose of marking. Tools and devices for marking, types, purpose and arrangement.
Planar marking process. Separation of marking order, methods of marking, checking marking and punching of parts. Marking according to drawings and templates. Marking from edges and center lines.
Safety precautions when marking.
Metal cutting.
Chisels and crosspieces, their design and dimensions. Sharpening angles for various metals being processed, bench hammers. Rational techniques manual cutting various metals.
Safety precautions when cutting metals.
Metal straightening and bending.
Methods and rules for straightening sheet, strip and round material and pipes. Tools and devices used for straightening. Possible defects during editing and measures to prevent them.
Purpose and application of bending. Rules and methods for bending sheet, strip and round materials, as well as pipes at various angles and radii. Equipment, tools and devices for bending. Safety precautions when straightening and bending.
Metal cutting.
Purpose, techniques and methods of cutting metal with a hacksaw, manual, disk, pneumatic, electric and other scissors, disk and band saws, abrasive wheels. Rules for using tools and mechanisms.
Safety precautions when cutting metal and pipes.
Metal filing
Allowance for filing. Files. Types and purpose of files. Filing techniques various surfaces details.
Safety precautions when filing.
Drilling, countersinking, reaming holes.
Tools and devices used for drilling. Drill design. Sharpening angles, drills for processing various metals. Installation, fastening and removal cutting tools. Installation and fastening of parts. Drilling along the contour and according to the markings. Drilling during reaming. Selection of drills.
Safety precautions when drilling
Countersinking of holes.
Design of countersinks and their operation. Cooling and lubrication during countersinking.
Safety precautions for countersinking
Reaming holes.
Deployment purpose. Deployment is manual and mechanical. Methods for deploying cylindrical and conical holes. Allowances for deployment.
Deployment Safety.
Thread cutting.
Thread profiles. Cutting tools external thread their design. Cutting tools internal thread, their designs. Mechanization of thread work.
Safety precautions when cutting threads.
Scraping.
The main types of scraping, techniques and methods for scraping planes. Techniques and methods for scraping curved surfaces. scraper for specified types scraping and rules for working with them. Methods for determining scraping accuracy. Sharpening and refilling scrapers.
Safety precautions when scraping
Lapping.
The process and types of lapping, the achieved degree of accuracy and tightness. Grinding materials, tools and devices used for lapping. Lapping allowance.
Safety precautions during lapping.
Riveting.
Purpose and use of riveting. Types of rivet seams. Types of rivets. Tools and devices used for riveting. Techniques and methods of riveting.
Safety precautions when riveting.
Pressing in and pressing out.
Tools, devices and equipment used for pressing and pressing (manual and mechanical).
Safety precautions when working on the press.
Purpose of power tools.
Preparing the tool for work. Abrasive tools and materials, types and purpose. Storage, transportation, distribution of abrasive and mechanized tools.
Safety precautions when working with hand-held power tools.
Topic 4. Fundamentals of general metal technology
Fundamentals of general metal technology. Basic information about metals and their properties. Ferrous and non-ferrous metals. The meaning and use of metals in national economy. Basic physical, chemical and mechanical properties of metals. The concept of testing metals.
Cast irons, their features, properties, scope of application, markings. Become. Production methods. Carbon steels, their chemical composition, mechanical and technological properties. Markings, application.
Alloy steels. Influence of alloying elements on the quality of steels. Mechanical and technological properties of alloy steels. High speed steels. Steel with special properties(heat-resistant, stainless). Markings of alloy steels and their application.
Thermal and chemical-thermal treatment of steels. Essences and types of heat treatment. Hard alloys. Their types, labeling and application.
Non-ferrous metals and alloys. Abrasive materials, marking and application.
Topic 5 The concept of tolerances and fits.
System of tolerances and landings according to OST as the basis for ensuring interchangeability. Unified system of admissions and landings. Tolerances for linear and angular dimensions. The concept of qualifications and degrees of accuracy. Plantings, their types and the purpose of planting schemes. Designation of fits and tolerances on drawings. Surface roughness. Surface cleanliness classes. Designation of cleanliness classes, on the drawings.
Topic 6 Reading drawings
Drawings and sketches of parts. Rectangular projections. Construction of the third projection based on two data. Analysis of drawings. Inscriptions on drawings. Scale. Dimensions, designation of diameters and squares, symbol threads, bolts, nuts. Rules for drawing up sketches and assembly drawings. Sections, sections and extensions on assembly drawings.
Topic 7 Instruments and measurement techniques
Measurement accuracy, factors affecting measurement accuracy.
Measuring tools used by a mechanic - repairman.
Vernier calipers, vernier depth gauge and height gauge with measurement accuracy of 0.1 and 0.05 mm. The device of the vernier, the accuracy of reading on it.
Measurement techniques. Tools for checking and measuring angles; templates, squares and universal protractors, rules for using them. Tools for thread inspection (ring and plug gauges, templates). Errors in measurement, causes of their occurrence and methods of prevention.
Topic 8 Information from technical mechanics.
Strength of materials. Operating conditions for machine parts. Actions external forces to structural elements. Internal forces and tensions. Margin of safety. General concepts about tensile and compressive deformation, bending, and torsional shear.
Topic 9 Information on electrical engineering
Basic laws of direct current. Alternating current. Electric motors and control gear. Electronic devices, their application. Issues of energy saving in relation to the equipment being serviced.
Topic 10 Technological process of repair of industrial equipment
General information about equipment repair.
Requirements for the operation of enterprise equipment. Wear and tear of equipment is the most important reason for disruption of its normal operation. Changes in the shape and size of equipment parts as a result of wear. The concept of permissible limits of equipment wear.
System of planned preventive maintenance (PPR). Its importance for maintaining equipment in good condition.
Frequency of overhaul maintenance, inspections and repairs. Sequence of equipment repair work. The concept of methods of installation and dismantling of industrial equipment.
Technological processes for repairing standard parts and assemblies
industrial equipment. Preparing equipment for repair. Disassembly. Washing and marking of parts and assemblies. Repair of fixed connections and pipelines. Typical defects of various fixed joints and the reasons for their occurrence. Repair methods.
Pipes and flanges, gaskets, fittings, taps and valves. Materials for compaction. Pipeline repair methods, individual parts and pipeline parts.
Repair of parts of translational motion mechanisms. Wear of parts with guide surfaces. Types and methods of repair Methods of checking for accuracy, straightness, correct location of guide surfaces.
Repair of mechanism parts rotational movement. Identification of defects and methods for repairing shafts and axles. Replacing spindles. Essential elements gearing. Examples of repair of gear and worm gear parts. Characteristic wear and defects in the operation of sprockets and chain drives. Repair methods.
Topic 11 Mechanization and automation of production
Hydraulic copiers. Clamping devices to machines with hydraulic power drive.
Pneumatic devices. Compressors, their purpose and operating principle. Electrical devices. Electric drills, electric files, electric impact wrenches and other electrified tools.
Replacement of manual filing, scraping and stripping with mechanical processing (milling, turning, grinding) using universal portable machines.
Topic 12 Qualifying exam
Thematic plan and industrial training program
| No. | Themes | Amount of days | |||
| 1 | Workplace safety briefing | ||||
| 2 | Learning plumbing | ||||
| 3 | Training in plumbing repair work | ||||
| 4 | Carrying out equipment repair work independently | ||||
| 5 | Qualifying trial work | ||||
| TOTAL: | |||||
Industrial training program
Topic 1 Training on TB in the workplace
Instruction on safety precautions at the workplace.
Familiarization with production process workshops and equipment.
Topic 2 Study of plumbing work
Study of work involving marking, cutting, straightening, bending and cutting. Familiarization with the equipment of a mechanic's workplace. Study of work involving filing of planes and curved surfaces.
Study of work involving drilling, countersinking and reaming of holes.
Exercises in controlling a vertical drilling machine. Metalworking of various production parts according to accuracy classes 5-7, including studied operations and types of work.
Topic 3 Training in plumbing and repair work
Disassembling components and mechanisms of the equipment being repaired, cleaning and washing parts, inspecting and checking their condition.
Repair of components and parts: replacing bolts, screws, studs and nuts, correcting crumpled threads, scraping guide surfaces, as well as performing other plumbing work to repair equipment.
Topic 4 Independent performance of equipment repair work
Independent performance of repair work in accordance with the requirements of the qualification characteristics of mechanics - repairmen of 3-4, 5-6 categories.
Mastering advanced working methods, established standards time, subject to compliance with production and technical instructions for the work performed and safety regulations. All work is performed independently under the supervision of an industrial training instructor.
Topic 5 Qualifying exam
List of used literature:
Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Part No. 2 of Issue No. 2 of ETKS
The issue was approved by Resolution of the Ministry of Labor of the Russian Federation dated November 15, 1999 N 45
(as amended by Order of the Ministry of Health and Social Development of the Russian Federation dated November 13, 2008 N 645)
Characteristics of work. Disassembly, repair, assembly and testing of simple components and mechanisms of equipment, units and machines. Repair of simple equipment, units and machines, as well as of medium complexity, under the guidance of a more highly qualified mechanic. Mechanical processing of parts for 12 - 14 qualifications. Washing, cleaning, lubricating parts and removing the fill. Perform work using pneumatic, electric tools and drilling machines. Scraping parts using power tools. Manufacturing of simple devices for repair and assembly.
Must know: basic techniques for performing work on disassembling, repairing and assembling simple components and mechanisms, equipment, units and machines; purpose and rules for using plumbing and instrumentation; basic mechanical properties of processed materials; system of tolerances and landings, qualities and roughness parameters; name, marking and rules for using oils, detergents, metals and lubricants.
Work examples
1. Open hearth furnace fittings, chokes, shut-off valves - removal, repair, installation.
2. Bolts, nuts, studs - filing, threading, changing them and fastening them.
3. Shut-off valves for air, oil and water - installation to suit the location.
4. Filling windows, lid lifter ropes and transfer devices - change.
5. Elbows, tees for pipelines - hydraulic testing and assembly.
6. Lubricators, linear feeders - repair, adjustment.
7. Oil coolers - disassembly, repair, assembly.
8. Piston pumps - repair, installation.
9. Equipment - neutralization from acidic and alkaline environments.
10. Fences - removal and installation.
11. Gaskets - manufacturing.
12. Gearboxes of tumbling drums - disassembly, repair and assembly.
13. Metal mesh - replacement, production, repair.
14. Sharpened emery machines and vacuum cleaners for them - repair, assembly, replacement and straightening of abrasive wheels.
15. Dowels - filing.
16. Creels of warping machines - repair and installation on the machine.
Characteristics of work. Disassembly, repair, assembly and testing of medium complexity components and mechanisms of equipment, units and machines. Repair, adjustment and testing of medium complexity equipment, units and machines, as well as complex ones under the guidance of a mechanic of higher qualifications. Mechanical processing of parts for 11 - 12 qualifications. Repair of lined equipment and equipment made of protective materials and ferrosilicon. Disassembly, assembly and compaction of faolite and ceramic equipment and communications. Manufacturing of devices of medium complexity for repair and assembly. Performance rigging work when moving loads using simple lifting equipment and mechanisms controlled from the floor.
Must know: arrangement of equipment being repaired; purpose and interaction of main components and mechanisms; technological sequence of disassembly, repair and assembly of equipment, units and machines; technical specifications for testing, adjustment and acceptance of components and mechanisms; basic properties of processed materials; arrangement of universal devices and used control and measuring instruments; system of tolerances and landings, qualities and roughness parameters; rules for slinging, lifting, moving loads; rules for operating lifting equipment and mechanisms controlled from the floor.
Work examples
1. High vacuum vacuum units for installations of medium complexity - repair.
2. Valves of all diameters - valve grinding.
3. Fans - repair and installation.
4. Inserts - fitting and filing along parallels.
5. Gas pipelines - sealing suction points with diabase putty and oil bitumen.
6. Chutes for pouring cast iron - replacement.
7. Complex casings and frames - manufacturing.
8. Metal conveyors - replacement of rollers.
9. Speed and feed boxes in metalworking machines of medium complexity - assembly and adjustment.
10. Blades, beaters, shafts, conveyor plates, turns of augers - straightening.
11. Lunettes - repair.
12. Tool magazines, automatic tool changers - repair, adjustment.
13. Winding machines (textiles) - major repairs of plates, lifting arms, cranks, spindles.
14. Filling machines - repair of conveyor chains, replacement of molds.
15. Coal loading machines - assembly and installation of a brake device with a lever.
16. Mills, screens, drying drums - current repairs.
17. Centrifugal pumps - repair, installation.
18. Semi-automatic welding machines, installations - medium and current repairs.
19. Gas-electric cutters - replacement of tips with centering of electrodes.
20. Sieves and knives - removal, installation and adjustment.
21. Woodworking machines - current repairs.
22. Weaving machines - changing lower shafts and clamps.
23. Lathes - complete repair of longitudinal and transverse slides, supports.
24. Heat exchangers - repair, assembly.
25. Pipelines - disassembly.
26. Spindle positioning devices - adjustment.
27. Slag trucks - inspection, lubrication and repair.
28. Electric furnaces - disassembly and repair.
Characteristics of work. Disassembly, repair, assembly and testing of complex components and mechanisms. Repair, installation, dismantling, testing, regulation, adjustment of complex equipment, units and machines and delivery after repair. Mechanical processing of parts and assemblies according to 7 - 10 qualifications. Manufacturing of complex devices for repair and installation. Preparation of defect reports for repairs. Carrying out rigging work using lifting and transport mechanisms and special devices.
Must know: installation of repaired equipment, units and machines; rules for regulating machines; methods for eliminating defects during repair, assembly and testing of equipment, units and machines; device, purpose and rules of use of the control and measuring instruments used; design of universal and special devices; methods for marking and processing simple various parts; system of admissions and landings; qualities and roughness parameters; properties of acid-resistant and other alloys; basic provisions for preventive maintenance of equipment.
Work examples
1. Devices column type- repair, assembly.
2. Oxygen and argon equipment for electric melting furnaces - repair, maintenance.
3. Shut-off valves - inspection, repair, installation.
4. Vibrating screens - replacement of whitefish.
5. Gas ducts - replacement of dampers.
6. Scrubber seals - adjustment.
7. Hydraulic boosters, hydraulic motors - repair, assembly, testing.
8. Multi-position automatic heads - repair, adjustment.
9. Granulators - replacement of lining and sides.
10. Crushers - repair with replacement and adjustment of worn parts, adjustment of crushing size.
11. Calenders, universal and rotary ironing presses - repair and adjustment.
12. Oxygen booster compressors - current and medium repairs.
13. Spindle cones - checking and restoration by lapping.
14. Speed and feed boxes of metalworking machines - assembly and adjustment.
15. Steam and hot water boilers - repair.
16. Drilling machines - installation and installation.
17. Die casting machines - repair.
18. Charging machines for open-hearth furnaces - alignment of columns along the vertical axis and level, repair of the rolling and rotating mechanism of the trunk.
19. Spinning machines - major repairs and adjustments.
20. Sewing machines - current and major repairs.
21. Mills, screens, drying drums - average repair.
22. Deep and sucker rod pumps - repair and assembly.
23. Caps for converter necks - dismantling, installation.
24. Fuel oil equipment - repair.
25. Equipment of preparatory workshops (areas) for production vegetable oils and apparatus for fat processing plants - assembly, adjustment and testing.
26. Pneumatic pumps, smoke exhausters, exhausters - repair.
27. Critical bearings - filled with babbitt and scraped.
28. Gearboxes of rotary kilns, steam mills, conveyors, plate conveyors, feeders - repair.
29. Air converter and water jacket systems - adjustment, major repairs.
30. Mixers and sulfurizers - replacement of shafts and couplings.
31. Woodworking and metal-cutting machines - major repairs, adjustment.
32. Weaving machines - major repairs and adjustment of the weft mechanism.
33. Sectional and spindle turbodrills - repair, assembly, adjustment, testing.
34. Pig stackers - repair with replacement of parts.
Characteristics of work. Repair, installation, dismantling, testing, regulation and adjustment of complex equipment, units and machines and delivery after repair. Mechanical processing of parts and assemblies according to 6 - 7 qualifications. Disassembly, repair and assembly of components and equipment in conditions of intense and dense landings.
Must know: design features of the equipment, units and machines being repaired; technical conditions for repair, assembly, testing and regulation and for the correct installation of equipment, units and machines; technological process of repair, assembly and installation of equipment; rules for testing equipment for static and dynamic balancing of machines; geometric constructions with complex markings; methods for determining premature wear of parts; methods for restoring and strengthening worn parts and applying a protective coating.
Work examples
1. Automatic multi-spindle turret lathes, copying machines, jig boring machines, gear planing and roll lathes - average repair, installation, adjustment, accuracy testing, start-up and commissioning.
2. High-pressure units (synthesis columns), separators, evaporators, water condensers, refrigerators - current and medium repairs.
3. Distillation and distillation devices - major repairs.
4. Apparatuses, high-pressure gas pipelines - inspection, repair and testing.
5. Complex film projection devices and developing machines - average repair.
6. Oxygen and argon equipment for open-hearth furnaces - repair, maintenance.
7. Gas blowers - overhaul and testing.
8. Vacuum drying and ironing rollers - repair and adjustment.
9. Gearboxes of semi-automatic lathes - assembly and switching with mutual fitting of splined rollers and gears.
10. Oxygen booster compressors - major repairs.
11. Lifting machines - repair, adjustment and leveling of crane tracks.
12. Machines for sorting letters - repair.
13. Charging machines for open-hearth furnaces - complete repairs with replacement of the shaft, adjustment of all mechanisms.
14. Loading machines - inspection of the movement and rotation mechanism, disassembly, assembly, alignment and replacement of parts.
15. Automated washing machines - repair and adjustment.
16. Mills, screens, drying drums - overhaul, testing, adjustment and delivery.
17. Hydraulic feed mechanisms of metalworking machines - repair and adjustment.
18. Mechanisms of hydraulic pipelines of machine tools - repair, assembly, adjustment.
19. Vacuum and fore-vacuum pumps - major repairs.
20. Blast furnaces - installation of an inclined bridge.
21. Reactors - repair.
22. Gearboxes for rotary kiln cranes and differential gearboxes for rolling mills - inspection, repair.
23. Robots and manipulators with program control with a repair complexity category of up to 20 units. - major repairs, adjustment.
24. Deep drilling rigs - repair.
25. Gear grinding, gear shaping, gear planing machines with complex curved guides - checking for accuracy.
26. Computer controlled machines - testing for rigidity.
27. Volumetric turbodrills, geared, jet-turbine, high-torque, with precision casting turbines - repair, assembly, installation, regulation, testing.
28. Vacuum evaporation units - disassembly, repair, assembly.
29. Cylinders, main and connecting rod bearings - check after running in and final fastening of all connections.
30. Economizers, steam superheaters, compressor and blower units - major repairs, delivery after testing.
31. Electric and ore-smelting furnaces - checking the alignment of the lifting screws, conveyor and fit of the furnace body on all four columns.
Characteristics of work. Repair, installation, dismantling, testing and regulation of complex large-sized, unique, experimental and experimental equipment, units and machines. Identification and elimination of defects during equipment operation and during inspection during repairs. Accuracy and load testing of repaired equipment.
Must know: design features, kinematic and hydraulic diagrams of the equipment, units and machines being repaired; methods of repair, assembly, installation, accuracy testing and testing of repaired equipment; permissible loads on operating parts, components, equipment mechanisms and preventive measures to prevent breakdowns, corrosive wear and accidents.
Work examples
1. Automatic multi-spindle lathes, semi-automatic multi-tool vertical lathes - major overhaul.
2. Hydraulic equipment - repair and adjustment.
3. Complex film projection devices and developing machines - major repairs.
4. Rolling mill stands - inspection, adjustment, testing and delivery after repair.
5. Automatic lines of all processing profiles, having complex units - major and medium repairs.
6. Automatic molding lines - major repairs, assembly, adjustment and delivery.
7. Complex mechanized lines for flour and confectionery, pasta and bakery products and automatic lines in perfumery and cosmetics production - repair and adjustment.
8. Sintering machines - regulation of machine movement and thermal clearance, alignment of the drive along the axis of the head radius.
9. Skip and cage mine lifting machines - repair, testing, delivery.
10. Precision equipment - repair, delivery.
11. Ore-smelting furnaces - overhaul of the contact system and rejection of defective parts.
12. Tubular furnaces - coil testing.
13. Hydraulic presses - major and medium repairs.
14. Steam-hydraulic presses - major repairs.
15. Robots and manipulators with program control with a repair complexity category of over 20 units. - installation, repair, adjustment.
16. Aggregate, drum-milling and special machines, automatic and semi-automatic special grinding machines for turning and grinding cam and conical shafts - repair.
17. Jig boring machines - restoration of coordinates.
18. Machines with program control - checking for accuracy, restoring coordinates, repair, testing.
19. Electric pulse machines - repair.
20. Supercentrifuges, imported paint grinding machines, planetary gearboxes, rotary vacuum pumps - repair.
21. Turbochargers - major repairs and delivery.
22. Air separation units - major repairs.
23. Launching device for launching ships - major repairs, alignment and regulation.
24. Refrigerators, high-pressure units (synthesis columns), separators, evaporators, water condensers - major repairs.
25. Extractor, small press, automatic and semi-automatic (dosing, cutting, packaging, etc.), compressors - assembly, adjustment and adjustment.
26. Electric furnaces, water jackets, converters - adjusting hydraulic equipment and checking the completeness of repairs.
Characteristics of work. Diagnostics, prevention and repair of complex equipment in flexible production systems. Elimination of equipment failures during operation by performing a range of works on repair and adjustment of mechanical, hydraulic and pneumatic systems.
Must know: design features, hydraulic and kinematic diagrams of complex equipment being repaired; methods of diagnostics, repair, assembly and installation, accuracy testing and testing of repaired equipment; permissible loads on operating parts, components, equipment mechanisms and preventive measures to prevent malfunctions; technological processes of repair, testing and commissioning of complex equipment.
Characteristics of work. Diagnostics, prevention and repair of unique and experimental equipment in flexible production systems and participation in the work to ensure that it reaches the specified operating parameters.
Must know: design, kinematic and hydraulic diagrams of experimental and unique equipment being repaired; instrumentation and stands for diagnosing, repairing and servicing equipment; technological processes repair of unique and experimental equipment.
Secondary vocational education required.
Note. The 7th and 8th categories of this profession are assigned only when working in pre-production workshops, in experimental and experimental workshops.
