maintenance of dyeing machine

Maintenance

Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013)Department : Wet Processing Technology Email: [email protected] : www. Textilelab.blogspot.com (visit)

Southeast University Department Of Textile Engineering

I/A 251,252 Tejgaon Dhaka Bangladesh

Prepared By :

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Maintenance

Maintenance is the actions taken to prevent a device or component from failing or to

repair normal equipment degradation experienced with the operation of the device to

keep it in proper working order.

Maintenance:

Classification of Maintenance:

1. Reactive/ Break down Maintenance.

2. Preventive/ Schedule Maintenance.

3. Predictive/ Planned Maintenance.

4. Capital replacement/ Restorative.

Types of Maintenance:

REACTIVE/ BREAK DOWN MAINTENANCE:Reactive maintenance is basically the “run it till it breaks” maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached.

Advantages: Low cost Less staff

Disadvantages: Increased cost due to unplanned down time of equipment. We are spending more dollars associated with capital cost because, while waiting for

the equipment to break, we are shorting the life of the equipment resulting in more frequent replacement or repair.

If it is a critical piece of equipment that needs to be back on line quickly, we will have to pay maintenance overtime cost.

Possible secondary equipment or process damage from equipment failure.

PREVENTIVE/ SCHEDULE MAINTENANCE:Preventive maintenance can be define as action performed on a time or machine-run-based schedule that detect, preclude or mitigate degradation of a component or system with the aim of sustaining or extending its useful life time to an acceptable level.

Advantage: Increase component life cycle. Flexibility allows for the adjustment of maintenance periodicity. Reduced equipment or process failure and estimated 12% to 18% cost savings over

reactive maintenance program.

Disadvantage: Labor intensive. Increased performance of unneeded maintenance. Potential for incidental damage to components in conducting unneeded

maintenance.

PREDICTIVE/ PLANNED MAINTENANCE:Predictive maintenance can be define as measurement that define the degradation of machine, thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicate current and future functional capability.Basically, predictive maintenance differs from preventive maintenance by basing maintenance need on the actual condition of the machine rather than on some preset schedule.

Advantage: Increased component operational life and availability. Allows preemptive corrective actions. Decrease in equipment or process downtime and estimated 8 to 12% cost savings

over preventive maintenance program. Better product quality. Improved worker and environmental safety. Decrease in cost for parts and labor.

Disadvantage: Increased investment in diagnostic equipment. Increased investment for proficient manpower and staff training. Savings potential not readily seen by management.

CAPITAL REPLACEMENT/ RESTORATIVE:If it is seen that the repairing cost of machine or machine parts is more or equal or little less than buying a new one, then the old one is replaced instead of repair. It is known as capital replacement.

1. To keep the factory plants, equipment, machine tool etc. in optimum working condition.

2. To ensure accuracy of product and time schedule to delivery customers.

3. To minimize down time of machine.

4. To prolong the useful life of factory plant and machine.

5. To modify or improve productivity of existing machine to meet the need for production and thus avoid sinking of additional capital.

OBJECTIVE/ ADVANTAGE OF MAINTENANCE:

1. Inspection or check-ups:

2. Crews kept for inspection should be well trained.

3. External inspection means to detect defects from abnormal sound, vibration, heat, smoke etc.

4. Internal inspection means to check internal parts of the machine.

5. Lubrication:6. Systematic lubrication means the application of right type of lubricant at right time at

right place and in right quantity.

7. It is done to minimize friction and reduce decay of machine parts.8. Planning and scheduling:

9. Every preventive maintenance work should be pre planned.

10. The program is specified in detail by mentioning daily, weekly and yearly attention.

11. Records and analysis:

Following are some important functions of maintenance department:

Operation manual

Maintenance instruction manual

History cards and history register

Inspection register

Log books

Defects register etc.

Training of maintenance personnel: The technician and supervisors of maintenance department should be well trained in a

systemic way.

Storage of spare parts: It is essential to store some essential spare parts which are needed every now and to

keep the machine running and reduce stoppage time for machine defects.

Following records are generally maintained:

1. Good supervision and administration of maintenance departments.

2. Operators should be well trained.

3. Proper maintenance record should be maintained.

4. Adequate stock of spare parts should always be kept.

5. Manufacturer of the machine tools should be consulted as and when required.

6. Maintenance department should remain in contact with planning and purchasing department deciding the type of machine tools to be purchased.

Requirements of good maintenance:

1. Dismantles equipment and removes worn or defective parts, using hand tools.

2. Replaces defective parts, such as plugs, reeds, needles, points, shuttles, cots, chains, heddles, slide rods, and side or frame hooks.

3. Adjusts parts and tension on parts, such as rollers, chains, and cylinders, using hand tools and gauges.

4. Repairs defective parts, such as flats, wires, shuttles, collars, frames, chains, and rollers, using hand tools and soldering and welding equipment.

5. Aligns, straightens, spaces, and levels parts, using hand tools, straightedge, level, and plumb bob.

6. Replaces worn covering (rubber, cork, leather, cloth, felt) on cylinders, rollers, and roller arbors, using hand tools and arbor press.

Tasks of the maintenance departments: -

7. Inspects and examines textile machines and equipment to detect defects, by observing or listening to machine or using micrometers and feeler gauges.

8. Verifies accuracy of part repair or replacement, adjustment, or alignment.

9. Installs special attachments to equipment.

10. Lubricates machinery and equipment.

11. Smoothes and polishes equipment, using abrasives and buffing, sanding, and grinding machines.

12. Cleans equipment with solvent, brushes, and airhose to remove dirt, lint, oil, and rust.13. Maintains parts and equipment inventory, receipt, and transfer records.

14. Moves equipment and machine components, using hoists, rollers, and handtrucks.

15. Sorts and stores parts and equipment according to type or size.

Tasks of the maintenance departments: -

There are different steps in wet processing technology. Now we are going to describe about the steps in textile wet processing system where maintenance needed.

Inspection: Neps, warp, end breakage, weft end breakage, hole spot remove.

Singeing: Projecting or floating fiber remove from the surface of the fabric.

Desizing: It’s done to remove the sized materials from the fabric.

Scouring: Using alkali ( NaOH, Na2CO3) for increasing absorbency of fabric.

Bleaching: The bleaching process is done to produce Permanent white of the fabric

Dyeing: Dyeing is the procedure done for producing color to the textile materials. There are lots of methods in dyeing. But it can be classed as three byes the normal method. Like 1. Yarn dyeing, 2. Fabric Dyeing, 3. Garments Dyeing,

Mercerizing: To maintain the proper length and width of the fabric.

Printing: Specific Color on the fabric

Finishing: Soft finish for consumer satisfaction.

Here the problem in the process and their maintenance are given below: -

Singeing machine: -When the changeable parts are changed and the replaceable parts are replaced then the flame intensity will uniform, the distance between the flame and the fabric will in the accurate distance. The bearing, motors and other maintenance parts will do their optimum jobs.

Desizing: -In the Desizing machine after good maintenance the machine parts will do their optimum jobs. The bearings, motors, the rollers, the guide roller and other parts will give better efficiency after change or replace the defective parts.

Scouring: -There is lots of roller in the scouring machine and bearings and motors. After doing good maintenance in the scouring machine the problems that caused by the defective elements will reduced.

Bleaching: -Now a day’s generally scouring and bleaching is done at a time or in the same machine. So the when the machine is under maintenance department that time the problems which induced in the bleaching time is reduced.

Efficiency: -

DYEING: -

In the dyeing machine there are lots of problems occurred by the defective roller,

bearings, winch, heating elements, motor, and inside surface of the machine. After

doing the solution of these problems the problems what induced by this defective

elements is reduced.

FINISHING: -

In the finishing section there are lots of finishing sections like calendaring, stentorian,

slitting, compactor and other machineries. There are lots of replaceable and change

able parts that given in the chart. After completing the changing or replacing the

defective parts the machine running is normal and natural and the defects that occurs

by the defective materials is reduced.

Efficiency: -

CONCLUSION:

Wet processing of textiles constitutes innumerable steps leading to finished product, each

having a number of complex variables and every lot is like a new lot and much depends on the

well-trained manpower rather than modern machines and technology. However, developments

are taking place at a rapid pace to satisfy the user with quality product and competitive price.

Though underlying principle for developments is satisfying user needs. This in turn will impart

cost competitiveness. Then, more functional finishes are also being developed. However trend is

to use more mechanical finishes than chemical finishes. The key to success in textile wet

processing technology will be the indication of highly trained.

MAINTENANCE : ELECTRICAL

SL NO. Items needs to be checked & serviced1 Check main panels2 Check panel cooling fan & clean its filter3 Clean main pump inverter & its cooling fan4 Check all circuit breaker ,magnetic conductors & relays5 Check current setting of all circuit breaker & motor over load6 Visual checking of all power & control cables7 Check ail motor’s terminals8 Check & clean fluff & dirt at all motor fan covers9 drive of kneel motors

10 Check all pressure switches11 Check calibration of main vessel & all addition tank12 Check all signal isolators13 Check setting & operation of lid safely switches14 Check setting of tangle sensors15 Check all pneumatic solenoids16 Check all indicating lamps 17 Check calibration of heating/ cooling modulating valve 18 Check all on/off switches

Power on/off.↓

MPF/Positive feeder current line off.↓

MPF belt out/loss.↓

Yarn cut.↓

Fabric out by handle.↓

Cleaning and Oiling.↓

Cam box out.↓

Needle & sinker out.↓

Needle & sinker cleaning by oil.↓

Cam box cleaning by air.

After opening & cleaning, machine is leveled by using leveling meter and follows the reverse process to ready the machine.

Maintenance Sequence of Circular Knitting Machine:

YEARLY MAINTENANCE CHECK LIST

DEMAG MONORAIL HOISTGrease all the moving parts and bearingsCheck all the nut and boltsCheck oil levelCheck each sprocket, chain and chain collector are okCheck the thickness of the linesCheck visually the damage of main girders

PRESSING MACHINE Check rotating table balls and lubricate. Lubricate the axial bearings

YARN SINGEING MACHINE Clean control cabinet using a vacuum cleaner. Do not touch the circuit card and soldering joints. Every 4 year change the battery on the RAM card.


SANTEX COMPACTOR MACHINE Check the machine for visual damages. Replace the worm reduction gear oils. Check the compacting shoes for wearing. Check the blankets for wearing. Check the foundation bolts of the machine.

FABRIC DYEING MACHINE Check the machine for visual damages. Drain & replace the main pump bearing oil. Drain & replace the oil of gearboxes. Check and if necessary replace all plaiter bearings balls. Check the platter/ J-box center alignment Check the manhole O-ring. Check and grease all greasing points. Check and tight all plaiter, catch basket, reel and other support bolts from the

inside of the machine. Check all the PTFE carbon supports and sleeves in the plaiting device system

inside the machine


SANTEX COMPACTOR MACHINE Check the machine for visual damages. Replace the worm reduction gear oils. Check the compacting shoes for wearing. Replace if necessary. Check the blankets for wearing. Check the foundation bolts of the machine.

DORNIER MERCERIZING MACHINE Grease all the bearings and moving parts. Check the bearing bolts and replace them if necessary. Change the gear oil of the gear boxes Check the rubber coating of the fixation & drive rollers Complete check of the cooling plant Check the spray rings, piping and armatures Check the pneumatic piping for proper connection Check and retighten the electric connections of machine Replace the chains and the chain wheels of the drives

HALF YEARLY MAINTENANCE

ALEA HANK DRYER MACHINE Adjust the chain tension and lubricate it Check the oil level of the gear box Change the gear oil once a year Lubricate the bearings with grease

CALATOR RUCKH INSPECTION MACHINE Lubricate chain and adjust the tension. Grease all the bearings. Change gear oil once a year.

PRECISION WINDING MACHINE Clean the cable channels and electric cabinet Clean the flyer set and displacement unit Check certain Every 5 year replace buffer batteries on the control cabinet

HALF YEARLY MAINTENANCE

LORIS BELLINI HANK DYEING MACHINE

Clean and check the compressed air filter.

Check the pneumatic cylinders.

Tightening of every bolt.

Tightening of foundation bolts.

Check and replace the roller bearings if necessary.

Maintenance for piston pneumatic valves.

Tightening of terminals of electric motors.

Tightening of terminals of electric boards.

Yarn singeing machine

Check condition of variator, remove any wound on thread.

Check automatic contrails of all sensors.

TWO MONTHLY MAINTENANCE

STALAM YARN DRYER

Check inside of the panel

Check the nut, bolts and belts of dryer

Grease the roller support every 4 month

MONTHLY MAINTENANCE CHECK LIST

ASSEMBLY WINDING MACHINE• Check the cone holder's looseness• Clean the inverters• Clean the yarn path properly• Check the package diameter sensor

JAEGGLI YARN MERCERIZING MACHINE• Grease hooks draught bearings. (B)• Grease function bearings of the squeegee roller (H)• Grease fulcrum bushes of the lifting cylinder(L)• Check the hydraulic oil pressure

LORIS BELLINI HANK DYEING.• Inspection of wear and tear of lid gasket• Lubricate the electric motors.• Check the mechanical seals of add pumps• Inspect the serviceability of safety valves.• Maintenance of stuffing box.


PRESSING MACHINE• Check the function of rotating table moving arm• Check thoroughly the sliding pneumatic parts.

YARN SINGEING MACHINE• Check spindle motor supply• Check function of the vacuum monitor of the suction off switch.• Check function of the compressed air monitor on the gas mix section

SCHOLL PACKAGE DYEING• Check main pump v- belt connection• Check the safety, steam and water valves

DORNIER MERCERIZING MACHINE• Clean and lubricate the motors the motors• Clean and lubricate the pumps and check the impellers• Clean the switch board and the switching elements visually• Check the bearings of all rollers• Check the bearings of the chain reversing sprockets• Check the magnetic attachment• Clean the entire plant


HYDRO EXTRACTOR MACHINE Lubricate the spindle bearings at the end of the shaft and greasing nipple on the

rotary treble behind the front part of removable casing. Lubricate the guide pulley behind the front part of removable casing.

MONFORTS PADDER, STRETCHER & DRYER MACHINELubricate:

Bearings of padder rolls with "N" Sprockets and chains with "E" Hand wheel, idle rollers with "B"

Check, Grease If necessary.- Nuts of width adjustment spindles for wear Check all spindle bearings for free running Free running of guide rollers, deflection rollers & contact rollers Pressure springs of chain pensioner Perform visual inspection: Gear box oil level Belts, pulleys Move width adjustment motor to the end position & check counters


MAHLO SETTER AND COMPACTOR Check, Grease if necessary: Nuts of width adjustment spindles for wear Check all spindle bearings for free running Free running of guide rollers, deflection rollers and contact rollers. Pressure springs of chain pensioner Perform visual inspection:- Gear box oil level Belts, pulleys Move width adjustment motor to the end position & check counters

CORINO SLITTING MACHINE Grease the squeeze for the rope fabric part Grease the dewatering bearings Grease the bearings of water slitting device & driving screw for basket opening Grease the bearings of open width squeezer Change gear oil once a year


SCLAVOS FABRIC DYEING MACHINE

Check the main pump oil level.

Check all bearings, seals, gaskets.

Check all mechanical seal flush pipes.

Discharge the water from air filter.

Check all m/c flange & platform bolts.

Grease RCR rotary joints every 2 weekly

Clean & check the control panel.

Check the adjustment of catch basket mechanism and plaiter system.


FABRIC DYEING MACHINE

• Check the machine for visual damages. Check the main pump bearing oil level.

Replace the oil. Check the operation of all alarms.

• Check and clean the sedo master controller.

• Clean the inlet filter of magnet level indicator.

• Check the pressure & temperature gauges.

• Check and grease all greasing points.

• Check all mechanical seal flush pipes. Specially check the plaiter water nozzle.

SANTEX COMPACTOR MACHINE

• Grease rotary joints.

• Grease heated rollers supports bearings.

• Grease all the bearings.

• Grease all the transmission chains.

• Grease centering device guide and bearings.

• Check driving belts tension and wear.

WEEKLY MAINTENANCE CHECK LIST

STALAM YARN DRYER

• Clean the dryer by compressed air

• Clean the foreign matters in the inductor and between electrode

• Clean the filter of asplirator air intake

HYDRO-EXTRACTOR

• Remove all the centrifugal heads & check

• Clean the entire machine

• Lift the c over & clean the drain cannel.

• Lubricate the rotary table behind the front part removable casing.

YARN PRESSING MACHINE

• Check the joints for tightness.

• Check the foundation bolts

• Check pneumatic oiler oil level

SCHOLL PACKAGE DYEING MACHINE.1. Flange connections checked for tightness.2. Open outlet of V68 valves and clean.3. Open outlet pipe after V, 38 valve and clean.4. Check lip seal & clean grease with PROBA 270( kluber)5. Upper side of cams on lid ring treated with lubricant. Use molykote

graphite grease.6. Checked oil level in atomizer

JAEGGLI YARN MERCERIZING MACHINE7. Ease bearings of stretching rollers. (A, E)8. Ease sleeves of stretching rollers. (F)9. Ease bearings of squeezer rollers. (G)10. Ease bushes candle. (I)11. Check hydraulic oil level and leakages.12. Check hydraulic -oil cooling system Is ok


LORIS BELLINI HANK DYEING MACHINE

• Clean the grid filter of the electric board

• Clean the protective grid of the electric motor

• Tighting all the bolts and nuts

• Maintenance of safety device with program test


MONFORTS PADDER, STRETCHER & DRYER MACHINE Perform visual inspection & clean In feed roller control unite cylinders Guide rod. guide roller & bearings Lifting device cylinders bearings Under liquor squeeze roller adjustment Teflon coated bearings, immersed rollers Belt tension, gear unit Universal joint shaft coupling Width adjustment functional wheels Selvedge sensor uncovers. Pinning shoes. brush Never grease graphite chain guide rails Brushes after pinning Clean & oil Filter housing & replace. Sprockets. Clamps with E Sliding guides cylinders Dryer removable screens Air suction control butterfly valves Oil level of pneumatic oiler filter


MONFORTS PADDER, STRETCHER & DRYER MACHINE

Lubricate:-

Bearings of padder rolls with "N"

Sprockets and chains with "E"

Hand wheel idle rollers with "B"

Check, Grease if necessary: -

Nuts of width adjustment spindles for wear

Check all spindle bearings for free running

Free running of guide rollers, deflection rollers & contact rollers.

Pressure springs of chain tensioner

Perform visual inspection:

Gear box oil level

Belts, pulleys

Move width adjustment motor to the end position & check counters


CALATOR RUCKH INSPECTION MACHINE• Clean the reflector for the edge guiding photocell• Check drive belt and chain• Check the inspection table with a cloth• Yarn singeing machine• Cleaning the burner rings.• Cleaning the root blower suction air filter.• Clean the traveling blower.

DORNIER MERCERIZING MACHINE• Visually check the motors and pumps• Check the chain drives and tension of chains• Check that all the expanders are properly adjusted Check the surface & readability

of the expander rollers.• Clean the machine from fluffs, dirt, chemicals• Check the function of the solenoid valve• Check the function of the cooling plant,• Check the spraying nozzles and clean them if blocked• Check the rubber coating of the drive rolls


CORINO SLITTING MACHINE

Check turntable tire pump & spring pressure.

Grease the turntable.

Check de twister speed reducer, transmission belts pneumatic brake.

Check oiler oil level of the fabric expander.

Check movable reel plaiter driving system.FABRIC DYEING MACHINE

Check the main pump oil level.

Check all bearings, seals, and gaskets.

Check all mechanical seal flush. pipes.

Discharge the water from air filter.

Check all m/c flang & platform bolts.

Grease RCR rotary joints every 2 weekly

Clean & check the control panel.

Check the adjustment of catch basket mechanism and plaiter system.


CORINO SQUEEZER MACHINE Clean the machine rollers with wet cloth.. Check visually all bearings & drive chains. Check all air and water hose joints. Clean compressor filter. Check tyre pump bellow the turntable. Check and clean fabric spreader. Check tension of trapezoidal belts. Grease turntable- bearing balls.

SANTEX COMPACTOR MACHINE Clean the machine properly. Check all bearings & chains. Check all mechanical joints. Check all the machine alignments. Top up the compressed air lubricant. Clean the panel A/C properly. Check tension and wear of the spreader belt pulleys.


DAILY MAINTENANCE CHECK LIST.

DORNIER MERCERIZING MACHINE

Check the quantity of fresh caustic soda in the caustic soda storage tank.

Check the complete machine and the auxiliary equipment visually.

Check whether all chains, chain wheels and drives are properly running.

Check the soda temperature to ensure that the cooling plant works properly

Check that all rollers are easily relatable.

MAINTENANCE: MECHANICAL

Machine: Dyeing Machines

Sl. No. Item needed to be checked & Serviced

1. Greasing of the winch bearing

2. Complete cleaning of machine

3. Cleaning of drain valves, replace seals if required

4. Checking of air supply filter, regulators, and auto drain seals

5. Cleaning of filter elements

6. Greasing of unloading roller bearings

7. Checking and cleaning (if required) of addition tank level indicator

8. Checking the oil level of pump bearing and refill if required

9. Checking the function of heat and cool modulating valves

10. Checking of all belts and belt tension

11. Check circulation, reel and other pumps

12. Checking of all door seals

Machine: Tensionless Dryer


1. Checking of gas pipe lines

2. Checking of gas burners

3. Checking of belt conveyor system

4. Checking of plaiting device

5. Checking of speed regulating unit

6. Cleaning of ventilation duct

7. Cleaning of m/c cabinet

Machine: Dewatering Machine


1. Cleaning of softener application unit

2. Checking of rotating device of rotating trolley unit

3. Checking of pneumatic pressure valves

4. Checking and replacement (if necessary) of rubber pads of stretching unit



Machine: Compactor Machine


1. Checking of Steam pipe lines

2. Checking of pneumatic pressure valves

3. Checking of belt conveyor system



6. Checking and replacement (if necessary) of compacting shoe

7. Cleaning of compacting shoe

Machine: Raising Machine


1. Checking of Gearing system and replacement of faulty gears

2. Cleaning of fiber deposits from the pile and counter pile rollers

3. Grinding of pins of pile and counter pile rollers

4. Lubrication of gearing system

1. Yarn Manufacturing TechnologyLink : http://www.facebook.com/pages/Yarn-Manufacturing-Technology/485014954866808

2. Fabric Manufacturing TechnologyLink : http://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605

3. Garments Manufacturing TechnologyLink : http://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126

3. Wet processing TechnologyLink : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404

4. Fashion-Design-and-TechnologyLink : http://www.facebook.com/pages/Fashion-Design-and-Technology/587655294583875?ref=ts&fref=ts

My Facebook Textile related Pages

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https://www.facebook.com/pages/Fabric-Manufacturing-Technology/459520217425605

https://www.facebook.com/pages/Garments-Manufacturing-Technology/472364799463126

https://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-/468645219825404

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