Maintenance in wet processing Machine

1. Maintenance Of Textile Machineries Maintenance Of Textile Machineries

2. Prepared By : Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh

3. Actions necessary for retaining or restoring a piece of equipment, machine, or system to the specified operable condition to achieve its maximum useful life. Maintenance is a set of organized activities that are carried out in order to keep an its in its best operational condition with minimum cost required. Maintenance: Machine, buildings and other facilities are subjected to deterioration due to their use and exposure to environmental condition. Process of deterioration, if unchecked, culminates in rendering these service facilities unserviceable and brings them to a standstill. In Industry, therefore has no choice but to attend them from time to time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so.

4. Maintenance:

5. Activities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition and these activities should be carried out with a minimum possible cost.

6. Objectives of Maintenance: 1.To keep the factory plants, equipments, machine tools in an optimum working condition. 2.To ensure specified accuracy to product and time schedule of delivery to customer. 3.To keep the downtime of machines to the minimum thus to have control over the production program. 4.To keep the production cycle within the stipulated range. 5.To modify the machine tools to meet the need for production

7. Maintenance of Machinery: Maintenance Preventive Maintenance Break Down Maintenance Electrical Maintenance Electrical Maintenance Mechanical Maintenance Mechanical Maintenance

8. Preventive Maintenance: Preventive maintenance is a predetermined routine actively to ensure on time inspection / checking of facilities to uncover conditions that may lead to production break downs or harmful description. Break Down Maintenance: In this case, repairs are made after the equipment is out of order and it can not perform its normal functions. Routine Maintenance: Maintenance of different machines are prepared by expert engineer of maintenance department. Normally in case of dyeing machine maintenance after 30 days complete checking of different important parts are done.

9. •To keep the m/c running continuously up to the maximum production level •To make sure the best use of utilities •To prevent the undesirable failure of the m/c. •Reducing break down and emergency shut down •optimizing resources utilization •Minimizing energy usage •Improving equipment efficiency.

10. Objects: • To Keep the machine running continuously up to the Maximum Production Level. • To make sure the best use of Utilities. • To prevent the undesireable failure of the machine.

12. Utilities Used • Gas-Gas Pressure for Boiler ,Dryer,Stenter Checking. • Air-Air Compressor. • Electricity-Electric Control ,Line voltage ,Electricity availability Checking. • Water- Water Pressure,Valve, Level Checking. • Steam- Steam Pressure,Valve,Supply checking

13. Mechanical Parts • • • • • • • • • • • • • • • • Free Roller, Guide Roller, Immersion Roller, Winch, Belt &Rope Drive, Steam Pipe(White Colored), Water pipe(Blue colored), Burner, Suction Hood, Adjustable Roller, Pump, Pressure controller, Tray, Squeeze Roller, Delivery Roller. And so on……………….

14. Electrical Parts • Motor, • Cables of electrical wireing • And so on…

15. Routine of Maintenance: •Daily Maintenance:Every machine is taken maintenance daily by the operators during production. When the operator starts a production after handing over from previous shift operator, he takes a routine maintenance on the machine. He cleans the machine, assures yarn is fed to all needles, cleans the eye pot of feeder, memminger, signal lamp sensor etc. Before a while of a roll cut from batch or cloth roller, operator cleans needles, cylinder base plate etc. All around of the machine are kept neat and clean as if there is no dirt with yarn in the fabric. •Schedule/Routine Maintenance:Every machine has a schedule of maintenance of 10 or 15 days. According to date, schedule maintenance is taken on the machines. Operators are informed about the time of maintenance. After pre-estimated production, they hand over the machine to the fitters. Thus, fitters assure all machines are OK. For any time. •Break Down Maintenance:When product quality hampered and to complete production in due time break down maintenance is taken. There are many faults seen in the fabric during production due to needle, sinker, take down roller etc. Then operators inform the mechanical fitters and they fix it. •Restorative Maintenance:Restorative maintenance is taken for design change or new design development. According to advice or order of production officer, a machine is fixed for new design and mechanical fitters rearrange cam and needle system. Planned and preventive maintenance are not taken on the machineries in this mill.

16. Maintenance Procedure: 1.For there is any mechanical fault of machine, which is responsible for production hamper, operator informs mechanical fitters in duty. Mechanical fitters come and observe the problem firstly, and then they begin to fix it. 2.If mechanical fitters were unable to fix it, then they inform technical in-charge, he then comes in spot and fixes it. 3.For there is any electrical problem of machine or serious founding mechanical problem, mechanical and electrical department are informed, they come and fix the problem. They commence at work after informing of knitting manager. There are two mechanical engineers in the department. 4.For restorative maintenance, senior production officer orders mechanical fitters to fit required machine for cam and needle arrangement and other necessary requirements in case of new design development.

17. Dyeing machine maintenance Schedule Daily 1. 2. 3. 4. Check belt tension Check steam or water system & air supply Check chemical pump Machine clean Weekly 1. 2. 3. 4. 5. Bearing & belt check Check leakage of air, steam & Water line Greasing bearing points Add gland packing at pump Monthly 1. 2. 3. 4. 5. Greasing bearing points Replace bearing points (if required) Gasket check Clean steam trap Lubricating all chemical pump

18. Quarterly 1. 2. 3. 4. 5. 6. Replace belts Repairing of pulley, shaft & bearing housing Painting m/c & pipe line Clean steam trap Replace seals (if leakage) Change gasket of stea m of water lines Half yearly 1. 2. 3. 4. 5. Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing Yearly 1. Machine overhauling

19. Maintenance Tools & Equipments: 1. Combination tools / spanner Function: Tightening & loosening of nuts & bolts. 2. Socket ratchet set Function: Tightening of nuts & bolts. 3. Slide range Function: Tightening & loosening of nuts & bolts. 4. Monkey pliers Function: Tightening & loosening of nuts & bolts. 5. Pipe threat cutting tools Function: To cut the threat in pipe. 6. Bearing puller Function: To assist the opening of bearing from shaft. 7. Pipe range Function: Tightening & loosening of pipe joint. 8. Pipe cutting tools Function: For pipe cutting. 9. Hole punch Function: Punching the hole. 10. Divider Function: For circle marking on metal & wood. 11. Easy opener Function: To open the broken head bolt. 12. External threat die Function: For external threat cutting.

20. Maintenance Tools & Equipments: 13. Heavy scissor Function: Cutting of gasket & steel sheet. 14. Oil can Function: Oiling of moving parts. 15. Drill machine and drill bit. Function: For drilling. 16. Grease gun Function: For greasing of moving parts of m/c. 17. Grinding m/c Function: For grinding & cutting of mild steel. 18. Welding m/c Function: For welding & cutting. 19. Spirit leveler Function: For perfect leveling. 20. File Function: For smoothing the surface. 21. Hammer Function: For scaling & right angling. 22. Circlip tools Function: Circlip opening & closing. 23. Hacksaw blade Function: For metal cutting. 24. Handsaw (wood)

21. Important Different Types of Tools: Photo: Oil Gun and Lead Pliers. Photo: Wrench set (1.5, 2, 2.5,3,4,5,6,8,10,14 mm 3/6’’)

22. Important Different Types of Tools: Photo: Screw Driver. Photo: Screw Driver.

23. Important Different Types of Tools: Photo: Thickness Gauge. Photo: Spade and Over Fall Bolt.

24. Important Different Types of Tools: Photo: 27mm Single Head and 36 mm single Head. Photo: 5.5×7 mm Double Head and 8×10 mm Double Head.

25. Important Different Types of Tools: Photo: 13×17 mm Double Head and IRO Drum. Photo: Spinner and Pin Lever.

26. Changeable parts for Fabric Dyeing M/cs   Mechanical Shaft Seal and Spares & Rubber Parts, Rubber, door Sealing Gasket, PT FE/ Teflon, Carbon Graphite Products Rubber  Parts Rubber  Parts Mechanical Shaft  Seal  and   Spares

27. Main Circulation & Injection/ Booster Pumps  Spares Main Circulation & Injection/ Booster Pumps Impellers, Shaft , Shaft Sleeve.

28. Mechanical Components  Actuator, Valves , Dye  Mechanical  Components Spindles Peroforted Tubes , Locking Caps with Bolts / Plates, Spacer for Dye Cones, head/ base plates. , Ball Valve , Carrier , Wing Nut .

29. Electronic  Components  Actuator, Valves, Dye Spindles Peroforted Tubes , Locking Caps with Bolts / Plates, Spacer for Dye Cones, head/ base plates. , Ball Valve , Carrier , Wing Nut . Elect Components

30. JUMBOO JIGGERS SPARES  Brake Drums: Ratchet / Bearing type Assemblies. Brake Drums Rolls:   S.S. Guide , Ebonite Coated , Teflon Coated , Rubber Coated , Hard Chromium Plated , aluminum Batching Roll Rolls

31. Check List of Different Parts Maintenance Machine : Dyeing machine : Mechanical SL. No. 1                 Items need to be checked & Serviced Crease the m/c bearing. 2 Complete cleaning of machine. 3 Cleaning of drain valves, replace seals if required. 4 Check air supply filters, regulators auto drain seals 5 Clean filters element and blow out. 6 Greasing of unloading roller bearing. 7 Checking of oil level and bolts of unloading roller gearbox. 8 Checking of unloading roller coupling and packing. 9 Checking & cleaning (if required) of main vessel level indicator. 10 Check the oil level of pump bearing and refill if required. 11 Check the function of heat and cool modulating valves 12 Check all door seals.

32. Maintenance Machine : Dyeing machine : Electrical SL.  No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18               Items need to be checked & Serviced Check & clean fluff and dirt at dirt at all motor fan covers. Check all motor’s terminals Check main panels (by using compressed air) Check panel cooling fan & clean its filter Clean main pump inverter and its cooling fan. Check all circuit breaker, magnetic conductors and relays. Check current setting of all circuit breaker & motor over load. Visual checking of all power & control cables. Check all pressure switches Check calibration of main vessel & all addition tank Check all pneumatic solenoids Check calibration of heating/cooling modulating value Check setting of tangle sensor. Check setting & operation of lid safely switches. Check all emergency switches Check all indicating lamps Check all on/off switches Check all signal isolators.

33. ABC analysis Types of problem Steam line valve Duration per break down 30 min Total no. of break down 6 Total break down 180 min Problem percentage (%) 6.06 Cooling valve Safety valve Heat exchanger Bearing damage 3.5 hrs 2 hrs 2 hrs 2 hrs 3 3 1 3 630 min 360 min 120 min 360 min 21.22 12.12 4.04 12.12 Steam trap Mechanical seal 2 hrs 4 hrs 4 2 480 min 480 min 16.16 16.16 Air unit Positioner TC oaring Butterfly valve Total 30 min 30 min 2 hrs 30 min 1 1 2 2 30 min 30 min 240 min 60 min 2970 min 1.01 1.01 8.08 2.02

36. Mechanism and working Procedure of Individual Machines Used in Wet Processing Industries

37. Jet Dyeing m/c Outer view

38. Jet Dyeing m/c (inside view)

39. Jet Dyeing m/c

40. Jet Nozzle

41. Jet dyeing machine Horizontal

42. Types of Jet dyeing m/c

43. Winch Dyeing m/c(Out side view)

44. Winch Dyeing M/c (Inside view)

45. Winch Dyeing m/c (Inside view)

46. Yarn Package Dyeing m/c

47. Jigger Dyeing m/c

48. Semi Continuous /Pad Batch Dyeing Method

49. Cold Pad Batch/Semi continuous Method

50. Difference between Semi continuous and Continuous Method In semi-continuous dyeing, the dye is applied continuously by a padding. The fixation and washing remaining discontinuous. Liquor Ratio in semi- continuous dyeing is not Important.