Maintenance in wet processing Machine

5.To modify the machine tools to meet the need for production Objectives of Maintenance:... Preventive Maintenance Break Down Maintenance Electrical Maintenance Mechanical Maintenance El

Maintenance Of Textile Machineries

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 Prepared By :

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

Maintenance:

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.

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

Objectives of Maintenance:

Preventive Maintenance Break Down Maintenance

Electrical Maintenance

Mechanical Maintenance

Electrical

Maintenance of Machinery:

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.

•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.

• 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.

Objects:

• Belt &Rope Drive,

• Steam Pipe(White Colored),

• Water pipe(Blue colored),

Electrical Parts

• Motor,

• Cables of electrical wireing

• And so on…

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

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

Maintenance Procedure:

1 Check belt tension

2 Check steam or water system & air supply

3 Check chemical pump

4 Machine clean

Weekly

1 Bearing & belt check

2 Check leakage of air, steam &

3 Water line

4 Greasing bearing points

5 Add gland packing at pump

Monthly

1 Greasing bearing points

2 Replace bearing points (if required)

3 Gasket check

4 Clean steam trap

5 Lubricating all chemical pump

Dyeing machine maintenance Schedule

1 Replace belts

2 Repairing of pulley, shaft & bearing housing

3 Painting m/c & pipe line

4 Clean steam trap

5 Replace seals (if leakage)

6 Change gasket of stea m of water lines

Half yearly

1 Replace belts

2 Repairing pulley, shaft & bearing housing

3 Painting m/c, pipe line

4 Replace seals

5 Machine body repairing

Yearly

1 Machine overhauling

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.

Function : To open the broken head bolt.

12 External threat die

Function : For external threat cutting.

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.

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’’)

Photo: Screw Driver.

Photo: Screw Driver.

Important Different Types of Tools:

Photo: Thickness Gauge.

Photo: Spade and Over Fall Bolt.

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.

Important Different Types of Tools:

Photo: 13×17 mm Double Head and IRO Drum.

Photo: Spinner and Pin Lever.

Important Different Types of Tools:

Rubber Parts Rubber Parts Mechanical Shaft Seal and

Spares

Changeable parts for Fabric Dyeing M/cs

Mechanical Shaft Seal and Spares & Rubber Parts, Rubber, door Sealing Gasket, PT FE/ Teflon, Carbon Graphite Products

Spares Main Circulation & Injection/ Booster Pumps

Impellers, Shaft , Shaft

Sleeve.

Main Circulation & Injection/ Booster Pumps

Mechanical Components

Actuator, Valves , Dye

Spindles Peroforted Tubes ,

Locking Caps with Bolts /

Plates, Spacer for Dye

Cones, head/ base plates ,

Ball Valve , Carrier , Wing Nut

.

Mechanical Components

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

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

Maintenance : Mechanical

Machine : Dyeing machine

SL No Items need to be checked & Serviced

1 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.

Check List of Different Parts

SL No Items need to be checked & Serviced

1 Check & clean fluff and dirt at dirt at all motor fan covers

2 Check all motor’s terminals

3 Check main panels (by using compressed air)

4 Check panel cooling fan & clean its filter

5 Clean main pump inverter and its cooling fan

6 Check all circuit breaker, magnetic conductors and relays

7 Check current setting of all circuit breaker & motor over load

8 Visual checking of all power & control cables

9 Check all pressure switches

10 Check calibration of main vessel & all addition tank

11 Check all pneumatic solenoids

12 Check calibration of heating/cooling modulating value

13 Check setting of tangle sensor

14 Check setting & operation of lid safely switches

15 Check all emergency switches

16 Check all indicating lamps

17 Check all on/off switches

18 Check all signal isolators

Machine : Dyeing machine

Types of

problem

Duration per break down

Total no of break down

Total break down

Problem percentage (%) Steam line valve 30 min 6 180 min 6.06

Cooling valve 3.5 hrs 3 630 min 21.22

Safety valve 2 hrs 3 360 min 12.12

Heat exchanger 2 hrs 1 120 min 4.04

Bearing damage 2 hrs 3 360 min 12.12

Mechanical seal 4 hrs 2 480 min 16.16

Butterfly valve 30 min 2 60 min 2.02

ABC analysis

Mechanism and working Procedure

of Individual Machines Used in Wet

Processing Industries

Jet Dyeing m/c Outer view

Jet Dyeing m/c (inside view)

Jet Dyeing m/c

Jet Nozzle

Jet dyeing machine Horizontal

Types of Jet dyeing m/c

Winch Dyeing m/c(Out side view)

Winch Dyeing M/c (Inside view)

Yarn Package Dyeing m/c

Jigger Dyeing m/c

Semi Continuous /Pad Batch

Dyeing Method

Cold Pad Batch/Semi continuous

Method

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.

What happened in Semi continuous

Dyeing

Continuous Dyeing m/c

Thermosol Dyeing m/c

Hydroextractor

Slitting m/c

Detwister in Slitting m/c

Relax Dryer

Stenter m/c

Compactor m/c

Knit Mercerising m/c

Woven Mercerising m/c

Singeing m/c &Desizing Tank

Washing m/c after Desizing/Semi

continuous Dyeing

Continuous Scouring &Bleaching

m/c

Cylinder Dryer

Sample Dyeing M/c

Singing Machine

Padding Box

Aging Station

Calendar Machine

Continuous Knit Fabric Processing

• Grey knit fabric Inspection

• Jet / Winch Dyeing m/c

• Scouring, Bleaching, Enzyme wash, Optical

Brightening, Dyeing,Softening.(In Rope form

fabric)

• Squeezing/Padding or Hydroextractor (to

remove excess water from the fabric)

• Open width fabric Slitting m/c is used(to slit the knit fabric along the needle drop line of the

fabric.

Knit fabric processing

• For tube knit fabric Relax Dryer is used to dry the fabric.

• For Open width fabric Stenter m/c is

generally used for drying as well as

finishing chemical addition

• For tube fabric Tube compactor is used to control shrinkage.

• For Open width fabric open width

compactor is used to control shrinkage

Continuous woven fabric

processing

• Woven fabric Inspection

• Singeing m/c & Desizing Tank

• Continuous Scouring & Bleaching

• Cold Pad Batch,Pad dry steam,Pad steam method (Dyeing m/c)

• Hot +Medium hot +Cold wash & Dry

• Stenter m/c (softener addition)

• Sanforizing (for shrinkage control)

1 Yarn Manufacturing Technology

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