Maintenance of dyeing machine

Items needs to be checked & serviced 1 Check main panels 2 Check panel cooling fan & clean its filter 3 Clean main pump inverter & its cooling fan 4 Check all circuit breaker ,magnetic c

Maintenance

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)

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:

Efficiency:

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 & serviced

1 Check main panels

2 Check panel cooling fan & clean its filter

3 Clean main pump inverter & its cooling fan

4 Check all circuit breaker ,magnetic conductors & relays

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

6 Visual checking of all power & control cables

7 Check ail motor’s terminals

8 Check & clean fluff & dirt at all motor fan covers

9 drive of kneel motors

10 Check all pressure switches

11 Check calibration of main vessel & all addition tank

12 Check all signal isolators

13 Check setting & operation of lid safely switches

14 Check setting of tangle sensors

15 Check all pneumatic solenoids

16 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 HOIST

Grease all the moving parts and bearings

Check all the nut and bolts

Check oil level

Check each sprocket, chain and chain collector are ok

Check the thickness of the lines

Check 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

YEARLY MAINTENANCE CHECK LIST

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

YEARLY MAINTENANCE CHECK LIST

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

MONTHLY MAINTENANCE CHECK LIST

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

MONTHLY MAINTENANCE CHECK LIST

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 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 pensioner

 Perform visual inspection:

 Gear box oil level

 Belts, pulleys

 Move width adjustment motor to the end position & check counters