cupdf.com_maintenance-in-wet-processing-machine.ppt

Machine Maintenance

1. Maintenance Of Textile Machineries

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

3. Actionsnecessaryforretainingorrestoringapieceofequipment,machine,orsystem
tothespecifiedoperableconditiontoachieveitsmaximumusefullife.Maintenanceis
asetoforganizedactivitiesthatarecarriedoutinordertokeepanitsinitsbest
operationalconditionwithminimumcostrequired.
Maintenance:
Machine,buildingsandotherfacilitiesaresubjectedtodeteriorationduetotheiruse
andexposuretoenvironmentalcondition.Processofdeterioration,ifunchecked,
culminatesinrenderingtheseservicefacilitiesunserviceableandbringsthemtoa
standstill.InIndustry,thereforehasnochoicebuttoattendthemfromtimetotimeto
repairandreconditionthemsoastoelongatetheirlifetotheextentitiseconomically
andphysicallypossibletodoso.

4. Maintenance of machineries is very important for any type of industries and it is
a must for a knit composite mill. All machines and machines parts of knitting,
dyeing and garments are maintained with extreme care. Because production
quality and quantity, both depends on the maintenance with regularity. Beximco
Knitting Ltd. lead maintenance with a troop of skilled mechanical fitters. There
are two types of maintenance department found in BeximcoKnitting Ltd. such
as:
1.Mechanical Department.
2.Electrical Department.
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. 1.Tokeepthefactoryplants,equipments,machinetoolsinanoptimum
workingcondition.
2.Toensurespecifiedaccuracytoproductandtimescheduleofdeliveryto
customer.
3.Tokeepthedowntimeofmachinestotheminimumthustohavecontrol
overtheproductionprogram.
4.Tokeeptheproductioncyclewithinthestipulatedrange.
5.Tomodifythemachinetoolstomeettheneedforproduction
Objectives of Maintenance:

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

8. PreventiveMaintenance:
Preventivemaintenanceisapredeterminedroutineactivelytoensureon
timeinspection/checkingoffacilitiestouncoverconditionsthatmayleadto
productionbreakdownsorharmfuldescription.
BreakDownMaintenance:
Inthiscase,repairsaremadeaftertheequipmentisoutoforderanditcannot
performitsnormalfunctions.
RoutineMaintenance:
Maintenanceofdifferentmachinesarepreparedbyexpertengineerof
maintenancedepartment.Normallyincaseofdyeingmachinemaintenance
after30dayscompletecheckingofdifferentimportantpartsaredone.

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. •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:

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:
•DailyMaintenance:Everymachineistakenmaintenancedailybytheoperatorsduring
production.Whentheoperatorstartsaproductionafterhandingoverfrompreviousshift
operator,hetakesaroutinemaintenanceonthemachine.Hecleansthemachine,
assuresyarnisfedtoallneedles,cleanstheeyepotoffeeder,memminger,signallamp
sensoretc.Beforeawhileofarollcutfrombatchorclothroller,operatorcleansneedles,
cylinderbaseplateetc.Allaroundofthemachinearekeptneatandcleanasifthereis
nodirtwithyarninthefabric.
•Schedule/RoutineMaintenance:Everymachinehasascheduleofmaintenanceof10
or15days.Accordingtodate,schedulemaintenanceistakenonthemachines.
Operatorsareinformedaboutthetimeofmaintenance.Afterpre-estimatedproduction,
theyhandoverthemachinetothefitters.Thus,fittersassureallmachinesareOK.For
anytime.
•BreakDownMaintenance:Whenproductqualityhamperedandtocomplete
productioninduetimebreakdownmaintenanceistaken.Therearemanyfaultsseenin
thefabricduringproductionduetoneedle,sinker,takedownrolleretc.Thenoperators
informthemechanicalfittersandtheyfixit.
•RestorativeMaintenance:Restorativemaintenanceistakenfordesignchangeor
newdesigndevelopment.Accordingtoadviceororderofproductionofficer,amachine
isfixedfornewdesignandmechanicalfittersrearrangecamandneedlesystem.
Plannedandpreventivemaintenancearenottakenonthemachineriesinthismill.

16. 1.Forthereisanymechanicalfaultofmachine,whichisresponsibleforproduction
hamper,operatorinformsmechanicalfittersinduty.Mechanicalfitterscomeand
observetheproblemfirstly,andthentheybegintofixit.
2.Ifmechanicalfitterswereunabletofixit,thentheyinformtechnicalin-charge,he
thencomesinspotandfixesit.
3.Forthereisanyelectricalproblemofmachineorseriousfoundingmechanical
problem,mechanicalandelectricaldepartmentareinformed,theycomeandfixthe
problem.Theycommenceatworkafterinformingofknittingmanager.Therearetwo
mechanicalengineersinthedepartment.
4.Forrestorativemaintenance,seniorproductionofficerordersmechanicalfitterstofit
requiredmachineforcamandneedlearrangementandothernecessary
requirementsincaseofnewdesigndevelopment.
Maintenance Procedure:

17. Daily
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

18. Quarterly
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 steam 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

19. 1.Combinationtools/spanner
Function:Tightening&looseningofnuts&bolts.
2.Socketratchetset
Function:Tighteningofnuts&bolts.
3.Sliderange
Function:Tightening&looseningofnuts&bolts.
4.Monkeypliers
Function:Tightening&looseningofnuts&bolts.
5.Pipethreatcuttingtools
Function:Tocutthethreatinpipe.
6.Bearingpuller
Function:Toassisttheopeningofbearingfromshaft.
7.Piperange
Function:Tightening&looseningofpipejoint.
8.Pipecuttingtools
Function:Forpipecutting.
9.Holepunch
Function:Punchingthehole.
10.Divider
Function:Forcirclemarkingonmetal&wood.
11.Easyopener
Function:Toopenthebrokenheadbolt.
12.Externalthreatdie
Function:Forexternalthreatcutting.
Maintenance Tools & Equipments:

20. 13.Heavyscissor
Function:Cuttingofgasket&steelsheet.
14.Oilcan
Function:Oilingofmovingparts.
15.Drillmachineanddrillbit.
Function:Fordrilling.
16.Greasegun
Function:Forgreasingofmovingpartsofm/c.
17.Grindingm/c
Function:Forgrinding&cuttingofmildsteel.
18.Weldingm/c
Function:Forwelding&cutting.
19.Spiritleveler
Function:Forperfectleveling.
20.File
Function:Forsmoothingthesurface.
21.Hammer
Function:Forscaling&rightangling.
22.Circliptools
Function:Circlipopening&closing.
23.Hacksawblade
Function:Formetalcutting.
24.Handsaw(wood)
Maintenance Tools & Equipments:

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

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

24. 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:

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

26. RubberParts RubberParts Mechanical
ShaftSealandSpares
Changeable parts for Fabric Dyeing M/cs
Mechanical ShaftSealandSpares & RubberParts,Rubber, doorSealingGasket,PT FE/ Teflon,
CarbonGraphiteProducts

27. Spares
MainCirculation& Injection/Booster Pumps
Impellers,Shaft
,ShaftSleeve.
MainCirculation& Injection/Booster Pumps

28. MechanicalComponents
Actuator,Valves ,Dye
SpindlesPerofortedTubes
,LockingCapswithBolts /
Plates,SpacerforDyeCones,
head/base plates. ,Ball
Valve ,Carrier ,Wing Nut .
MechanicalComponents

29. Electronic Components
Actuator,Valves,Dye
SpindlesPerofortedTubes
,LockingCapswithBolts /
Plates,SpacerforDyeCones,he
ad/base plates. ,Ball Valve
,Carrier ,Wing Nut .
Elect Components

30. JUMBOO JIGGERS SPARES
Brake Drums:Ratchet /
Bearingtype Assemblies.
Brake Drums
Rolls:
S.S.Guide,EboniteCoate
d ,Teflon Coated ,Rubber
Coated , Hard
ChromiumPlated ,
aluminum Batching Roll
Rolls

31. Maintenance :Mechanical
Machine :Dyeingmachine
SL. No. Items need to be checked & Serviced
1
Creasethem/cbearing.
2
Completecleaningofmachine.
3
Cleaningofdrainvalves,replacesealsifrequired.
4
Checkairsupplyfilters,regulatorsautodrainseals
5
Cleanfilterselementandblowout.
6
Greasingofunloadingrollerbearing.
7
Checkingofoillevelandboltsofunloadingrollergearbox.
8
Checkingofunloadingrollercouplingandpacking.
9
Checking&cleaning(ifrequired)ofmainvessellevelindicator.
10
Checktheoillevelofpumpbearingandrefillifrequired.
11
Checkthefunctionofheatandcoolmodulatingvalves
Check List of Different Parts

32. SL. No. Items need to be checked & Serviced
1 Check&cleanfluffanddirtatdirtatallmotorfancovers.
2 Checkallmotor’sterminals
3 Checkmainpanels(byusingcompressedair)
4 Checkpanelcoolingfan&cleanitsfilter
5 Cleanmainpumpinverteranditscoolingfan.
6 Checkallcircuitbreaker,magneticconductorsandrelays.
7 Checkcurrentsettingofallcircuitbreaker&motoroverload.
8 Visualcheckingofallpower&controlcables.
9 Checkallpressureswitches
10 Checkcalibrationofmainvessel&alladditiontank
11 Checkallpneumaticsolenoids
12 Checkcalibrationofheating/coolingmodulatingvalue
13 Checksettingoftanglesensor.
14 Checksetting&operationoflidsafelyswitches.
15 Checkallemergencyswitches
16 Checkallindicatinglamps
17 Checkallon/offswitches
18 Checkallsignalisolators.
Maintenance : Electrical
Machine : Dyeing machine

33. 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
Steam trap 2 hrs 4 480 min 16.16
Mechanical seal 4 hrs 2 480 min 16.16
Air unit 30 min 1 30 min 1.01
Positioner 30 min 1 30 min 1.01
TC oaring 2 hrs 2 240 min 8.08
Butterfly valve 30 min 2 60 min 2.02
Total 2970 min
ABC analysis

34. 0
5
10
15
20
25
Stea
m line
valve
Coolin
g
valve
Safety
valve
Heat
excha
nger
Beari
ng
dama
ge
Stea
m trap
Mech
anical
seal
Air
unit
Positi
oner
TC
oaring
Butter
fly
valve
Problem percentage (%)6.06 21.2212.12 4.04 12.1216.1616.16 1.01 1.01 8.08 2.02
Axis Title
Problem percentage (%)

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.

51. What happened in Semi continuous
Dyeing

54. Continuous Dyeing m/c

55. Thermosol Dyeing m/c

56. Hydroextractor

57. Slitting m/c

58. Detwister in Slitting m/c

59. Relax Dryer

60. Stenter m/c

61. Compactor m/c

62. Compactor m/c

63. Knit Mercerising m/c

64. Woven Mercerising m/c

65. Singeing m/c &Desizing Tank

66. Washing m/c after Desizing/Semi
continuous Dyeing

67. Continuous Scouring &Bleaching
m/c

68. Cylinder Dryer

69. Sample Dyeing M/c

70. Singing Machine

71. Padding Box

72. Aging Station

73. Calendar Machine

74. 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.

75. 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

76. 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)

78. 1. Yarn Manufacturing Technology
Link : http://www.facebook.com/pages/Yarn-Manufacturing-
Technology/485014954866808
2. Fabric Manufacturing Technology
Link : http://www.facebook.com/pages/Fabric-Manufacturing-
Technology/459520217425605
3. Garments Manufacturing Technology
Link : http://www.facebook.com/pages/Garments-Manufacturing-
Technology/472364799463126
3. Wet processing Technology
Link : http://www.facebook.com/pages/Wet-Processing-Technology-Dyeing-
/468645219825404
4. Fashion-Design-and-Technology
Link : http://www.facebook.com/pages/Fashion-Design-and-
Technology/587655294583875?ref=ts&fref=ts
My Facebook Textile related Pages
http://www.textilelab.blogspot.com(Visit My Blog for more Info )