Maintenance Of Textile MachineriesMaintenance Of Textile Machineries

Prepared By : Mazadul Hasan sheshirID: 201000040000813th Batch (session 2009-2013)Department : Wet Processing Technology Email: mazadulhasan@yahoo.comBlog : 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:

Maintenance

Preventive Maintenance

Break Down Maintenance

ElectricalMaintenance

MechanicalMaintenance

ElectricalMaintenance

MechanicalMaintenance

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:

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

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……………….

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:

Daily1. Check belt tension2. Check steam or water system & air

supply3. Check chemical pump4. Machine clean

Weekly1. Bearing & belt check2. Check leakage of air, steam &3. Water line4. Greasing bearing points5. Add gland packing at pump

Monthly1. Greasing bearing points2. Replace bearing points (if required)3. Gasket check4. Clean steam trap5. Lubricating all chemical pump

Dyeing machine maintenance Schedule

Quarterly1. Replace belts2. Repairing of pulley, shaft & bearing housing3. Painting m/c & pipe line4. Clean steam trap5. Replace seals (if leakage)6. Change gasket of stea m of water lines

Half yearly1. Replace belts2. Repairing pulley, shaft & bearing housing3. Painting m/c, pipe line4. Replace seals5. 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.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.

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)

Maintenance Tools & Equipments:

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 : MechanicalMachine : Dyeing machine

SL. No. Items need to be checked & Serviced1 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 seals5 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 valves12 Check all door seals.

Check List of Different Parts

SL. No. Items need to be checked & Serviced1 Check & clean fluff and dirt at dirt at all motor fan covers.2 Check all motor’s terminals3 Check main panels (by using compressed air)4 Check panel cooling fan & clean its filter5 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 tank11 Check all pneumatic solenoids12 Check calibration of heating/cooling modulating value13 Check setting of tangle sensor.14 Check setting & operation of lid safely switches.15 Check all emergency switches16 Check all indicating lamps17 Check all on/off switches 18 Check all signal isolators.

Maintenance : ElectricalMachine : 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 21.22Safety valve 2 hrs 3 360 min 12.12Heat exchanger 2 hrs 1 120 min 4.04Bearing damage 2 hrs 3 360 min 12.12

Steam trap 2 hrs 4 480 min 16.16Mechanical seal 4 hrs 2 480 min 16.16

Air unit 30 min 1 30 min 1.01Positioner 30 min 1 30 min 1.01TC oaring 2 hrs 2 240 min 8.08Butterfly valve 30 min 2 60 min 2.02Total 2970 min

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)

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

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 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

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