A Swiss Bangladesh joint venture thread swing dyeing Industries

A Swiss Bangladesh joint venture thread swing dyeing Industries

Chapter-One

Introduction

1.1 Origin of the report

This report has been prepared as an integral part of the internship program for the Bachelor of Electrical and Electronic Engineering Program at the Department of Electrical and Electronic Engineering (BSEEE), IUBAT-International University of Business Agriculture and Technology. The Etafil (Bangladesh) Limited Was nominated on Operation and Maintenance Fong’s Yarn Dyeing Machine for the practicum while honorable Engr. Abul Bahar Coordinator of Electrical and Electronic Engineering Department, rendered his kind consent to academically supervise the internship program.

1.2 Objective

The broad objective of the report has been made for Operation and Maintenance Fong’s Yarn Dyeing Machine. The main objective of the report has been done show the total working procedure and the related other aspect of the Etafil (Bangladesh) Limited. It is discussed generally about the factor and the terms of the pacific garment:

The specific objective of this report includes:

  • To study Inspection and maintenance activities of Yarn Dyeing Machine.
  • To study the process of operating other instruments of Dyeing.
  • To make an analysis of total maintenance of the Yarn Dyeing Machinery the load

Demands.

  • To show a total view of a Yarn Dyeing Machinery related industry as well as knit Dyeing f

1.3 Scope

This report will cover the Operation and Maintenance Fong’s Yarn Dyeing Machine a broad knowledge of different kinds of Electrical and Electronic maintenance. Managing the Maintenance activities of dyeing instrument to maintain required standard and user perception toward it is the main scope of discussion in this report.

The scope will be limited to only this type of instrument and that it’s not limited in Bangladesh of this is it very important for design.

1.4 Background

Now days in a developing county like Bangladesh Garment factories are too much important and beneficial economically. Etafil (Bangladesh) limited is one of these industries. Here the opportunity for the operation, maintenance and the overall checking is a good fact for having a good knowledge and experience. Basically, the total maintenance is the min criteria of the factory. Although it has been running but it has got the total independent production comparing with others. As it is assumed that within a short time the production of the total power will be improved as far continued demand. General concept shows that the demand of this kind of industry is continually increasing day by day. From these aspects are working with different section for the total maintenance. All the equipments are up to date with good efficiency and use for future use there has been kept sufficient space and maintenance facilities.

1.5 Methodology

A qualitative practicum method has been used to conduct this study. MP Module has been implemented in the field of every industry Sector. Etafil (Bangladesh) Limited is one of the most important export oriented industry in this country to start using MP Module for the O and M activity. The information of this report has been collected from the following sources:

  • Information source of this company
  • To get the primary information, the following sources has been contacted
  • Personal interviews to the employees and management of the company
  • Official documents of the company

The author of the report is directly working in the O and M unit of Etafil (Bangladesh) Limited and has extensive expertise in the use of MP Module for the O and M activities, so it was easier for him to observe the system closely and collect necessary information to prepare the report.

As the report is focused on O and M activities of this factory MP System, which is very much familiarized in Bangladesh industry sector, but it has shown tremendous growth in international markets, So to have some view on the related issues within the scope of this report are collected through secondary resources like related report, publications, books, journals, articles, magazines and online resources.

1.6 Limitations

This report has been prepared on the MP system through which a knitting industry is maintaining O and M related work which may give a very good export oriented service provider several advantages than others in the same field. Therefore, it was not possible to present a complete report like statistics, financial involvement etc regarding the topic or the opportunity. During the report, it had to be taken care off that the report does not contain any company confidential information and harm the organization in their strategic stance.

Chapter Two

Company Overview

This chapter is included the following items:

2.1 Company overview

2.2 About Etafil (Bangladesh) Ltd

2.3 Company vision

2.4 Company mission

5.5 Company goal

5.6 Company service

5.7 Present support and service

5.8 Back-up service

5.9 Stock house

2.1 About Etafil (Bangladesh) Limited

Etafil (Bangladesh) Limited at first established at mirpur- 1 since 1989 only four Yarn Dyeing Machine. When our company machine is increased then our company shifted to bhadam, Tongi, Gazipur near Asulia landing station in 1996. Our company has four projects this are-

Etafil (Bangladesh) Limited, Tamishna fashion wear Ltd, Tamishna washing plant Ltd, and Tamishna appeals Ltd. Our companies at first collect the normal Yarn from outside country such as Taiwan, China, and India. This Company already supplied lot of Yarn in this country.

2.2 Company Vision

Etafil (Bangladesh) Limited is a market driven, technology based Group which aims to grow by satisfying customers in selected markets.

2.3 Company Mission

As members of the Etafil (Bangladesh) Limited family, our mission is to fully utilize talents to anticipate and completely satisfy our customers’ needs for value added high quality products. We will be the standard for total performance in the market we serve.

2.4 Company Goal

We commit ourselves to continue improvements in all that we do. We will measure our progress against our primary goals.

  • Quality Products
  • Customer Satisfaction
  • Environmental Safety
  • Tam Member Satisfaction

2.5 Company Services

  • Sales: Our Company sales all kinds Yarn
  • Maintenance and Troubleshooting: Etafil (Bangladesh) Limited has expert troubleshooting Engineer (Electrical and Mechanical)

2.6 Present Support and Service Office

  • Uttara shahMaghdum Avenue, Sector-12
  • Mirpur-1, Dhaka
  • Bhadam, Tongi, Gazipur

2.7 Back-Up Service

  • 24 Hours service

2.8 Stock House:

Etafil (Bangladesh) Limited has store rooms for Emergency and current Yarn supply. There stocked as per need.

Chapter-Three

DESCRIPTION OF THE MACHINE

The machine is capable to process the material (such as package, cheese, bums, loose stock, hank etc.) when the appropriate carrier is used. The machine can only partially fill up with Dyeing liquid for the air pad operation.

A circulation pump is used to circulate the dye liquid through the processed material.

Two pressure gauges indicate the pressure differential across the processed material in the inside-out / outside in direction when the pump is running as will as the static pressure inside the vessel when all pumps are stopped. A service tank is used for the preparation of dyestuff and chemical additives. A feed pump delivers the dye solution into the suction line of the circulation pump. Fill and drain values are provided for filling and draining the machine. On the top of the lid, there is a pneumatic operated overflow rinse value. The value also serves as one of the means to release pressure when the pressure is low. The kier operating pressure is normally maintained at the specified maximum rating allowing the Dyeing temperature to be increased to 140?C (284?F). A safety interlock vent value is provided at a position bellow the shell flange. The liquid above the shell flange is drained or the pressure of any is released and the lid can be rotated to be opened when the safety interlock vent value is in the open position. A pneumatic cylinder which is spring returned is hooked up with a temperature is above 85?C (285?F) or the pressure switch is still activated by the liquid above the shell flange. When the cylinder extend, the lid is prevented from rotation thereby it cannot be opened when the machine temperature is below 85? (285?). Until the machine temperature is below85?C (285?F) and the liquid is lower than shell flange, the cylinder retracts to release position. The lid may be returned to open position. The machine has an external heat exchanger as standard design.

The vessel is classed as an unfired pressure vessel and has been designed and manufactured in accordance with the appropriate pressure vessel code. Permission must be obtained from the relevant local authority before putting it into service. Depending on the design, a dial thermometer or an external digital display unit (optional) is provided for the indication of machine temperature. The dial thermometer or the external digit display unit indicates the actual temperature inside the kier only when the circulation pump is running. An optional equal capacity open type preparation tank is being used for the advanced preparation of liquid for injecting into the machine after a dye bath is drained. It can also be used for the storage of the dyeing liquid level-out from the machine. There are values to isolate / connect the preparation tank from / to the machine.

A counter weight is mounted over the hinge to assist opening / closing of the lid after it is fully rotated to open / close position. When the machine is ordered with out lid opened by a pneumatic actuator, the opening of the lid will also be hooked up with the machine temperature is below 85?C (285?F) and the liquid inside the kier is below the shell flange. All pilot solenoid valves, air pressure reducing valve, filter and water separator are mounted on a pneumatic control panel (box). The solenoid valves are wired to a common terminal ready for wiring to control cabinet.

High temperature draining device with cold mixing (optional) is provided when ordered. The device has a mixing chamber than the high temperature dyeing liquid is mixed with code water. A temperature sensor senses the temperature. When the temperature detected by the sensor is below 85?C the high temperature draining valve is allowed to open.

Chapter-Four

ERECTION

You may erect and install the MACHINE without help from Fong’s. In such case, please remember to read and thoroughly understand all the documented instructions provided by this manual, before you start any work on the MACHINE.

Alternative, you can hire Fong’s commissioning engineer, by at least 2 weeks advance notice and under separate contract terms, to come to your site and supervise your personnel for the job.

You are also responsible to observe all the local regulatory requirements for any occupational safety and health devices, and inspections for MACHINE as may be applicable.

It is normally necessary to connect external piping to the machine by welding equipment. Some electric devices which have already been fixed on the machine will be damaged by the electric flowing through during wilding.

4.1 ERECTION –MECHANICAL

This has to be done by experienced mechanics, plumber, and welders with the help of lifting equipment and rough helpers.

Relevant drawings are provided with this manual to give the required erection information. Read them carefully and start any work only after fully understanding all the documented instructions.

  • Have the drawings handy.
  • Ensure that the foundation both holes are already prepared.
  • Lift the MACHINE on to the designed space provided according to the foundation both holes orientation.
  • Level the MACHINE including the pumps. The shell flange face may be taken as the datum for leveling reference.
  • Apply foundation bolts and grout all foundation bolt holes fully leaving no cavities. After the grout has set, recheck alignment.
  • Complete all the installations indicated by the drawings, including the lines from the machine to the pressure gauges.
  • Adding lubrication oil:

The necessary lubrication oil required for the circulation pump bearing housing is not supplied by Fong’s.

Fill the bearing housing of the circulation pump with correct amount, type and grade of lubrication oil.

Refer to the applicable Technical Supplement for specification.

  • Connect the water supply Connect the steam supply.
  • Connect the compressed air supply.
  • Make conception between the point solenoid values valves on the pneumatic control panel and the pneumatic operated valves and / or cylinder if supplied on the machine with pneumatic tubing.
  • Make all the drain pipe connections, including the drain at the funnels.
  • The lifting equipment such as overhead traveling crane (not supplied by Fong’s) to lift the carrier out from and into the machine has to be installed and provided. The travel of the crane must not exceed the center of the vessel in the direction of lid opening.

Put gaskets between flanges, remove any protective plug / cap found on a valve or a pump when installing. Suggest installing cut-off valves in front of the stream, water and air line so that future maintenance can be easily carried out. Strainers shall be installed ahead of the control valves which are connected to external services such as steam, water and drain line. Supply pressure of water and steam shall not exceed the specified value in the specification sheet or otherwise pressure reducing valves shall be installed to keep pressure to blown specified value. The external piping, strainers etc. must be blown with compressed air or flushed with water to clear their interior of any foreign particles before the piping is permanently connected.

4.2 ERECTION-ELECTRICAL

The electrical connection must be made only by qualified electricians.

Schematic wiring diagrams are supplied with this manual to give the required connection information. Read them carefully and start any wiring only after fully understanding all the documented instruction.

It is only necessary to make the external connections between the control cabinet / panel and the relevant devices on the MACHINE.

When making external wiring connections, observe all the electrical wiring regulations, as lay down by local authorities.

  • Have the electrical wiring diagrams handy and locate the relevant cabinet to the designated positions.
  • Make sure the mains supply in the plant matches the electrical power requirement for this machine.
  • Make external wiring necessary between all the motors, solenoid valves, instruments, etc. and the power / control circuit.
  • With the mains isolator shifted to the “0” (Off) position, make external wiring between the mains supply line to the machine at the appropriate terminals.
  • Check all the wiring with the wiring diagrams supplied. Correct any mistake found immediately. Remember faulty wiring connection can kill.
  • Temporarily disengage the motors from its driven units. Test runs the motor to ensure correct start-up and direction of rotation. Correct any problems found and apply couplings back into the motors.
  • The cut-off fuses of the motors may be temporarily taken away so that function test of control elements can be carried out.

4.3 SPEED REGULATION OF THE LID ACTUATOR

If the opening / closing of the lid is actuated by a pneumatic cylinder, flow regulators are fitted at boat inlet ports of the pneumatic cylinder to regulate the flow rate of exhaust air, i.e. rate of opening / closing. Check to ensure that the flow regulators are installed in the correct direction such that the flow of air can be regulated when flowing from the pneumatic cylinder. The flow regulators shall be adjusted so that the time for closing / opening the lid is not less than 15 sec. Do not set the time shorter than specified as there will be an excessive impact. Check to ensure that the cushioning screws at both ends of the pneumatic cylinder are at their optimum position. For the lower cushioning screw its position must be adjusted until the lid passes over the center of the hinge when the lid is opened. For the upper cushioning screw, its position must be adjusted until the lid is sitting on the lid seal but not pressing when the lid is closed. After setting, tighten up the lock nut on the flow regulators. Never remove, by pass the flow regulators or use faulty regulators.

4.4 HIGH TEMPERATURE DIRECT DRAIN

With high temperature direct drain device, the dye liquid (>85?C) (>185?F) is not cooked down to below 85?C (185?F) when it is drained.

When draining with a high temperature drain device with cold miming, the dye liquid is also drained at temperature above 85?C (185?F) except that the liquid is cooled down to 85?C (185?F) by mixing with coldwater. For safety purpose, the external piping for both draining method should be done as described below.

Observe the following precautions when installing and operating the HT draining device:

  • The outlet of the device should be connected with a pipe that leads directly to a sewer tank with a strong cover and the pope should be secured with clamps.
  • The outlet pipe of the device should be separated from any other drain line. It should not be connected to the plant’s normal draining system.
  • Check valves shall be installed in all drain pipes to prevent back flow of liquid.
  • Large enough main drain pipes shall be considered to absorb the energy being dumped into the system by the HT draining device.
  • Drain pipe must be made of such material capable or resisting corrosion, thermal and pressure stresses.

4.5 Prevent the machine from vibration

The machine is a vertical dank. Loose foundation bolts or parts attached to the machine will subject the vessel easily to vibration which in true will induce cycle stress. Excessive and prolonged cyclic stress will cause material failure. Therefore, the machine must be damped, eliminated, or isolated from the machine.

CHAPTER-FIVE

MACHINE RUNNING AND OPERATIONS

The primary purpose of trial running is to check and make sure that the machine will perform correctly before being put into production after its erection, repair or overhaul.

5.1 Prerequisite

· Make sure that person responsible for trial running has thoroughly read this manual and understood how the machine works and is aware of all necessary precautions and safety procedures, including those procedures prepared by the user, to guard against injury and or property damage.

· Final checkout on all installations is property and correctly connected and setting connection (mechanical, electrical, pneumatic) are free from obvious defect or out of adjustment.

· Check to ensure that the water, electrical power, steam and compressed are supplies to the machine are normal and available.

· Check to ensure that a sufficient amount of the correct type of lubrication oil has been added into the bearing housing of the circulation pump.

· Drain the water, if any inside the air/water separator at the pneumatic control panel.

· Check to ensure that correct lubricant which can stand up to 140?C (284?F) has been added into the bearing housing of the reversal valve.

· Check to ensure that lubricant which can stand up to 180?C (356?F) has been added to the valve stem of the pneumatic diaphragm valve.

· Check to ensure that lubricant has been added to pillow bock of the lid hinge.

5.2 Initial run

Prior to committing the machine to regular production, an initial run can help to reveal if any device on the MACHINE is out of adjustment, connected, leaking or defective.

Factory Seconds’ material may be prepared and used during the initial run. In this way if any defect exists in the MACHINE, it can be detected without sacrificing valuable first grade material.

Check also those optional components supplied with the machine even if they are not dealt with in this manual.

If no further problem is encountered, the MACHINE may be put into regular production.

5.3 Safety interlocks device-lid opening and closing

A pressure switch has been installed in addition to the mechanical interlock device to monitor the opening / closing the lid.

The pressure switch, capable of measuring 4 inches of water column, is used to detect the level to below the shell flange ring before the lid can be opened.

5.4 General description of functions

This section describes the operations of all available function not machine. Among them, some are optional features. Therefore, compiling your own procedure, refer only to those applicable.

In case there is any optional function not included in the machine, DO NOT ATTEMPT to modify the control circuit by you. Consult Fong’s for assistance. Undue consideration will lead to unsafe operation condition.

5.5 Power and operation mode

· At the switch cabinet, pull the handle of the mains isolator anticlockwise until it is engaged so that the mains supply is connected.

· Push “POWER ON” button to activate the control power.

· Select operation mode by turning the AUTO / MANUAL selector switch.

Note: “Manual mode of operation” is an operation initiated by the machine operator. It may be semi-automatic operation, for instance, by pushing a button to activate a solenoid valve to allow compressed air to drive a pneumatically operated valve.

Depending on the function of the push button on the control cabinet, part of them has illumination. When it is pushed once, the light illuminates to indicate that the signal is connected. When it is pushed once again, the light extinguishes to indicate that the signal is cut off. The illumination of the light is omitted is the following paragraph.

5.6 Operation-manual mode

  • Opening the lid-balanced by counter weight refer to sec. 1.3
  • Opening the lid-lid counter weight with pneumatic cylinder assisted lid actuator. Refer to sec. 1.3.
  • Closing the lid-balanced by counter weight. Refer to sec. 1.4.
  • Closing the lid-counter weight with pneumatic cylinder assisted lid actuator. Refer to sec. 1.4
  • Loading:
    • Follow the procedure in opening the Lid.
    • Lift the carrier loaded with the process material into the kier.
    • Follow the procedure in closing the Lid.
  • Filling (at atmospheric temperature and pressure

When carrying out the FILLING (Main machine) Operation, the following must be confirmed:

· The lid is closed.

· The safety interlock vent valve is closed.

· The overflow rinse valve is opened. (This valve opens automatically when the fill valve is opened)

· The pressure release valve opens. (This valve opens automatically when the fill valve is opened)

  • Filling (first fill) (cold fill)
    • Check to ensure that the drain valve is closed.
    • When fill valve is opened, overflow rinse valve opens automatically by the controller.
    • At the switch cabinet, push the button (kier) “FILL 1”.

The machine supplied with the optional second Fill is basically operated in the same procedure as described in sec.

The machine applied with the optional Blend Fill is basically operated in the same procedure as described. In addition, observe the following:

  • The temperature of the blended water must not be higher than 80?C (176?F)
  • When a temperature controller is used to monitor the temperature of the blended water, set the temperature before carrying out the fill procedure.

Circulation

The position of the reverse valve is controlled by the push button (kier) “O-I” and “I-O” on the control cabinet.

Circulation without flow reversing

At the control cabinet

  • Push the button (kier) “SEMI-AUTO”, the main pump starts and the reverse valve is positioned accordingly.
  • Turn the knob (kier) “M.D Adj” to adjust the main pump speed to an appropriate flow rate.

At the control cabinet

  • Push the button (kier) “SEMI-AUTO”, and turn the knob “M.P. Add” to adjust the main pump speed to an appropriate flow rate
  • The reverse valve will reverse the flow direction according to the set time from inside-out to outside-in continuously.

Pressurization

Push the button (kier) “Pressure” When the pressure inside the kier reaches the maximum setting of 2 bar, it stops automatically. When the temperature of the liquor increases, the pressure inside the kier also increases and exceeds the aforementioned pressure setting. Otherwise, there may be leakage at the seals or the pressure gauge is malfunction. In such cases, perform the following.

  • Check to ensure that the lid seal is tight, there is not leakage at the piping and the pressure gauge is functioning properly.
  • When maintenance is required, follow strictly the maintenance procedure.

Heating

The heating function in the Manual mode controls the heating rate by controlling the current of modulation valve for heating. Set the red pointer of thermometer to 140?C (284?F) for the upper limit, if the temperature reaches 140?C (284?F), the modulation valve for heating will close automatically.

  • Push the button (kier)”HEAT” and turn the adjusting knob (kier) “TEMP. ADJ to adjust the opening of the modulating valve to control the heating rate.
  • The steam inlet valve and the condensate outlet valve shall open.
  • When the temperature reaches the desired value, push the button (kier) “HEAT” AGAIN.

Cooling

  • Push the button (kier) “SOOL” and turn the adjusting knob (kier) (TEMP.ADJ)” to adjust the opening of the modulating valve to control the cooling rate.
  • The cooling water inlet and outlet valves at the heat exchanger opening.
  • When the temperature reaches the desired valve, push the button (kier) “COOL” again to close the cooling water inlet and out valves.

Dyestuff injection

The dyestuff and chemical additives required for the dyeing process shall be added via the service tank (or dosing tank).

At the control cabinet

  • Push the button (SIDE TAND) “FILL” to add water into the service (or dosing) tank. When the level is reached, push the button (DIDE TANK) “FILL” to close the fill valve.

At the machine

  • Add the dyestuff or chemical into the service (or dosing) tank. Open the direct steam manual heating valve to heat up the soluti9on when needed.
  • When the desired temperature is reached, close the direct steam manual heating valve.

At the control cabinet

· When mixing is needed, push the button (SIDE TANK) “MIXER” to start the stirrer push the button (SIDE TANK) to start mixing by the feed pump.

· When injection into the machine is needed, push the button (SIDE TANK) “DOSING” to start the feed pump, and turn the adjusting knob (SIDE TANK) “DOSE ADJ” to adjust for a suitable injection rate.

· The level at the service tank (or dosing tank) lowers while the level inside the machine rises.

· When the injection is over, push again the button (SIDE TANK) “MIXER”, “DOSE” AND “MIXING”.

· To clean the service tank (or dosing tank), push the button (SIDE TANK) “FILL” to add water into the tank, and push the button (SIDE TANK) “MIXING” to clean the feed pump and the piping. Then push the button (SIDE TANK) “FILL” and “MIXING” to close the fill valve and mixing valve. Push the button (SIDE TANK) “DRAIN” to drain away the residual water from the tank.

Overflow Rinsing

It is a continuous process of filling and overflow drain from the overflow rinse valve.

To carry out the rinsing process, there must be pressure inside the Machine and the temperature of the liquid has been cooled down to below 85?C (185?F).

At the cabinet

  • Push the button (KIER) “OVERFLOW”. The fill valve and overflow rinse valve of the machine open simultaneously.
  • Check the outlet of the overflow rinse valve that the dye liquor flowing out is clear or according to process technique, stop the overflow rinsing
  • Push the button (KIER) “OVERFLOW”. The fill valve and overflow valve of the machine close.

Draining

Check to ensure that

  • The temperature of the dye liquid has been cooled down to below 85?C (285?F). If not, cool down the machine temperature before proceeding further.
  • The circulation pump and the feed pump are stopped.

At the switch cabinet

  • Push the button (KIER) “DEPRESSURE” to open the pressure release valve.
  • After a time delay, push the button (KIER) “OVERFLOW” to open the overflow rinse valve.
  • After another time delay, push the button (KIER) “DRAIN 1” or DRAIN 2” to open the corresponding valve.

Note: All other drain valves are optional except DRAIN 1 valve.

  • When the draining completes, push the button (KIER) “DRAIN 1” or “DRAIN 2” and “OVERFLOW”, “DEPRESSURE” to close the drain valve, the pressure release valve and the overflow rinse valve.

Draining (At temperature above boiling point: 100) (Optional)

During the draining operation, the pressure gauges and temperature indicator are not indicating correct reading correct readings. Until the machine is filled with water and the circulation pump is running, the indicators are indicating the actual temperature and pressure inside the machine. It is important for the user to bear in mind that when draining liquid at a temperature above boiling point, the liquid is forced out from the machine at a saturated pressure corresponding to that temperature, the piping system carrying away the hot liquid must be strong enough to withstand the pressure and temperature. The pipe clamps must also be strong to hold the pipes in place.

The installation requirements detailed must be observed.

  1. Draining at high temperature (Equipped with high temperature draining device) (Optional)
  • Confirm that the compressed air supply is normal
  • This function can only be completed in the AUTO made by the micro-processor.
  • When the above conditions are fulfilled, the machine is ready for high temperature direct drain operation

Preparation tank (Optional)

      • Fill

§ At the control cabinet, push the button (AUX. TANK) “FILL” to open the fill valve of the preparation tank.

§ When the level inside the preparation tank is reached, push again the button (AUX. TANK) “FILL” to close the fill valve of the preparation tank.

      • Draining

§ At the control cabinet, push the button (AUX. TANK) “FILL” to open the fill valve of the preparation tank.

§ When the level inside the preparation tank is all drained away, push again the button (AUX. TANK) “DRAIN” to close the drain valve of the preparation tank.

  • Heating
    • At the control cabinet, push the button (AUX. TANK) “HEAT” to open the heating valve.
    • When the preparation is reached, push again the button (AUX. TANK) “HEAT” to close the valve.
    • In case there is a temperature controller (Optional), set also the temperature.
  • Level in (Preparation Tank ? kier)

It is a procedure to draw the liquid inside the preparation tank into the kier.

§ Confirm that

· The machine is loaded.

· The lid is closed properly.

· The safety interlock vent valve is opened.

· The overflow rinse valve is opened.

· The pressure release valve is opened.

· All other valves are closed.

· The level at the preparation tank is at high level.

· The level at the kier is at low level.

· At the control cabinet push the button (AUX. TANK) “LEVEL IN” to start the level-in procedure that the liquid the preparation tank is transferred into the kier.

· At the control cabinet push the button (KIER) “I-O” to start the main pump and reverse valve at the inside-out position.

· When the level reached the preset level, push the button (AUX TANK) “LEVEL IN” to start the level-in procedure.

· The machine is ready for the next step.

Level-out (From the kier? preparation tank)

Do not perform level-out when there is pressure inside the kier and the machine

temperature is above 85?C (285?F) while the machine is running.

This is a procedure to let the liquid the machine transfer into the

preparation tank.

Confirm that the temperature of the dye liquor has been cooled down to below

85?C (185?F). If not, do not proceed any further. Cool down the machine

temperatur before proceeding.

At the switch cabinet

· Push the button (KIER) “HEAT” or “COOL” to heating or cooling.

· Push the button (SIDE KTANK) “INJKECTION” to stop the feed pump.

· Push the button (KIER) “I-O” or “O-I” to stop the circulation pump.

· Push the button (KIER) “DEPRESSURE” to open the pressure release valve.

· Push the button (KIER) “ORERLOW” to open overflow rinse valve.

· Push the button (AUX. TANK) “LEVEL OUT” to start the level out procedure. The liquid inside the kier is transferred to the preparation tank.

· When the level at the preparation tank reaches the high level or the level inside the kier reaches the low level, the level-out procedure stops.

· The machine is ready for the next step.

Running the machine with the lid opening (Non standard operation procedure)

The control program will be modified to provide this function only when the customer has confirmed by writing that he accepts all the responsibility for any accident inherent with this procedure.

When the machine temperature is above 60?C (140?F) and the liquid contains chemical which reacts with each other very vigorously, running the machine with the lid opened will cause personnel injury or property damage. Hot liquid splashing out from the kier will cause severe burns. Wear protective gear when the machine is running.

When running the machine with the lid opened, check to ensure that

  • The machine is half-filled.
  • The machine temperature is below 60?C (140?F).
  • Heating is stopped before the circulation is started.

If the level inside the kier is more than a half, drain the machine before loading the carrier into the kier.

When dyeing procedure is carried out, close the machine as described in this manual.

Operation- Automatic mode

Before starting the program

Before proceeding to the machine operation, prepare a documented dyeing program.

  1. At the switch cabinet, select operation mode by turning the AUTO / MAN selector switch to position AUTO.
  1. Download the dyeing program into the memory of the micro-processor cording to the procedures described in the manual for microprocessor.
  1. After program is downloaded, DO NOT start the program yet.
  1. If there is a level control (Optional), check that the level sensor is placed at the correct level.
  1. Check to insure that the lid is closed and locked.
  1. Check to insure that the all manual valves are closed after loading.
  1. Check to insure that the compressed air supply is normal.
  1. Check to insure that the light indicator of all control switches is extinguished except the “POWER ON” button.

When sampling call signal is illuminated, carry out sampling procedure described in the manual. When documenting a dyeing program, safety precaution steps must be included, especially to the following control functions:

1. Filling

There must be no step calling for heating prior to the FILL step.

2. Draining

There must be no step calling for heating prior to below at least 85?C (185?F) and hold the temperature for 2 minutes. Prior to executing the DRAIN step.

3. Sampling

There must be a step calling for cooling to below at least 85?C (185?F) and hold the temperature for 2 mines. In case the bath temperature is higher than 85?C (185?F)

4. Continuous Overflow Rinsing

If the program includes a rinsing step, rinsing time must be in the microprocessor when the machine is running in the AUTO mode.

Chapter-six

MAINTENANCE AND TROUBLES HOOTING

6.1 General Maintenance

The following maintenance scheme is suggested to be carried out periodically in accordance with your normal maintenance schedules.

Normally a dyeing machine comprises the following major components which periodic maintenance is necessary (Applied only to those installed on your machine)

§ A circulation pump

§ A dyestuff feed pump

§ Flow reversal device

§ A main switch cabinet or switch gear

§ A pneumatic control panel

§ Gear motor

§ Transmission with belts

§ Pneumatic actuated pistons

§ Pneumatic actuated or manual operated butterfly valve

§ Sealing / Gasket at removable door

§ Flow reversal device

The Teflon sleeve inside the device shall be checked for wear every 2-3 months.

§ Main switch cabinet or switch gear

The components inside the cabinet shall be cleaned by sucking with a vacuum cleaner every 6 months.

§ Pneumatic control panel air water separator: Drain the water daily

§ Gear motor

Refer to the instruction manual of the gear motors for scheduling lubrication and replacement of bearing.

  • Transmission with belts

The belts shall be checked for air tightness every 6 months.

  • Pneumatic actuated piston

The piston seals shall be checked for air tightness every 9 months.

  • Pneumatic actuated or manual operated butterfly valve

The valve seat and the gland packing shall be checked for their tightness every 9 months.

  • Sealing or gasket at removable service door

The sealing or gasket shall be checked for tear and wear out every 3 months.

  • Pneumatic actuated diaphragm valve

The valve seat and the gland packing shall be checked for tightness every 9 months.

6.2 6.2 Trouble shooting

TROUBLE CAUSE REMEDY
1. Pneumatic diaphragm valve failure Lack of compressed air supply or insufficient pressure. Adjust air supply.
Valve diaphragm failure. Replace the valve diaphragm.
O-ring located below the diaphragm has deteriorated and air is leaking. Replace the O-ring.
Valve seat or seat ring worn out. Replace the valve seat or seat ring.
Pneumatic hose between panel and valve is leaking. Find and replace leaking pneumatic hose or bad connection.
2. No heating or heating speed abnormally slow. Alarm indicated by temperature control system. Respond and correct the alarm.
Lack of steam supply or insufficient steam pressure. Improve steam supply and /or pressure.
Failure on pneumatic valve associated with steam / condensate pipe work. Improve steam supply and / or pressure.
Blocked steam trap. Open the steam trap, clean and remove any substance depositing inside it.
Steam trap connected wrongly (Upside down or inlet / outlet interchanged). Reconnect the steam trap correctly.
Differential pressure across steam trap too small. Improve condensate return line
Temperature control system faulty. Check temperature control system and the temperature sensor.
No or low cooling water Improve cooling water supply and
pressure. / or pressure.
Diaphragm valve malfunctioning. Improve cooling water supply and / or pressure.
Temperature control system faulty. Check temperature control system and the temperature sensor.
Temperature control system faulty. Check temperature control system and the temperature sensor.
Temperature control system faulty. Check temperature control system and the temperature sensor.
3. No cooling or cooling rate is abnormally slow Diaphragm valve malfunctioning Check temperature control system and the temperature sensor.
Temperature control system faulty. Check temperature control system and the temperature sensor.
Temperature control system faulty. Check temperature control system and the temperature sensor.
Temperature control system faulty. Check temperature control system and the temperature sensor.
4. poor dyeing result Incorrect setting of flow rate. Adjust the pump speed.
Insufficient static pressure. Check air pressure K
No change in flow direction. Check flow reversal valve and control system.
Flow reversal valve faulty. Check flow reversal valve and control system.
Package too tight. Check and correct.
Lack age between package and spacer. Check and correct.
  1. Low or no pressure indication
 Leak age in pimp suction. Check piping system.
Flow reversal valve at wrong position. Check flow reversal valve and control system.
Faulty Gauges. Check and replace.
Loose connection pipe. Check and tighten.
  1. Flow reversal valve faulty.
 Pneumatic Cylinder not working. Check air supply, check pneumatic cylinder.
Limit switch activated. Check and replace.
Worn-out shaft. Check and replace.
Jammed bearing. Check and replace.
  1. Vessel pressure / temperature continue to increases when machine stops.
 Pneumatic diaphragm valve leak age. Check and replace.
Gland packing leak. Check and replace or tighten.
  1. No fill or drain
 Sensors short-circuited. Check clean, and replace.
Float jammed. Check clean, and replace.
Kier temperature above 85 Cool machine temperature.
Pressure inside kier above lower flange ring. Open safety interlock vent valve when liquid temperature <85.
  1. Safety interlock pin does not retract.
 Kier temperature above <85 Cool machine temperature.
Level inside kier above lower flange ring. Open safety interlock vent valve.
Pressure inside kier. Open safety interlock vent valve when liquid temperature <85.
Air line broken. Check and repair.
Pilot solenoid valve faulty. Check and repair.
Control system faulty. Check and repair.
PLCI / O error. Check.
  1. Machine does not run.
 PLC error lost of memory. Check and replace battery.
  1. No level-out / level out.
 Line temperature above <85. Col machine temperature.
Air supply is cut off. Check air line and solenoid valve.
Pressure inside kier. Check and release pressure.

Chapter-Seven

Machine safety

7.1 Machine safety

The machine is designed for operation at high temperature and pressure. No person should be allowed to operate the machine until he has been instructed in the safe operation procedures and been advised of the hazards that could result from incorrect operation.

7.2 General

Taking the following precautions can prevent accidents.

· Do not exceed the correct fill level, including the open service tank.

Before draining the machine, stop the circulation and injection pumps and discontinue heating or cooling.

· Do not attempt to open the lid, until the machine temperature is below 85?C (185?F), both the circulating and injection pump are stopped, pressure gauges read “0” and the liquid level inside the kier has been lowered by level-out or the machine is completely drained.

· Do not attempt to increase temperature unless the machine is filled to the correct level, the lid is closed and locked, the safety interlock vent valve is closed and the circulating pump is running.

· Do not attempt to open the lid when the machine is full of liquid.

· Do not carry out maintenance on the machine when it is not empty.

· Do not carry out maintenance on the machine when it is pressurized. Observe all other precautions and safety procedures outlined in this manual whenever they are appropriate.

· Perform inspection of all switches and calibration of all pressure gauges, thermometers, indicators, and sensors at least once a year.

· Do not operate the machine when the pressure gauges and thermometer are out of calibration or their indications are suspected to be incorrect.

· Perform inspection and thickness check at least once a year on the closure elements of the vessel to ensure that their thickness has not been reduced to below the minimum required.

· Perform inspection at least once a year on the hinge and connecting elements of the lid to ensure that all parts are intact.

· Perform inspection at least once a year on the hinge and connecting elements of the lid to ensure that all parts are intact.

7.3 Care of stainless steel

  • The mechanism of localized corrosion

Metallurgical experts pointed out long time ago that pitting, crevice corrosion and stress corrosion cracking which are serious localized attacks may occur in stainless steel subject to solution containing chloride. The localized corrosion is frequently observed in most the dyeing vessel surfaces of which are not properly cleaned, maintained and protected.

When a clean stainless steel surface is exposed to an oxidizing condition or environment such as the atmosphere or a dilute nitric acid solution, due to the oxidation process, the chromium at the surface of the stainless steel is oxidized to forma then chromium oxide film which separates the stainless steel from its surrounding medium. It is the chromium oxide film preventing further corrosion in the stainless steel.

the chromium, oxide film is damaged, either chemically or mechanically, and it cannot be restored, localized corrosion in the exposed area occurs. When the stainless steel is in an acidic reducing solution, oxide film may not be formed. Thereby the metal remains active and is continuously dissolved in the reducing solution.

In some dyeing processes such as sulphur dyeing or vat dyeing, a reducing solution technique is employed in some phases of the processes. The reducing solution reduces the amount of oxygen inside the vessel and in the dyeing solution. When there is already deposited substance adhered to the metal surface, the oxygen entrapped there to will all be reduced. The lock of oxygen will highly interfere with the maintenance of the passivity of the recovery of the protective chromium oxidized film on the stainless steel surface.

At weak spots of the passive chromium oxide film, chloride ions penetrate the film leading to localized corrosion attacks. The penetrated area forms an anode and the

Chloride salt and concentration of the solution, we suggest treating the machine by using a liquid both at 40?C (140?F) with 3%nitric acid. The steel surface must be exposed to the solution for at least an hour to obtain the best passivity. Before the passivity process is carried out, the stainless steel surface must be cleaned from foreign particle and chemical.

The nitric acid solution must be neutralized with sodium carbonate before draining and the machine must be flushed

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