A Swiss Bangladesh joint venture thread swing dyeing Industries by lawjuris

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

Chapter-One Introduction

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

1.3 Scope This report will cover the Operation and Maintenance Fongâ&#x20AC;&#x2122;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 itâ&#x20AC;&#x2122;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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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 areEtafil (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 customersâ&#x20AC;&#x2122; needs for value added high quality products. We will be the standard for total performance in the market we serve.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

2.7 Back-Up Service ď&#x192;&#x2DC; 24 Hours service

2.8 Stock House:

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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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. 10

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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. 12

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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 85Ë&#x161;C (285Ë&#x161;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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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 85Ë&#x161;C the high temperature draining valve is allowed to open.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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 16

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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: 18

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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 ď&#x192;&#x2DC; 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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 Secondsâ&#x20AC;&#x2122; 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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 Fongâ&#x20AC;&#x2122;s for assistance. Undue consideration will lead to unsafe operation condition.

5.5 Power and operation mode 23

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 

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. 32

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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 levelout 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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Before proceeding to the machine operation, prepare a documented dyeing program. a. At the switch cabinet, select operation mode by turning the AUTO / MAN selector switch to position AUTO. b. Download the dyeing program into the memory of the micro-processor cording to the procedures described in the manual for microprocessor. c. After program is downloaded, DO NOT start the program yet. d. If there is a level control (Optional), check that the level sensor is placed at the correct level. e. Check to insure that the lid is closed and locked. f. Check to insure that the all manual valves are closed after loading. g. Check to insure that the compressed air supply is normal. h. 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)

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

6.2

6.2 Trouble shooting

TROUBLE CAUSE 1. Pneumatic Lack of compressed air supply or diaphragm valve insufficient pressure. failure Valve diaphragm failure. O-ring located below the diaphragm has deteriorated and air is leaking. Valve seat or seat ring worn out.

REMEDY Adjust air supply. Replace the valve diaphragm. Replace the O-ring. Replace the valve seat or seat ring.

Pneumatic hose between panel Find and replace leaking and valve is leaking. pneumatic hose or bad connection. 2. No heating or Alarm indicated by temperature Respond and correct the alarm. heating speed control system. abnormally slow. Lack of steam supply or Improve steam supply and /or insufficient steam pressure. pressure. Failure on pneumatic valve Improve steam supply and / or associated with steam / pressure. condensate pipe work. Blocked steam trap. Open the steam trap, clean and remove any substance depositing inside it. Steam trap connected wrongly Reconnect the steam trap (Upside down or inlet / outlet correctly. interchanged). Differential pressure across Improve condensate return line steam trap too small. 39

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Temperature faulty.

control

system Check temperature control system and the temperature sensor.

No or low cooling water

Improve cooling water supply and

pressure.

/ or pressure.

Diaphragm malfunctioning. Temperature control faulty. Temperature control faulty.

valve Improve cooling water supply and / or pressure. system Check temperature control system and the temperature sensor. system Check temperature control system and the temperature sensor.

Temperature faulty.

system Check temperature control system and the temperature sensor.

control

Diaphragm valve malfunctioning 3. No cooling cooling rate abnormally slow

or is

Temperature faulty. Temperature faulty. Temperature faulty.

control control control

Check temperature control system and the temperature sensor.

system Check temperature control system and the temperature sensor. system Check temperature control system and the temperature sensor. system Check temperature control system and the temperature sensor.

Incorrect setting of flow rate. Insufficient static pressure. No change in flow direction.

Adjust the pump speed. 4. poor dyeing result Check air pressure K 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 Check and correct. spacer. a. Low or no Leak age in pimp suction. Check piping system. pressure Flow reversal valve at wrong Check flow reversal valve and indication position. control system. c. Faulty Gauges. Check and replace.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Loose connection pipe. e. Flow reversal Pneumatic Cylinder not working. valve faulty.

Check and tighten. Check air supply, pneumatic cylinder.

check

Limit switch activated. Check and replace. Worn-out shaft. Check and replace. Jammed bearing. Check and replace. i. Vessel pressure Pneumatic diaphragm valve leak Check and replace. / temperature age. continue to Gland packing leak. Check and replace or tighten. increases when machine stops. k. 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 Open safety interlock vent valve flange ring. when liquid temperature <85. o. Safety interlock does retract.

Kier temperature above <85

Cool machine temperature.

pin not Level inside kier above lower Open safety interlock vent valve. flange ring. Pressure inside kier. Open safety interlock vent valve when liquid temperature <85. Air line broken.

Check and repair.

Pilot solenoid valve faulty. Control system faulty.

Check and repair. Check and repair.

PLCI / O error. v. Machine does PLC error lost of memory. not run. w. No level-out / Line temperature above <85. level out. Air supply is cut off.

Check. Check and replace battery. Col machine temperature. Check air line and solenoid valve. 41

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  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. 43

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 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 40Ë&#x161;C (140Ë&#x161;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.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur The nitric acid solution must be neutralized with sodium carbonate before draining and the machine must be flushed intensively with water. 1. Opening the lid The following procedure must be carried out in the exact sequence described. Do not attempt to open the lid if the operator has not been trained for the operating procedure.  While the machine is running, check to ensure that the machine temperature is below 85˚C (185˚F). If not, do not proceed any further. Cool down the temperature before proceeding.  Stop heating / cooling.  Stop the circulating and injection pumps.  Check pressure gauges- they must read “0”.  Ensure that no person is in a position which would be injured or no object would obstruct the lid while opening.

 Do not allow personnel other than the authorized machine operator to stay in the vicinity of the machine. a. Open the flow return valve, than open the safety interlock vent valve. Check to ensure that there is no discharge of air or liquid. If such discharge takes place, wait until it has completely stopped before proceeding. If such discharge does not stop, do not proceed further. Call maintenance personnel. b. The pneumatic cylinder for locking carrier must be firstly retracted before proceeding with step 7a.  When discharge stops check again to ensure that all gauges read “0”. Insert the geared opening lever in the first socket, move it to the fullest extent of travel. The kier lid should move easily with light pressure applied. Do not attempt to force lid open by lengthening the geared opening lever or applying unusual effort. The first movement of the geared lever removes the compressive force from the sealing

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur gasket while retaining the lid in the closed position. Check to ensure that, no liquor of air is escaping around the periphery of the lid. If such discharge does not stop, do not proceed further. Call maintenance personnel.  When any such discharge has stopped, transfer the feared lever to the second socket.  When the lid has been rotated fully counter-clockwise, it may be opened by pushing the lid counter weight downward (If equipped with a pneumatic assisted lid actuator or lid counter weight with pneumatic assisted lid actuator). 5. Closing the lid  Check to ensure that the carrier Hold-down device is securely tightened.  Conform that all spindles have their package hold-down devices properly fastened.  Check to ensure that no loose item have been laid on top of the packages.  Make sure that no person is in a position to be injured by the lid or no object is in a position to obstruct the lid while it is closing.  Check to ensure that the geared lever is not in one of the sockets.  Lower down the lid by lifting the lid counter weight (If equipped with a counter weight) of actuating the lid switch to the closing position (If equipped with a pneumatic assisted lid actuator or lid counter weight with pneumatic assisted lid actuator) a. After the lid is lowered down to the closing position-Insert the geared lever is the right hand socket and moves it to the fullest extent of its travel so as to move the lid in the clockwise direction. Transfer it to the left hand socket and repeat the operation. b. The pneumatic cylinder for locking carrier must be firstly retracted before proceeding with step 7a.  Confirm y testing that the discharge passage of the over-flow rinse valve and the safety interlock vent valve are not jammed, blocked, and clogged by foreign particles.  Close the safety interlock vent valve and over-flow rinse valve.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

7.4 How to depressurize the machine  While the machine is running check to ensure that the machine temperature is below 85˚C (185˚F), of not, do not proceed any further, Cool down the temperature before proceeding.  Stop heating / cooling.  Stop the circulation and injection pumps.  Do not allow personnel other than the authorized machine operator to stay in the vicinity of the machine.  At the control cabinet, push the button “DEPRESSURE” to open the pressure release valve.  Check if there is vapor and liquid still discharging from the valve. If not, wait until discharge stops before proceeding. If such discharge does not stop, do not precede further, call maintenance personnel.

7.5 Emergency cooling When the cooling water inlet valve at the heat exchanger is inoperative, and the machine is at a temperature higher then 85˚C (185˚F), the machine operator should call the maintenance personnel immediately to deal with the situation. The latter must follow the following procedures for an emergency cooling.  Isolate the electric power supply.  Isolate the steam supply.  Cover all electric installation at the machine with water-resistant material.  Spray the external surface of the machine kier with water.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur  When temperature is below 85˚C (185˚F) reinstate the electric power supply and follow the normal start-up procedure. Check the temperature again when the circulation pump is running.

 Only when the temperature of the dyeing liquid with the circulation pump running is below 85˚C (185˚F), depressurization or other operation can then be carried out.  If the temperature is still above 85˚C (185˚F), repeat the above steps.

7.6 Pressure indication Depending on the design, two pressure gauges are mounted on the top of the switch cabinet or at the machine to indicate the pressure inside the kier. When the machine stops, the pressure indicated is the static pressure inside the kier. When the machine is running, one of the gauges is indicating the static pressure inside the kier plus the pump discharge pressure while the other gauge is indicating the static pressure inside the kier plus the pump suction pressure.

7.7 Temperature indication  While the machine is running, the actual temperature of the dyeing liquor is indicated by:  

Depending on the design, a capillary type temperature indicator or an external digital indicator and The microprocessor

 The capillary type temperature indicator has th5ree pointers which are colored separately as black, red and yellow.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur The black pointer indicates the kier temperature. The yellow and red pointers are indicator with electrical contacts. They do not move with temperature changes. The yellow pointer is factory set at 85˚C (185˚F) so that the fill, drain, overflow, follow return, injection and connection valves cannot be opened except the high temperature draining.

The red pointer is factory set at 140˚C (284˚F) so that the steam inlet valve will be cut off when the kier has reached its maximum design temperature of 140˚C (284˚F) in the case of manual heating.  When the both temperature is above 85˚C (185˚F), the electrical signals controlling the solenoid valves of the following pneumatically actuated valves are isolated:

Fill valve



Drain valve



Connection valve



Flow return valve



Overflow rinse valve



Injection valve

 In the system there are valves other than those mentioned in sec 1.9. The ports of these valves connected to the system are under pressure and temperature above atmospheric while the other ports are at atmospheric conditions when the machine is running. The pneumatically controlled valves having the described operating characteristics are isolated when temperature is above 85˚C (185˚F).

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

7.8 Always keep the lid closed The lid should be always kept in its closed position when the machine is not in use. 14. Safety valve Taking the following precaution may prevent accidents:  When the pressure and temperature inside the kier is above atmospheric, do not carry out any maintenance on the safety valve  When opening the level of the safety valve, always wear protective gear such as high temperature cloths, gloves and goggles  Never attempt to set the safety valve to other set pressure  Check the safety valve at least once a year  Stop the machine before carry out maintenance on or repair the safety valve.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

Chapter Eight Conclusion From this study I have Knowledge about “Operation and maintenance of fang’s yarn dyeing machine. Such as maintenance activities, through whole operation systems, study troubleshooting of Textile Machinery, integrated Servicing schedule of all the equipment, manpower and other resources of the organization etc. Yarn dyeing machine is used for yarn color and wash purpose. Lots of single yarn cone dyeing by a career beam. One career contain about 400-500 single yarn cone. This process is used for dyeing machine. Dyeing is the most critical process for textile for thread dyeing unit. This machine is too much expensive machine for dyeing project. From this machine various types of color yarn production is possible. This dyeing process is called slashes dyeing process and also another is called rope dyeing process. This machine is run at automatically and capable of various design, this machine run by programmable logic control system. Individually there are 100 KG, 250 KG, 500KG, 1000 KG, 2000 KG and 3000 KG dyeing machine working together. There have much type machinery in organization. But I cannot describe this report. Because I chouse for practicum report only “Operation and 51

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Maintenance Fong’s yarn dyeing machine” and I hope it will helpful for me in my service life immensely. This will help in deciding which equipment will best serve the purpose. Finally, experience is also a big factor.

Recommendation As a very fast blooming industry “Etafil (Bangladesh) Limited” has been designed nicely with its proper dyeing section. During my practicum I faced some problem. I think that if this problem can be overcome then production will be increased. Although, the system has got a balance with the mentioned procedure but it should be better of the industry might take some good move towards future with some remarkable steps. Those should be like.

 More Generating plant should be made to meet the future demand.  All the equipment should be kept orderly.  Proper instructions should be followed for any kind of yarn dyeing problem.  More expert people should be given in charge for time being; more skilled people should be appointed.  For safety purpose more steps should be made as there dyeing section.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

Chapter-Glossary Accuracy: The closeness of an indication or reading of a measurement device to the actual value of the quantity being measured. Usually expressed as Percents of full scale output or reading.

Active power: The product of the voltage across a branch of an alternating-current circuit and the component of the electric current that is in phase with the voltage. Adapter: A mechanism or device for attaching non-mating parts. Air Compressors: An air compressor or a gas compressor operates on the simple principle of taking in a quantity of air or a certain gas and increasing its pressure many times over by reducing its volume. Ammeter: An instrument used to measure current. Ampere (amp): A unit used to define the rate of flow of electricity in a circuit; units are one coulomb per second. Amplifier: A device which draws power from a source other than the input signal and which produces as an output an enlarged reproduction of the essential features of its input. Amplitude Span: The Y-axis range of a graphic display of data in either the time or frequency domain. Usually a log displays but can also be linear. Amplitude: A measurement of the distance from the highest to the lowest excursion of motion, as in the case of mechanical body in oscillation or the peak-to-peak swing of an electrical waveform.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Application Program: A computer program that accomplishes specific tasks, such as word processing.

Apparent Power: The product of the root-mean-square voltage and the root-meansquare current delivered in an alternating-current circuit, no account being taken of the phase difference between voltage and current. ASCII: American Standard Code for Information Interchange. A seven or eight bit code used to represent alphanumeric characters. It is the standard code used for communications between data processing systems and associated equipment. ASME: American Society of Mechanical Engineers. ASTM: American Society of Testing and Materials. Auto-Zero: An automatic internal correction for offsets and / or drift at zero voltage input. Automatic Reset: 1.A feature on a limit controller that automatically resets the controller when the controlled temperature returns to within the limit bandwidth set. 2. The integral function on a PID controller which adjusts the proportional bandwidth with respect to the set point to compensate for droop in the circuit, i.e. adjusts the controlled temperature to a set point after the system stabilizes. AWG: American wire Gage. Beat Fit Straight Line (BFSL): A line midway between two parallel straight lines enclosing all output vs. pressure values. Beta Ratio: The ratio of the diameter of a pipeline constriction to the unconstricted pipe diameter. BLAS Current: A very low-level DC current generated by the panel meter and superimposed on the signal. Breakdown Voltage Rating: The DC or AC voltage which can be applied across insulation portions of a transducer without arcing or conduction above a specific value. Bridge Resistance: See input impedance and output impedance. 54

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

Buffer Capacity (B): A measure of the ability of the solution to resist PH change, when a strong acid or base is added. Bulb (Liquid-in-Glass Thermometer): The area at the tip of a liquid-in-glass thermometer containing the liquid reservoir. Capacitor: An electric circuit element used to store charge temporarily, consisting in general of two metallic plates separated and insulated from each other by a dielectric.

Ceramic: Polycrystalline ferroelectric materials which are used as the sensing units in piezoelectric accelerometers. CFM: The volumetric flow rate of a liquid or gas in cubic feet per minute. Charge Sensitivity: For accelerometers that are rated in terms of charge sensitivity, the output voltage (V) are proportional to the charge (Q) divided by the shunt capacitance (C). This type of accelerometer is characterized by high output impedance. Chatter: The rapid cycling on and off of a relay in a control process due to insufficient bandwidth in the control. Circuit Breaker: An automatic switch that stops the flow of electric current in a suddenly overloaded or otherwise abnormally stressed electric circuit. Clear: To restore a device to a prescribed initial state, usually the zero state. Clipping: The term applied to the phenomenon which occurs when an output signal is limited in some way by the full range of an amplifier, ADC or other device. Clock: The device that generates periodic signals for synchronization. Closeness of Control: Total temperature variation from a desired set point of system.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Current Transformer: In electrical engineering, a current transformer (CT) is used for measurement of electric currents; Current transformers are also known as instrument transformers. CPU: Central processing unit. The part of the computer that contains the circuits that control and perform the execution of computer instructions. DC: Direct current; an electric current flowing in one direction only and substantially constant in value. Density: Mass per unit of volume of a substance i.e. grams / cu. cm. Or pounds / cu. ft. Derivative: Derivative function senses the rate of rise or fall of the system temperature. Deviation: The difference between the value of the controlled variable and the value at which it is being controlled. Dissipation Constant: The ratio for a thermostat which relates a change in internal power dissipation to a resultant change of body temperature. Duplex Wire: A pair of wires insulated from each other and with an outer jacket of insulation around the inner insulated pair. Duty Cycle: The total time to one on / off cycle. Usually refers to the on / off cycle time of a temperature controller. Dynamic (Two- Plane) Balancing Machine: A dynamic balancing machine is a centrifugal balancing machine that furnishes information for performing two-plane balancing. Electrical Interference: Electrical noise induced upon the signal wires that obscure the wanted information signal. Electrode Potential established between an electrode and a solution when the electrode is immersed in the solution.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Electromotive Force (emf): The potential difference between the two electrodes in a cell. The cell emf is the cell voltage measured when no current is flowing through the cell. It canbe measured by means of a PH meter with high input impedance. Electronic industries Association (EIA): A standards organization specializing in the electrical and functional characteristics of interface equipment. EMF: Electromotive force. A rise in potential energy. End Points: The end points of a full scale calibration curve. Ferrule: A compressible tubular fitting that is compressed into a probe inside a compression fitting to form a gas-tight seal. Ferranti Effect: A rise in voltage occurring at the end of a long transmission line when its load is disconnected. Frequency: Number of cycles over a specified time period over which an event occurs. Gain: The amount of amplification used in an electrical circuit. Galvanometer: An instrument that measure small electrical current by means of deflecting magnetic coils. Generator: A device that produces electric current, usually by rotating a conductor in a magnetic field, thereby generating current through electromagnetic induction. Hertz (HZ): Units in which frequency is expressed. Horse Power: A unit of power in the U.S. Customary System, equal to 745.7 watts or 33,000 foot-pounds per minute.

Impedance: The total opposition to electrical flow (Resistive plus reactive). Input impedance: The resistance measured between two insulated points on a transducer when a specific DC voltage is applied at room temperature. IPTS-48: International Practical Temperature Scale of 1948. Fixed points in thermometry specified by Ninth General Conference held in 1948. ISA: Instrument Society of America. 57

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Isolation: The reduction of the capacity of a system to respond to an external force by use of resilient isolating materials. Isolator: A passive attenuator in which the loss in one direction is much greater than that in the opposite direction; a ferrite isolator for waveguides is an example. Joule: The basic unit of thermal energy. Junction: The point in a thermocouple where the two dissimilar metals are joined. Kilowatt (KW): Equivalent to 1000 watts. Kilowatt Hour (kwh): 1000 watt-hours. Kilovolt amperes (kva): 1000 volt amps. Kinetic Energy: Energy associated with mass in motion, i.e. Â˝ rV2 where r is the density of the moving mass and V is its velocity. kVA: Kilovolt amperes (1000-volt amps) Lag: 1. A time delay between the output of a signal and the response of the instrument to which the signal is sent. 2. A time relationship between two waveforms where a fixed reference point on one wave occurs after the same point of the reference wave. Leakage Rate: The Maximum rate at which a fluid is permitted or determined to leak through a seal. The type of fluid, the differential limits of Error; A tolerance band for the thermal electric response of thermocouple wire expressed in degrees or percentage defined by ANSI specification MC-96.1 91975). Lightning surge: A transient disturbance in an electric circuit due to lightning. Load Impedance: The impedance presented to the output terminals of a transducer by the associated external circuitry. Load: The electrical demand of a process expressed as power (watts), current (amps) or resistance (ohms).

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Load Line: a straight line drawn across a series of tube or transistor characteristic curves to show how output signal current woll change with input signal voltage when a specified load resistance is used. Maximum Power Rating: The maximum power in watts that a device can safely handle. Micro amp: One millionth of an ampere, 10-6 amps, ÂľA. Microvolt: One millionth of a volt, 10-6 volts. Mil: One thousandth of an inch (.001"). Milliamp: One thousandth of an amp, 10-3 amps symbol mA. Millimeter: One thousandth of a meter, symbol mm. Mill Volt: Unit of electromotive force. No Connection (N / C): A connector point for which there is no internal connection. NBS: National bureau of Standards. NEC: National Electric Codes. Negative Temperature Coefficient: A decrease in resistance with an increase in temperature. Null: A condition, such as balance, which results in a minimum absolute value of output. O.D: Outside diameter. Octal: Pertaining to a base 8 number system. Ohmmeter: An instrument used to measure electrical resistance. On / off Controller: A controller whose action is fully on or fully off. Open Circuit: The lack of electrical contact in any part of the measuring circuit. Peripheral: A device that is external to the CPU and main memory, i.e. printer, modem or terminal, but is connected by the appropriate electrical connections.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur Phase Difference: The time expressed in degrees between the same references points on two periodic waveforms. Phase proportioning: A form of temperature control where the power supplied to the process is controlled by limiting the phase angle of the line voltage. Phase: A time based relationship between a periodic function and a reference. In electricity, it is expressed in angular degrees to describe the voltage or current relationship of two alternating waveforms. Power Supply: A separate unit or part of a circuit that supplies power to the rest of the circuit or to a system. Resistance Temperature Characteristic: A relationship between a thermostatâ&#x20AC;&#x2122;s resistace and the temperature. Resistance: The resistance to the flow of electric current measured in ohms (1/2) for a conductor. Resistance is function of diameter, resistively and length. Resistor: A device used to control current in an electric circuit by providing resistance. SAMA: Scientific Apparatus Makers Association. An association that has issued standards covering platinum, nickel, and copper resistance elements. SCE: Saturated calomel electrode. SCR: Silicone controlled rectifier. Scroll: To move all or part of the screen material up to down, left or right TEMPCO: Abbreviation for â&#x20AC;&#x153;temperature coefficientâ&#x20AC;? The error introduced by a change in temperature. Terminal: An input / output device used to enter data into a computer and record the output. Thermal Conductivity: The property of a material to conduct heat in the form of thermal energy. Thermal Gradient: The distribution of a differential temperature through a body or across a surface. 60

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

Ungrounded Junction: A form of construction of a thermocouple probe where the hot or measuring junction is fully enclosed by and insulated from the sheath material. Union: A form of pipe fitting where two extension pipes are joined at a separable coupling. Vacuum: Any pressure less than atmospheric pressure. Vacuum pressure: The pressure exerted by a vapor in equilibrium with solid or liquid phase. Voltage: An electrical potential which can be measured in volts. Voltmeter: An instrument used to measure voltage. Watt Density: The watts emanating from each square inch of heated surface area of a heater. Youngâ&#x20AC;&#x2122;s Modulus: Youngâ&#x20AC;&#x2122;s Modulus is equivalent to the ratio of normal stress to strain. Zero point: The electrical zero Point where zero mill volts would be displayed. Zero Power Resistance: The resistance of a thermostat or RTD element with no power being dissipated. Zero Voltage Switching: The making or breaking of circuit timed such that the transition occurs when the voltage wave form crosses zero voltage.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur

CHAPTER-ACRONYMS A AC ACIA ACL AS AVC

Alternating Current (DC) Asynchronous Communication Interface Adapter Advanced CMOS Logic Advanced Schottky Automatic Volume Control

B BASIC Beginners All purpose Symbolic instruction Code BEV Billion Electron Volts BNC Baby N Connector BW Bandwidth C CC CCD CV CW

Constant Current Charge Coupled Device Constant Voltage Clock wise

D D/A DAC DC DCD DPI

Digital to Analog Digital to Analog Converter Direct current Date Carrier Detect Dots per Inch

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur E EGA ESA ESD EV

Enhanced Graphics Adapter European Space Agency ELECTROSTATIC Sensitive Device Electron Volt

F FET

Field Effect Transistor

FF FFT FIFO FILO

Flip flop Fast Fourier Transform First In First Out First In Last Out

G GA GAL GCS GIGO

Gate Array Generic Array Logic Gate Controller Switch Garbage In Garbage Out

H HD HTS HDC HZ

High Density High Tension Switchgear Hard Disk Controller Hertz

I IP IR ISN ISO

Interface Processor Infrared Information Systems Network In Search Of

J JFET Junction Field Effect Transistor JIS Japanese Industrial Standard JUG Joint Users Group K K KA

Kilo Kilo Ampere 63

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur KEV KHz KVA KWH

Kilo Electron Volts Kilo Hertz Kilo Volt Amperes Kilo Watt Hours

L LC LCD LED LIFO LW

Inductance and Capacitance] Liquid Crystal Display Light Emitting Diode Last In First Out Long Wave

M MHz Megahertz N NEDA National Electronics Distributors Association NEMA National Electronics Manufacturers Association NTSC National Television Systems Committee O OEM OS OTP OVP

Original Equipment Manufacturer Operating System One Time Programmable Over Voltage Protection

P PCM PEC PF PG

Pulse Code Modulation Photo Electric Cell Power Factor Power Gain

Q QA QC

Quality Assurance Quality Control 64

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur QIC Quarter inch Cartridge QIP Quad Inline Package QSM Quad Surface Mount

T TC TD TEM TF TWT

Temperature Coefficient Tunnel Diode Transverse Electromagnetic Transfer Function Traveling Wave Tube

U UHF UPS UTC UV

Ultra High Frequency Uninterruptible Power Supply Universal Time Code Ultraviolet

V VA Volt Ampere VAC Volts Alternating Current VOM Volt Ohmmeter W WV WW

Working Voltage Wire Wound

X XMT Transmit XTAL Crystal Y YAG Yttrium Aluminum Garnet YIG Yttrium Iron Garnet Z ZD

Zero Defects 65

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur ZIF ZIP

Zero Insertion Force Zigzag inline Package

BIBLIOGRAPHY 1. Metha, and Rohit Mehta. Principle of Power System. New Delhi: S. Chand and Company Ltd, 2002. 2. Nagpal. G.R. Power Plant Engineering. Delhi: Hanna Publishers, 2005. 3. Van Valkenburgh, Nooger, and Neville, Basic Electricity, Vol. 5, Hayden Book Company. 4. Buban and Schmitt, Understanding Electricity and Electronics, 3rd Edition, Mc GrawHill. 5. Kidwell, Walter, Electrical Instruments and measurements, Mc Graw-Hill. 6. Mason, C. Russel, The Art and Science of protective Relaying, John Wiley and Sons. 7. Wikipedia, 2009. D:\voltage stab\Voltage stabilizer (Oneline) (Updated on 2009) Available at: 8. http://en.wikipedia. Org/wiki/v/d 9. Alstom, T&D. â&#x20AC;&#x153;Tutorial of system protection Grading Studyâ&#x20AC;?. Analysis and protection 10. Of power System Coerce, London: 2002 11. Rao, Sunil S. Switchgear protedtion and Power system. 12th ed. Delhi: khanna 12. Publishers, 2003.

Etafil (Bangladesh) Limited (A Swiss Bangladesh joint venture thread swing dyeing Industries) Bhadam, Nishatnogor, Tongi, Gazipur 13. Specialist Engineers of GEC Measurement. Protective Relays Application Guide. 2 nd ed. 14. London: General Electric, 2001. 15. Stevenson, jr.Willium D. Elements of Power System Analysis. 4 th ed. Tokyo: McGraw-Hill, 2001.