I. Daily Maintenance Points
1. Pre-operation Inspection: Check the temperature gauge, pressure gauge, safety valve, and other instruments to ensure they are functioning properly. Confirm that there is no risk of leakage or short circuit in the electrical circuit, motor, and lighting system. Ensure the dyeing vat seals are intact to prevent leakage under high temperature and pressure.
2. Filtration System Cleaning: The filter screen is crucial to prevent the dye liquor from clogging the nozzles. When producing medium-length fiber fabrics, clean it once per shift; when producing polyester filament fabrics, clean it daily; before producing whitening products, the light-colored vat must be thoroughly cleaned.
3. Lubrication and Tension Adjustment: Regularly add lubricating oil to the bearings and main pump shaft seat to avoid dry friction leading to overheating and damage. Check the tension of the V-belts and maintain appropriate tension to ensure transmission efficiency.
4. Electrical and Control System Inspection: Check that the wiring connections are secure and that the PLC control system is operating normally. Address any abnormal alarms promptly to prevent the fault from escalating.
II. Regular Deep Maintenance (Recommended every 6 months)
1. Complete Shutdown Inspection: After shutdown, disassemble and inspect all mechanical parts, paying particular attention to the nozzles, guide rollers, and lifting rollers for wear or deformation. Replace any damaged parts immediately.
2. Internal Cleaning of the Dyeing Vat
Light Color Post-treatment: Hot water cleaning is sufficient.
Medium-Dark Color Post-treatment: Enhanced reduction cleaning is required. Use sodium hydrosulfite and detergent to remove residual dye and improve color vibrancy and fastness.
Dyeing Vat Cleaning Before Lightening: When dyeing a light color after a dark color, use 4–6 kg of 98% caustic soda + 1–2 kg of detergent. Clean at 130℃ for 60–90 minutes, maintain the temperature, and then drain at high temperature.
3. Special Cleaning of Nozzles and Pipes: Disassemble removable parts such as nozzles and filters, soak them in a special cleaning agent, and use a brush to remove stubborn stains. For hard-to-reach corners, use small tools or high-pressure nozzles for auxiliary cleaning.
4. Corrosion Prevention and Drying Maintenance: After cleaning, wipe dry with a cloth and allow to air dry naturally by turning on the ventilation system. For long-term storage, apply rust-preventive oil to the metal surface to prevent corrosion.
III. Safe Operating Procedures:
1. Do not directly inject cold water to cool the equipment at high temperatures, as this may cause thermal shock damage or wrinkles on fabrics.
2. Before opening the lid, ensure all pressure is released from the cylinder, the pressure gauge is at zero, and the temperature has dropped below 80℃ to prevent steam from escaping and causing injury.
3. Operators must wear protective clothing, rubber gloves, respirators, and other personal protective equipment to ensure operational safety.
