I. Daily Maintenance: Essential Daily Tasks, Prevention is Better Than Cure
Basic checks and cleaning should be performed before each start-up and after each shutdown to ensure the equipment is in good standby condition.
It is essential to check the sensitivity and effectiveness of the temperature gauge, pressure gauge, and safety valve. Confirm that the motor, circuit, and lighting system are functioning correctly to prevent accidents caused by instrument malfunctions. The sight glass should be intact, and the sealing rings should show no signs of aging or leakage.
The screen and filter screen need to be cleaned once per shift, especially when producing medium and long fiber fabrics, as impurities can easily clog pipes and affect the uniformity of dye liquor circulation. If producing polyester filament fabrics, the filter screen should be brushed at least once a day.
At the same time, check that all valves (steam valve, drain valve, steam trap, etc.) are unobstructed, and that all cylinder head bolts are complete and tightened diagonally to avoid air leaks or insufficient pressure due to poor sealing.
II. Lubrication and Tightening: Ensuring Smooth Machine Operation
Lubrication of mechanical components is key to maintaining the flexibility of the equipment.
Monthly, apply high-temperature lubricating oil to friction parts such as bearings, gears, and guide roller shaft seats to prevent dry friction from causing wear or overheating. If grease leakage or moisture intrusion is found, it must be dealt with immediately to avoid bearing damage.
The tension of the V-belts also needs to be checked regularly to maintain proper tension, ensuring the main pump and the lifting roller operate at a moderate synchronous speed, preventing slippage or breakage.
Weekly, check bolts and connectors for looseness, especially at the cylinder and pipe interfaces, to prevent vibration from causing loosening.
III. Periodic Deep Maintenance: Phased Implementation, Systematic Management
To avoid "small holes left unrepaired, big holes causing trouble," a tiered maintenance system should be established:
Monthly: Conduct a special inspection of vulnerable parts, such as nozzles, sealing gaskets, and impellers, and replace them promptly if wear is found.
Every Six Months: Conduct a comprehensive shutdown and overhaul, focusing on checking the circulation pump, heat exchanger, valve control system, and electrical control panel for proper functioning. This can be combined with cylinder cleaning to thoroughly remove internal deposits.
Annually: A complete overhaul of the machine is performed, including calibrating all instruments, replacing aging wiring, inspecting the stainless steel inner wall for corrosion or scratches, and conducting functional tests on the safety valves.
IV. Cleaning and Tank Cleaning: Key Steps to Prevent Cross-Contamination
When changing colors, especially from dark to light, the dyeing machine must be thoroughly cleaned; otherwise, staining or whiteness deviations are highly likely.
When changing from dark to light colors, it is recommended to use 4-6 kg of 98% caustic soda and 1-2 kg of detergent, maintaining a temperature of 130℃ for 60-90 minutes, followed by high-temperature drainage to ensure complete removal of residual dyes and oligomers.
For whitening products, a dedicated light-colored tank should be used, and the tank should be prepared before use to prevent residual red pigments from affecting whiteness.
During the cleaning process, a suitable amount of waste cloth can be added to the tank to allow the high-speed water flow to reach the "dead corners" of the nozzles and circulation system, improving the cleaning effect.
In addition, deposits such as oligomers, calcium salts, and tar require specialized cleaning agents based on their composition. For example, NaOH is used to remove oligomers, while TF-105F cleaning agent effectively removes alkaline scale without corroding the stainless steel inner wall.
V. Safety and Sealing Management: Details That Cannot Be Ignored
Under high temperature and high pressure environments, sealing performance directly affects production safety and dyeing consistency.
The sealing ring (gasket) is one of the important factors affecting cylinder differential. If the joint leaks, it will not only lead to uneven dyeing but also waste heat energy. Therefore, any leaks must be replaced immediately.
Tempered glass observation windows must never be wiped with a damp cloth when the temperature exceeds 100℃, as excessive temperature difference may cause the glass to shatter, resulting in a serious safety accident.
After adjusting the bath ratio, the upper and lower shut-off valves of the water level glass tube should be closed promptly to avoid leakage caused by misoperation.
