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  1. 1. Dyeing Fabric Supervision By : Sir Haris Mehmood Khan :Sir Imran Rasheed Presentation By: Tanveer Hussain 2009-bt-chem-22 Syed Hasnan Bukhari 2009-bt-chem-31
  2. 2. • • • • • Overview of Plant Startup/shutdown of plant Troubleshooting of a Equipment Plant Interlocking's Safety on Plant/Hazards
  3. 3. Polyester Dyeing Chemicals CHEMICAL PURPOSE Hostal Pal,Imacol MPE-PK,D 600 Leveling agents Rucogen Wbl,Dekol SNS,Biavin DFG Soaping agent(Detergent) H2O2, Caustic Soda Bleaching agent Citric acid PH controller Accetic Acid,Ecozyme Pk Neutralizing agent Sodium Acetate Buffer Ceranine HCS (Past) 13% Solution,Ceralube NVJ Softener Dyes synolon,Disperse,and Dyannix etc.
  4. 4. Cotton Dyeing Chemicals CHEMICAL Purpose SeraBid MIP,AlbaTex DBC,Biavin DFG Leveling agent,anti creasing agent, wetting agent H2O2, Caustic Soda(50%) Bleaching agent Citric Acid PH Controller(5-6) Globular salt Fixing agent, increase specific gravity Soda ash Picking agent Dekol SNS,Biavin DFG Detergent Ceranine HCS,Ceralube NVJ Softener
  5. 5. Turn off steam valve Reinzing cooling is done Completely drain Machine. Turn off pump Switch off machine
  6. 6. Problem: Uneven dyeing,patches,creezing on dyed fabric Consequences: Sudden shut down of Machine, Improper heating and cooling Suggested Remedies: DO proper shutdown to machine Follow S.O.P for Shut down/Heating and cooling as described in M/C manual
  7. 7. Problem: Entanglement of fabric lot inside machine nozzles Consequences: Low or high Nozzle Pressure Suggested Remedies: • Turn reverse switch clock- wise to pull back fabric lot in order to remove entanglement of fabric lot
  8. 8. Machine does not fill with water • check the water line pressure • check the level indicator is working • Recheck the programmed quantity • check the machine’s temperature
  9. 9. Poor rate of heating and cooling • check the steam supply pressure • check that the heating and cooling valves are opened/closed • recheck that the programmed parameters are correct • check that the heat exchanger is not blocked
  10. 10. • Insufficient nozzle pressure • is the filter system clean? • check that the slits of the nozzle are not blocked • check that the pump is not blocked • check that the heat exchanger is not blocked
  11. 11. • Chemical addition tank pressure pump does not operate • check that the pipe line from the addition tank is not blocked • check the electrical connections and fuses
  12. 12. General Safety Rules • NEVER open a machine at temperatures above 80°C or 180°F ! • NEVER open a machine that is under pressure! • NEVER cool a machine by spraying it with water!
  13. 13. Quick-opening doors interlocking Device o A temperature sensitive interlock is provided to prevent the doors being opened while the temperature of the liquor inside the vessel exceeds 80°C.
  14. 14. • Temperature and pressure relief devices o Safety valves are provided with the machine in order to release high temperature and pressure inside machine.
  15. 15. • • • • • High Temperature Fire Noise Hazardous Chemicals Accidents/Injuries
  16. 16. Hazard Consequences Safety High Temperature High Temperature(135-140°C) dyeing Machines Ensure use of drinking water After regular interval of time during working Provide first Aid and then contact with Doctor Provide proper ventailtion to working area Provide coolers to working area
  17. 17. Hazard Consequences Safety Fire use of flammable substances, or oxidizing agents or fluff, waste materials, dust, trash Do not smoke at working Place/chemical area. Provide fire alarm pull station; fire extinguisher and fire blanket; Provide smoke detector at working area.
  18. 18. Hazard Noise Consequences Running of high speed machines Safety Wear air plug particularly during working at machines
  19. 19. Hazard Consequences Safety Hazardous Chemicals inhalation or skin contact causes toxicity and carcinogenicity Use proper PPE such as mouth mask ,gloves , Charcoal mask, goggles and safety shoes, Protective clothing
  20. 20. Hazard Consequences Safety Accidents/Injuries Explosion of pressurized equipments,fire,Chemical Hazards  Appropriate first aid facilities should be provided  Employees should be trained in first aid
  21. 21. Chemicals must be stored in a safe and orderly condition.
  22. 22. Compressed air must only be used for cleaning equipment and not the employee’s body. Improper use of compressed air to clean the employee. Proper use of compressed air to clean equipment.