Table of Content

Page Number

I. Preparatory Part
A. Title Page ......................................................................................I
B. Title Fly ...............................................................................................................II
C. Letter of transmittal.....................................................................................................III
D. To Whom It May Concern..................................................................................IV
E. Student's Declaration........................................................................................... V
F. Acknowledgement..............................................................................................VI
G. Executive Summary................................................................................. VI I

II. Body of The Report

A. Introductory
A. Title..............................................................................................................1
B. Background......................................................................................1
C. Broad Objective...............................................................................1
D. Specific Objectives.................. ...........................................................2
E. Methodology............................................................................................2
F. Limitation............................2

B. Organizational Part
Chapter 01: Overview of Bengal Denim Ltd.
1.1 Background.. ..................................................................................... 4
1.2 List of machine...........................................................................................................4
1.3 History..............................................................................................................................5
1.4 Vision..............................................................................................................................5
1.5 Mission.............................................................................................................................5
1.6 Theme...............................................................................................................5
1.7 Quality Commitment................................................................................5
1.8 Uncompromising Integrity ......................................................................................6
1.9 Respect & care for Others.........................................................................................6

Chapter 02: Management system

2.1 The process Approach..................................................................................8
2.2 Product Realization Process.................................................8
2.3 Measurment, Analysis And Improvement Process...........................................8
2.4 Management System of the Company.............................................................................9

C. Main Topic
Chapter 03: General Overview of OBEM Yearn Dyeing Machine
3.1 Introduction to OBEM Yearn Dyeing Machine-------------------------------------------------------11
3.2 API/V Introduces OBEM----------- --------------------------------------------------------------------12
3.3 Some features of API/V OBEM-----------------------------------------------------------------------12
3.3.1 Higher performance by optimization of the insertion parameters-----------------------12
3.3.2 Higher performance with balanced construction------------------------------------------13
3.3.3 Higher performance by minimal downtime------------------------------------------------13
3.3.4 Highest Yearn quality immediately---------------------------------------------------------13
3.3.5 Full modularity, for a bolt-on future--------------------------------------------------------14

Chapter 04: Dyeing Process

4.1 Soft winding process----------------------------------------------------------------------------------17
4.2 Loading process of yearn bobbin to the yearn carrier----------------------------------------------18
4.3 Inserting process of yearn bobbin carrier------------------------------------------------------------19
4.4 Dyeing yearn squeeze by the hydro extractor machine---------------------------------------------21
4.5 Moisturizing yearn by dryer machine----------------------------------------------------------------22

Chapter 05: Machine operation and maintenance

5.1 Version----------------------------------------------------------------------------------------------------25
5.2 Basic machine-------------------------------------------------------------------------------------------- 25
5.3 Technical information------------------------------------------------------------------------------------26
5.4 Transport---------------------------------------------------------------------------------------------------27
5.5 Storage-----------------------------------------------------------------------------------------------------27

5.6Installation-------------------------------------------------------------------------------------------------27
5.8 Steam supply connection---------------------------------------------------------------------------------27
5.8 Condensate discharge-------------------------------------------------------------------------------------28
5.9 Super heated water supply-------------------------------------------------------------------------------29
5.10 Hydraulic connection---------------------------------------------------------------------------------- 30
5.11 Electrical connection------------------------------------------------------------------------------------30
5.12 Pneumatic connection-----------------------------------------------------------------------------------30
5.13 Drains-----------------------------------------------------------------------------------------------------30
5.14 Safety valve discharge-------------------- -------------------------------------------------------------31
5.15 Machine start--------------------------------------------------------------------------------------------31
5.16 Hydrostatic test------------------------------------------------------------------------------------------32
5.17 Parallel connection and reduction---------------------------------------------------------------------33
5.17.1 Parallel-------------------------------------------------------------------------------------33
5.18 Control panel--------------------------------------------------------------------------------------------33
5.19 Machine loading------------ ---------------------------------------------------------------------------33
5.20 Machine loading with automatic closing------------------------------------------------------------35
5.21 Filling the machine by the water input valve-------------------------------------------------------35
5.22 Filling machine from the preparation tank----------------------------------------------------------35
5.23 Static pressure pump starting-------------------------------------------------------------------------36
5.24 Circulation pump---------------------------------------------------------------------------------------36
5.25 Heating and cooling------------------------------------------------------------------------------------36
5.26 Washing with valves-----------------------------------------------------------------------------------36
5.27 Recirculation in the preparation tank----------------------------------------------------------------37
5.28 Recycle cooling-----------------------------------------------------------------------------------------37
5.29 Single/Parallel control----------------------------------------------------------------------------------37
5.30 Machine drain-------------------------------------------------------------------------------------------37
5.31 High temperature drain---------------------------------------------------------------------------------37
5.32 Opening the doors---------------------------------------------------------------------------------------37
5.33 Sampling--------------------------------------------------------------------------------------------------38
5.33.1 Sampling device loading--------------------------------------------------------------------38
5.33.2 Sampling device unloading-----------------------------------------------------------------39

5.34 Protective cloths-----------------------------------------------------------------------------------------40

5.35 Spare parts------------------------------------------------------------------------------------------------41
5.36 Periodic checks ------------------------------------------------------------------------------------------41
5.37 Lamps check---------------------------------------------------------------------------------------------41
5.38 Safety devices--------------------------------------------------------------------------------------------42
5.39 Seals-------------------------------------------------------------------------------------------------------43
5.40 Pumps-----------------------------------------------------------------------------------------------------43
5.40.1 Main pump------------------------------------------------------------------------------------43
5.40.2 Static pressure pump-------------------------------------------------------------------------45
5.40.3 Parallel and transfer pumps-----------------------------------------------------------------46
5.41 valves------------------------------------------------------------------------------------------------------47
5.41.1 Control valves--------------------------------------------------------------------------------48
5.42 OBEM pneumatic valves-------------------------------------------------------------------------------50
5.42.1 OBEM type valves---------------------------------------------------------------------------50
5.42.2 safety valves----------------------------------------------------------------------------------52
5.42.3 Manual interception valves-----------------------------------------------------------------53
5.43 Pressure gauges------------------------------------------------------------------------------------------53
5.44 Thermometers and thermo regulators ----------------------------------------------------------------53
5.45 Periodical lubrication-----------------------------------------------------------------------------------54
5.46 Belts ------------------------------------------------------------------------------------------------------55
5.47 Technical report regarding the operation------------------------------------------------------------55
5.47.1 Description -----------------------------------------------------------------------------------55
5.48 Device operation ----------------------------------------------------------------------------------------56
5.48.1 Liquid introducing phase--------------------------------------------------------------------56
5.48.2 Cover opening phase-------------------------------------------------------------------------56
5.49 Dyeing machine care -----------------------------------------------------------------------------------58
5.49.1 Machine Cleaning----------------------------------------------------------------------------59
5.49.2 Oligomers Removal--------------------------------------------------------------------------59
5.49.3 Heat Exchanger Cleaning-------------------------------------------------------------------60

Chapter 06: Electrical and Electronics part

6.1 Sub station-------------------------------------------------------------------------------------------------64
6.2 Electrical characteristics of OBEM-------------------------------------------------------------------- 65
6.2.1 Circuit breaker---------------------------------------------------------------------------------66
6.2.2 Magnetic contractor---------------------------------------------------------------------------67
6.2.3 Fuse---------------------------------------------------------------------------------------------68

Chapter 07: PLC Part

7.1 Block Diagram of PLC----------------------------------------------------------------------------------71
7.2 Power Supply system------------------------------------------------------------------------------------74
7.3 PLC Size Classification----------------------------------------------------------------------------------77
7.4 Advantages of a PLC Control System-----------------------------------------------------------------77
7.5 PLC a Real World Relay Replacement----------------------------------------------------------------78
7.6 PLC Signal Process---------------------------------------------------------------------------------------81
7.7 Control Panel With a PLC Controller -----------------------------------------------------------------81
7.8. Advantages of control panel that is based on a PLC controller can be presented in few basic
points ------------------------------------------------------------------------------------------------------82
7.9 Systematic approach to designing a process control system----------------------------------------82

Chapter 08: Inverter Part

8.1 Introduction------------------------------------------------------------------------------------------------87
8.2 Main part of Inverter--------------------------------------------------------------------------------------87
8.3 Inverter Specification-------------------------------------------------------------------------------------88
8.4 Key pad feature------------------------------------------------------------------------------------------104
8.5 Types of fault---------------------------------------------------------------------------------------------105
8.6 Inverter Overload----------------------------------------------------------------------------------------106
8.7 Electrical and electronic element----------------------------------------------------------------------110
8.7.1 D.C. Driver or converter-------------------------------------------------------------------110

8.8 Maintenance----------------------------------------------------------------------------------------------111

Supplementary Part
Chapter 9: Conclusion
9.1 Conclusion----------------------------------------------------------------------------------------------113
9.2 Recommendations--------------------------------------------------------------------------------------114
9.3 Glossary of Terms -------------------------------------------------------------------------------------115
9.4 Acronyms------------------------------------------------------------------------------------------------123
9.5 Bibliography--------------------------------------------------------------------------------------------128

List of Tables:
Table 1: Main Electric Element------------------------------------------------------------------------------62
Table 2: List of Electric Elements---------------------------------------------------------------------------62

List of Figures:
Fig 3.1: OBEM Yearn Dyeing Machine-------------------------------------------------------------------10
Fig 3.2 OBEM Dyeing Machine ------------------------------------------------------------------------11
Fig 4.1 : Soft Winding Machine--------------------------------------------------------------------------17
Fig 4.2 : Yearn Bobbin Carrier---------------------------------------------------------------------------18
Fig 4.3 : Machine Tank------------------------------------------------------------------------------------18
Fig 4.4 : Colored Yearn---------------------------------------------------------------------------------------19
Fig 4.5: Panel Board of OBEM Machine-------------------------------------------------------------------20
Fig 4.6 : Closing Door The Dyeing Machine--------------------------------------------------------------20
Fig 4.7: Hydro-extractor Machine---------------------------------------------------------------------------21
Fig 4.8: Dryer Machine------------------------------------------------------------------------------------22
Fig 4.9 : Hard Winding Machine-------------------------------------------------------------------------23
Fig 5.1 : Basic Machine-----------------------------------------------------------------------------------26
Fig 5.2: Machine Scheme---------------------------------------------------------------------------------29
Fig 5.3 : Drain Process-------------------------------------------------------------------------------------31
Fig 5.4 : Exit Safety Valve---------------------------------------------------------------------------------32
Fig 5.5 : Manual Closing System----------------------------------------------------------------------------34
Fig 5.6 : Sampling Device Unloading System-------------------------------------------------------------39

Fig 5.7 : Single And Parallel Control System--------------------------------------------------------------40

Fig 5.8: Safety Devices-------------------------------------------------------------------------------------42
Fig 5.9: Pump Setting-----------------------------------------------------------------------------------------45
Fig 5.10 : Static Pressure Pump Setting--------------------------------------------------------------------46
Fig 5.11: Parallel And Transfer Pump Setting-------------------------------------------------------------47
Fig 5.12 : Control Valves System---------------------------------------------------------------------------50
Fig 5.13: Pneumatic Valve-----------------------------------------------------------------------------------52
Fig 5.14: Weight Type Safety Valve-----------------------------------------------------------------------53
Fig 5.15 : Thermometer And Thermo Regulator---------------------------------------------------------54
Fig 5.16: Belt system-----------------------------------------------------------------------------------------55
Fig 5.17 : API/V Safety Device Scheme No 8537/1-----------------------------------------------------58
Fig 6.1 : Sub Station -----------------------------------------------------------------------------------------64
Fig 6.2 : Panel Board-----------------------------------------------------------------------------------------65
Fig 6.3: Magnetic Contactor---------------------------------------------------------------------------------67
Fig 7.1: Hardwar Configuration of a Typical PLC--------------------------------------------------------72
Fig 7.2: Structure of PLC-------------------------------------------------------------------------------------73
Fig 7.3: Programming Device-------------------------------------------------------------------------------76
Fig 7.4: Electromagnetic Relay-----------------------------------------------------------------------------77
Fig 7.5: Relay Replacement---------------------------------------------------------------------------------78
Fig 7.6: PLC Control System Panel Board----------------------------------------------------------------81
Fig 7.7: Physical View of PLC------------------------------------------------------------------------------83
Fig 7.8: Power Circuit of PLC-------------------------------------------------------------------------------84
Fig 7.9: Control Circuit of PLC-----------------------------------------------------------------------------85
Fig 8.1: Inverter iG5A-4--------------------------------------------------------------------------------------89
Fig 8.2: Inverter IV5------------------------------------------------------------------------------------------99
Fig 8.3: Connection Diagram of Inverter--------------------------------------------------------------105
Fig 8.4: Main Power PCB----------------------------------------------------------------------------------108
Fig 8.5: Main Power PCB ---------------------------------------------------------------------------------109
Fig 8.6: D.C Drive Card------------------------------------------------------------------------------------110