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Acknowledgment
I would like to thank Mr. RAMFUL Raviduth, the placement coordinator of level 3 students of
Mechanical Engineering, who made the necessary arrangement for my internship at Companie
Mauricienne de Textile Ltee (CMT).
I thank Mr. Bhoomitra Sharma TOOLSY, my University Supervisor. He helped me and coached
me during my internship by giving me feedback and tips on how to handle and approach
situations. He always had time to answer all my questions concerning my internship.
I really want to thank all the staff of the organization in general. They have made my training
experience a memorable and unforgettable moment.
I thank Mrs. Natasha BHOODHNA (Human Resource Manager) for giving me the opportunity
to follow my internship at CMT. I am very grateful to my site supervisor Mr D. Khelawon, and
the staff of the mechanical department for their support and guidance throughout. They have
been very sympathetic and of great help. My appreciation goes to them for their willingness to
share their knowledge and professional past experience which helped me to understand the future
role of an engineer. I found the people highly professional and talented and they were a pleasure
to work with. I have a deep appreciation and an honest respect for the people who work at CMT.
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Table of Contents
A.
Acknowledgment ..........................................................................................1
1.
Introduction....................................................................................................3
2.
Literature review...........................................................................................3
3.
3.1
4.
4.1
4.2
5.
6.
Nozzle ...........................................................................................................15
7.
Boiler .............................................................................................................19
7.2
7.3
Cochran Burner...............................................................................................21
10
Conclusion ...................................................................................................32
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1. Introduction
Companie Mauricienne de Textile Ltee (CMT) was founded by Louis Lai Fat Fur and Francois
Woo Shing Hai in 1986. In Mauritius, the branch at La Tour Keonig consist of four different
sections namely FM1 (Fabric Mill 1), FM2 (Fabric Mill 2), Knitting and Spinning. During the
first week a site visit was carried out in both FM1 and FM2 to have an overview of the main
activities being carried out in these 2 sections and to get acquainted with the technical staff. I was
assigned to work in FM2 which comprises mostly of fabric dyeing, yarn dyeing and finishing.
The dyeing section of FM2 consists of 16 fabric dyeing machines and 24 yarn dyeing machines.
Servicing is carried out on all 40 machines over a period of 2 months by the maintenance crew
comprising of Mr. Avinash and Mr. Clyde for the mechanical part and Mr. Irshad for the
electrical part under the supervision of Mr Lynley. Breakdown maintenance staff consists of
Mr. Gerard and Mr. Jean Noel.
As usual in the morning the maintenance task is assigned by the chief engineer Mr. D.
Khelawon, through which the intervention is known thus a plan for the day is established. The
current maintenance strategy adopted is a combination of both preventive and breakdown
maintenance.
2. Literature review
Background of the company
Companie Mauricienne de Textile Ltee (CMT) specialised in the design and production of fastfashion jersey wear products for the finest clothing brands and fast-fashion retailers on the high
streets. The company started out with 30 employees and was involved mainly in cut, make and
trim operations. The company eventually grew to become the largest jersey wear manufacturer in
Mauritius and the Sub-Saharan region with a turnover of US $200 million and employing around
10,000 people.
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The Company starts out with raw cotton of the best quality and carries out the following
activities:
1. Spinning
2. Knitting
3. Dyeing
4. Finishing
5. Cutting
6. Sewing
Cotton
Cotton of the highest quality is used as raw material
Spinning
Carried out at spinning section at La Tour Koenig
Knitting
Carried out at the knitting section at La Tour Koenig
Finishing
Undertaken at FM1 and FM2
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The company offers a full-package service to its customers, ranging from design to landed
delivery in distribution centres in Europe and the US. CMT has complete control over the full
supply chain making it a reliable reliable total service provider of a vast array of value-added
jersey garments designed to meet the unique and ever-changing needs of its customers.
3. Fabric Dyeing
Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is
normally done in a special solution containing dyes and particular chemical material. After
dyeing, dye molecules have uncut chemical bond with fiber molecules. Temperature and time
control are key factors in dyeing.
Fabric mill 2 consists mainly of three types of dyeing machine:
1. Jet dyeing machine
2. Sample dyeing machine
3. Winch dyeing machine
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Metering wheel is also fixed on winch by external electronic unit. Its purpose is to record the speed
of the fabric. The thermometer, pressure gauge is also fixed in the side of the machine to note the
temperature and pressure under working. A simple device is also fixed to note the shade under
working.
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As shown in figure 3, the main components of a jet dyeing machine are as follows:
Main pump
Dosing pump
Heat exchanger
Lint filter
Nozzle airflow
Unload motor
Winch motor
A checklist is provided to the maintenance crew and after each servicing has been carried out,
the checklist has to be filled and signed by the maintenance crew. The checklist comprises of all
the components that need to be visually inspected and repaired or replaced in case they are
damaged.
The following procedures are followed when carrying out servicing on a machine:
The shift dyer is informed that servicing will be carried out on the machine.
The machine is then switched off and a notice of Machine under maintenance is
displayed as a safety measure.
Servicing is then carried out on all components according to the checklist provided.
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4. Pneumatic valves
4.1 Slanted valves
Most slanted valves are normally closed and opens when actuated. During servicing all slanted
valves are checked for any leakage via the following procedure.
1. Pressure is supplied to the slanted valve while it is still in place.
2. It is known whether the valve is operating smoothly via the indicator shown below.
Indicator
3. If a continuous hissing sound is heard when the valve is actuated, it indicates a leakage
and the valve is replaced with a new one (O-ring is replaced when repairing valve.
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Spring
O-ring
Threading
Indicator
Seat
Bolt
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Gasket
It was noticed by the operator of sample dyeing machine A01 that temperature was not rising in
the machine. The steam valve was closed and an intervention was carried out on the machine.
Eventually the root cause of the problem was identified to be the steam trap valve.
The five bolts holding the valve were removed with the help of a spanner.
After dismantling the steam trap valve (Inverted Bucket Type) and from visual inspection
the problem was found to be the damaged gasket located between the bucket and the top
part of the valve (head).
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Bolts
Gasket
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Floater
Gasket
Lesson Learnt: If a steam trap valve malfunctions, pressure in the machine is not retained and
temperature fails to rise since condensate remains trapped in the machine.
6. Nozzle
A nozzle is a device designed to control the direction or characteristics of a fluid flow
(especially, to increase velocity) as it exits (or enters) an enclosed chamber or pipe.
A nozzle is often a pipe or tube of varying cross sectional area, and it can be used to direct or
modify the flow of a fluid. Nozzles are frequently used to control the rate of flow, speed,
direction, mass, shape, and/or the pressure of the stream that emerges from them. In a nozzle, the
velocity of fluid increases at the expense of its pressure energy.
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Knit Fabrics
Dye Liquor Entry path
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Winch motor
Nozzle
Broken O-ring
A broken O-ring was found after 6 years of operation and was replaced with a
new one.
The mechanical on the shaft of the winch, having a lifespan of 8760 hours was also replaced.
A mechanical seal is a device that helps join systems or mechanisms together by preventing
leakage containing pressure, or excluding contamination. The effectiveness of a seal is
dependent on adhesion in the case of sealants and compression in the case of gaskets.
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Winch Shaft
Rotary Mechanical
Seal
Both the stationery and the rotary mechanical seal are replaced after 1 year and ean one bears a
cost of Rs 40,000.
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7. Boiler
Fabric Mill 2 consists of 3 Heavy fuel oil (HFO, Cochran) steam fire tube boilers. A fire-tube
boiler is a type of boiler in which hot gases from a fire pass through one or many more tubes
running through a sealed container of water. The heat of the gases is transferred through the
walls of the tubes by thermal conduction, heating the water and ultimately creating steam.
Their advantage over flued boilers with a single large flue is that the many small tubes offer far
greater heating surface area for the same overall boiler volume. The general construction is as a
tank of water penetrated by tubes that carry the hot flue gases from the fire
Blow-down valve
7.2
Water is fed into the softening plant before being pumped into the boiler. In order to remove
Magnesium and calcium found in the water, sodium chloride (NACL) is added in the softening
tank. Sodium chloride reacts with the excess magnesium and calcium to form calcium chloride
and magnesium chloride which are both solids at room temperature. The water is then filtered
and sent to the boiler via the 2 feed water pumps.
Once the required amount of water is fed into the boiler, the burner starts automatically, heating
the water to a temperature of about 135 C. Once the specified temperature is reached the burner
shuts down automatically and starts again when the temperature drops. The operator has to check
the water level indicator regularly along with the sight glass which indicates whether the burner
is operating properly. The boiler operates properly at a pressure of 8.5 - 9 bar.
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7.3
Cochran Burner
The burner mixes the fuel and oxygen together and, with the assistance of an ignition device,
provides a platform for combustion. This combustion takes place in the combustion chamber,
and the heat that it generates is transferred to the water through the heat exchanger. Controls
regulate the ignition, burner firing rate, fuel supply, air supply, exhaust draft, water temperature,
steam pressure, and boiler pressure. If insufficient air is provided to the burner, incomplete
combustion takes place resulting into the formation of harmful gases like carbon monoxide.
Pressure and temperature at which the burner is operating is checked by the operator on a daily
basis via the pressure and temperature indicator. The operating pressure of the burner is set at 8.5
bar.
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Temperature indicator
Sight glass
Pressure indicator
Daily maintenance on the burner is carried out via the following procedures:
The nozzle is visually inspected and cleaned along with the sight glass.
Once the nozzle has been cleaned the door is closed and the burner is then switched on.
When the pressure indicator displays a pressure of 8.5 bar excess air is sucked in via the
motor and ignition takes place inside the burner.
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Sight glass
Nozzle
Electrical Motor
(Driving pulley)
The electrical panel along with the proper functioning of the alarm and sensors is checked every
day. The proper functioning of the motor sucking air in by the burner is also of essential
importance. The alarm is set off once any malfunction is detected and the boiler is shut down.
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8 Yarn dyeing
Yarn dyeing is carried out by the LABWIN (Laboratory Package Dyeing machine)
The dyeing process of cotton yarn with reactive dyes at package form is as follows:
The raw yarn is wound on a spring tube to achieve a package suitable for dye penetration.
These softened packages are loaded on a dyeing carrier's spindle one on another.
The packages are pressed up to a desired height to achieve suitable density of packing.
The carrier is loaded on the dyeing machine and the yarn is dyed.
After dyeing, the packages are unloaded from the carrier into a trolley.
Now the trolley is taken to hydro extractor (Galvanin) where water is removed.
The packages are hydro extracted to remove the maximum amount of water leaving the
desired color into raw yarn.
The packages are then dried to achieve the final dyed package.
Once the above procedures have been completed, the dyed yarn packages are then packed and
delivered.
These yarn dyeing machines are not connected directly to the color service unit nor the chemical
distribution unit. Thus the dyes along with the required amount of chemicals are added
separately by the operators. Several interventions were carried out on these machines due to
malfunctioning of dosing pump or drain valves.
Main Vessel
Tank
Pneumatic valve
Main pump
Dosing pump
Figure 23 displays a brief schematic of the laboratory package dyeing machine whereby the read
arrows represent the passage of steam and the blue arrows represent the passage of water. All
dyes and chemicals are added in the tank by the operators and the mixture is then pumped into
the main vessel via the dosing pump.
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Electrical motor
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F18(FONG) is equipped with a Cucchi Dosing pump with the following rating:
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After removing the dosing pump from the machine it was then dismantled in the workshop. A
visual inspection was then carried out and a damaged O-ring was found to be the root cause of
the leakage.
New O-ring
Main pump
After the operator of the yarn dyeing machine signaled a leakage in the main pump, an
intervention was carried at once via the following procedures:
The shift dyer was informed of the intervention and all chemical and dyes being sent to
the machine was stopped at once.
The machine was switched and a notice of Machine under maintenance was displayed
to prevent any operator from starting the machine.
The electric motor was then decoupled from the pump as shown on figure 29.
The problem was found to be a damaged O-ring. The O-ring ceases to be O shaped
and was permanently deformed into a flat sided oval, the flat sides of which were the
original seal interface and under compression before failure.
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Pump
Coupling
Electrical motor
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The main cause of failure for the ring was most probably due to a compression set. An effective
O-ring seal requires a continuous seal line between the sealed surfaces. The establishment of
this seal line is a function of gland design and seal cross-section which determines the correct
amount of squeeze (compression) on the O-ring to maintain seal integrity without excessive
deformation of the seal element. The following factors can lead to a compression set failure of Orings:
Selection of O-ring material with inherently poor compression set properties.
Improper gland design.
Excessive temperature developed causing the O-ring to harden and lose its elastic
properties.
Volume swell of the O-ring due to system fluid.
Excessive squeeze due to over tightening of adjustable glands.
Incomplete curing (vulcanization) of O-ring material during production.
Introduction of fluid incompatible with O-ring material.
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10 Conclusion
It will be worthy to say that the different activities have definitely contributed to my knowledge,
skills, attitudes and professional attributes. My training has emphasized on the benefits of
practical knowledge as well as the ability to endure the conditions and hardships of the real
engineering world. The experience was good in terms that I was able to familiarize myself more
with the technical side of engineering rather than just the theoretical side. Working along with
people of different level again reminds me of how leadership and communication skills play an
important role in carrying out a job properly.
As a final conclusion, the industrial training undertaken during the 3 months was an amazing
experience for me. It is a challenging work to do, as it disconnects us from the usual learning
process and provides a new learning platform in which we are prone to achieve something at the
end.
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