I. Daily Inspection: Identifying Potential Problems Immediately
Perform a standardized inspection of the following four areas before starting, during operation, and after shutdown each day:
Look, Listen, Touch, and Test
Pay special attention to the following eight core areas:
1. Machine Head R-corner Area: Check for seepage, grayish-white crystals (chloride ion precipitation), or surface bulges.
2. Cylinder Head and Flange Sealing Surface: Check for aging or cracking of the sealing rings, tightening of bolts, and signs of leakage.
3. Circulating Pump and Pipeline Interfaces: Listen for abnormal operating sounds, check for stable pressure gauge readings, and check for leaks at the interfaces.
4. Nozzles and Overflow Ports: Confirm there are no blockages or deformations, and observe whether the dye liquor spray is uniform and symmetrical.
5. Heat Exchanger Inlet and Outlet: Check if the temperature difference is normal, and for scale, seepage, or corrosion on the outer wall.
6. Lifting Roller and Guide Roller: Check for flexible rotation, abnormal bearing noise, and a smooth surface.
7. Electrical Control Cabinet and Temperature Control System: Check the accuracy of instrument displays, the normal operation of PLC indicator lights, and whether wiring terminals are loose or overheating.
8. J-Type Box Inner Wall and Plastic Pipes: Ensure the inner wall is smooth and free of burrs, and the plastic pipes are not cracked to prevent fabric abrasion.
✅ It is recommended to create inspection cards and implement a "whoever inspects, signs, and is responsible" system to achieve closed-loop management.
II. Cleaning and Pickling: Preventing Scale and Corrosion (Every 10-15 batches or once a month)
1. Purpose of Cleaning: Remove dye residue, fiber debris, and scale to prevent nozzle clogging and reduced heat exchange efficiency.
2. Pickling Cycle: It is recommended to perform pickling after every 10-15 production batches. In areas with poor water quality, this should be shortened to 7-10 batches.
3. Pickling Agent and Proportion: Use 2%~3% citric acid solution or a special stainless steel cleaner;
Control the pH at 3.5~4.5 to avoid strong acid corrosion of the stainless steel substrate;
Add a corrosion inhibitor (such as hexamethylenetetramine) to protect the metal surface.
4. Operating Procedure: Empty the dyeing tank and fill it with clean water to the full level;
Add the pickling agent and circulate for 60~90 minutes, controlling the temperature at 60~80℃;
After draining, rinse 2~3 times with clean water until the pH is neutral;
Check the nozzles and filters for blockages, and disassemble and clean them if necessary.
⚠️ Never use chlorine-containing cleaning agents (such as hydrochloric acid) to prevent stress corrosion cracking.
III. Inspection and Replacement of Seals (Replace every 3~6 months or when aging is observed)
1. Key Parts: Cylinder head seal ring, valve packing, flange gasket, pump shaft seal.
2. Inspection Standards: The sealing ring should be free from cracks, hardening, deformation, or permanent compression deformation; the flange bolts should be evenly pre-tightened and not loose; there should be no dripping or steam leakage during operation.
3. Replacement Recommendations: Fluororubber (FKM) or EPDM seals are preferred due to their high temperature resistance and resistance to corrosive liquids; when replacing, clean the sealing groove and apply a small amount of silicone grease for lubrication to avoid installation damage.
