welspun report
TRANSCRIPT
TRAINING REPORT AT WELSPUN INDIA LTD. VAPI, MORAI
01/07/2014 SUBMITTED TO: - WELSPUN INDIA LTD
SUBMITTED BY:-
PRIYANKA RATHOD (E.C.E)
NIKUNJ SHARMA (E.C.E)
LAXMI INSTITUTE OF TECHNOLOGY,
SARIGAM, VALSAD
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ACKNOWLEDGEMENT
We would like to express my gratitude to Mr. Sanjib Sen, Mrs. Suruchi Nayyar and Ms. Barkha Gupta from HCM Department for allowing us to do our internship in this esteemed organization and also for their cooperation, guidance and encouragement which led to successful completion of the training at WELSPUN INDIA LIMITED, VAPI.
We also thank Mr. Vijay Patel (engineering department), Mr. Bhairav Zaveri (LT room),Mr. Paresh Garala (process section), Mr. R.D Rathod (LT room), Mr. Manish Mistry(LT room),Mr. Jitendra Chaudhary(ETP),Mr. J.M sanadhiya (power plant),Mr. Kishore Kalwadiya(spinning section), for continued support throughout period of internship training.
We are also thankful to the management and the staff members of WELSPUN, for their help and support.
I sincerely extend my gratitude to our mentors Mr. Atul Chaudhry (LT room), Mr. Bhavesh Lad, Mr. Pawar(LT), Mr. Surendra sir(ETP), Mr. Dinesh patel (instrumentation lab) for providing the help during internship.
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PREFACE
A fiber undergoes various transformations, before it is converted into a fabric. The transformations were carried out under various stages that include a variety of process.
The primary textile processes are broadly classified into:
1. Yarn production(blending of yarns, spinning) 2. Dry processes (Weaving, etc.) 3. Wet processes (sizing, de sizing, scouring, bleaching, mercerization, dyeing,
printing, finishing etc.)
The former two were dry process .the wet processes as the name suggests were exclusively carried out under wet condition conditions and require bulk quantities of water.
The spinning process starts from the blow room where the squeezed cotton was opened up and spread continued by carding, drawing, combing, roving, open end spinning and ring spinning.
In weaving the interlacement of warp and weft yarn takes place to form a terry towel.
The terry towel obtained in a processing unit is called grey cloth and is subjected to various treatments like de sizing, scouring bleaching, and mercerization, dyeing or printing and finishing.
All these wet processes may be carried in an integrated unit or each wet process as separate units. Some units may carry two or three operations.
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BOARD OF DIRECTORS
The board of directors consists of people who are the motivating and driving leaders of the company. They are as follows,
Chairman-Mr. G.R. Goenka
Vice chairman and Managing Director-Mr. B.K Goenka
WELSPUN INDIA LIMTED
WELSPUN INDIA LIMTED is textile division of the Welspun group that produce terry towel, sheeting and especially polyester filament yarn. Welspun retail limited is also part of WIL for the domestic retail home textile.
ABOUT THE COMPANY:
WELSPUN INDIA LIMETED a part of the Welspun group had its beginning in 1993 as terry towel manufacturing until Vapi.
The company exports more than 90 % of its total production to over 34 countries and caters 12 to out of the 20 top retailers in the world.
The company’s share in US home textiles market is on the rise as it is moving up the value chain from selling to mass merchant ,at the bottom the market pyramid to designer brands at the uppermost tip of the pyramid.
With licensed life style brands in home textiles, the company’s desire to expand its business on high value products and distribution channels as part of its overall risk free strategy.
Company has also entered into the domestic market with the brand name spaces, offering holistic home textile solution. Spaces has a retail presence in over 800 stores. Address of the plant: Welspun India Limited, Village- Morai Vapi, Gujarat-396191.
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WELSPUN GROUP COMPANIES
COMPANY AREAS OF BUSINESS
Welspun India Ltd Manufacturer of Home Textile
Welspun Gujarat Stahi Rohren LSAW, spiral and HFIW pipe manufacturing & coatings, plate-cum-coil manufacturing.
Welspun syntex Ltd. Specialty polyester filament yarn, texturized & dyed yarns.
Welspun Zucchi textiles Ltd. Bathrobes
Welspun power & steel Ltd. Ingots/Billets and TMT bars.
Welspun Maxsteel Ltd. Sponge iron
Welspun tubular LLC. SAW pipes plus coating & bending.
Welspun Natural Resources Ltd. Oil and Gas exploration.
Welspun investments Ltd. Investments
Welspun Global Brands Ltd. Marketing, sales & distribution of home textiles.
Welspun Retail Ltd. Home textiles retail under brands ‘Spaces Home & Beyond’ and ‘Welhome’ in India.
Welspun UK Ltd. Home textiles under brands ‘Christy’ and ‘Kingsley Home’.
Sorema, Portugal Bath rugs and Shower Curtains under brands ‘Sorema’ and ‘Graciozza’.
Welspun Mexico SA DE CV Decorative & basic bedding
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DIVISION AND DEPARTMENT
WELSPUN, VAPI is a completely vertically integrated plant, right from spinning to confectioning. The firm has been divided into 2 divisions.
DIVISION-1 – TERRY TOWELS
1. SPINNING 2. WEAVING 3. PROCESSING 4. FINISHING 5. PACKAGING
DIVISION-2 – RUGS
1. TUFTING 2. LATEX COATING 3. CUT AND SEW 4. PROCESSING 5. FINISHING AND PACKAGING
CAPACITY DETAILS OF VAPI PLANT
spinning 86mt/ day weaving 50mt/day processing 68mt/day finishing 50-55mt/day
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Theory of Thermal Power Station
The theory of thermal power station or working of thermal power station is very simple. The
steam is obtained from high pressure boilers. Generally in India, bituminous coal, brown coal
and peat are used as fuel of boiler. The bituminous coal is used as boiler fuel has volatile matter
from 8 to 33 % and ash content 5 to 16 %. To increase the thermal efficiency, the coal is used in
the boiler in powder form.
In coal thermal power plant, the steam is produced in high pressure in the steam boiler due to
burning of fuel (pulverized coal) in boiler furnaces. This steam is further supper heated in a super
heater. This supper heated steam then enters into the turbine and rotates the turbine blades. The
turbine is mechanically so coupled with alternator that its rotor will rotate with the rotation of
turbine blades. After entering in turbine the steam pressure suddenly falls and corresponding
volume of the steam increases. After imparting energy to the turbine rotor the steam passes out
of the turbine blades into the condenser. In the condenser the cold water is circulated with the
help of pump which condenses the low pressure wet steam. This condensed water is further
supplied to low pressure water heater where the low pressure steam increases the temperature of
this feed water, it is again heated in high pressure.
For better understanding we furnish every step of function of a thermal power station as follows,
1) First the pulverized coal is burnt into the furnace of steam boiler.
2) High pressure steam is produced in the boiler.
3) This steam is then passed through the super heater, where it further heated up.
4) This supper heated steam is then entered into a turbine at high speed.
5) In turbine this steam force rotates the turbine blades that means here in the turbine the stored
potential energy of the high pressured steam is converted into mechanical energy.
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Line Diagram of Power Plant
6) After rotating the turbine blades, the steam has lost its high pressure, passes out of turbine blades and enters into a condenser.
7) In the condenser the cold water is circulated with help of pump which condenses the low pressure wet steam.
8) This condensed water is then further supplied to low pressure water heater where the low pressure steam increases the temperature of this feed water, it is then again heated in a high pressure heater where
the high pressure of steam is used for heating.
9) The turbine in thermal power station acts as a prime motor alternator
The working fluid is water and steam. This is called feed water and steam cycle. The ideal Thermodynamic Cycle to which the operation of a Thermal Power Station closely resembles is the RANKINE CYCLE.
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In steam boiler the water is heated up by burning the fuel in air in the furnace & the function of
the boiler is to give dry super-heated steam at required temperature.
The steam so produced is used in driving the steam Turbines. This turbine is coupled to
synchronous generator (usually three phase synchronous alternator), which generates electrical
energy.
The exhaust steam from the turbine is allowed to condense into water in the steam condenser of
turbine, which creates suction at very low pressure and allows the expansion of the steam in the
turbine to a very low pressure. The principle advantages of condensing operation are the
increased amount of energy extracted per kg of steam and thereby increasing efficiency and the
condensate which is fed into the boiler again reduces the amount of fresh feed water.
The condensate along with some fresh make up feed water is again fed into the boiler by pump
(called the boiler feed pump).
In condenser the steam is condensed by cooling water. Cooling water recycles through cooling
tower. This constitutes cooling water circuit.
The ambient air is allowed to enter in the boiler after dust filtration. Also the flue gas comes out
of the boiler and exhausted into atmosphere through stacks. These constitute air and flue gas
circuit. The flow of air and also the static pressure inside the steam boiler (called draught) is
maintained by two fans called Forced Draught (FD) fan and Induced Draught (ID) fan.
The total scheme of a typical thermal power station along with different circuits is illustrated
below.
Inside the boiler there are various heat exchangers, viz.’ Economizer’, ‘Evaporator’ (not shown
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in the fig above, it is basically the water tubes, i.e. down comer riser circuit), ‘Super Heater’
(sometimes ‘Reheater’, ‘air preheater’ are also present).
In Economizer the feed water is heated to considerable amount by the remaining heat of flue gas.
The Boiler Drum actually maintains a head for natural circulation of two phase mixture (steam +
water) through the water tubes.
There is also Super Heater which also takes heat from flue gas and raises the temperature of
steam as per requirement.
the boiler use in this industry water tubes boiler, and DM water (De mineralize water) are used in boiler for steam generation Therefore in this power plant the steam produces is used in various industry plants for drying purpose, therefore two same type boiler are used in steam generation.
DIESEL POWER PLANT:
Diesel power plants are also popularly used as standby supply of different industries, commercial
complexes, hospitals, etc. During power cut, these diesel power generators are run to fulfil
required demand.
Advantages of Diesel Power Station
1. This is simple in design point of view.
2. Required very small space.
3. It can also be designed for portable use.
4. It has quick starting facility, the small diesel generator set can be started within few
seconds.
5. It can also be stopped as when required stopping small size diesel power station, even
easier than it’s starting
6. As these machines can easily be started and stopped as when required, there may not be
any standby loss in the system.
7. Cooling is easy and required smaller quantity of water in this type power station.
8. Initial cost is less than other types of power station.
9. Thermal efficiency of diesel is quite higher than of coal.
10. Small involvement is less than steam power station.
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Disadvantages of Diesel Power Station
1. As we have already mentioned, the cost of diesel is very high compared to coal. This is
the main reason for which a diesel power plant is not getting popularity over other means
of generating power. In other words the running cost of this plant is higher compared to
steam and hydro power plants.
2. The plant generally used to produce small power requirement.
3. Cost of lubricants is high.
4. Maintenance is quite complex and costs high.
Different Components of Diesel Power Station
In addition to diesel generator set or DG set there are many other auxiliaries attached to at diesel
power station.
Let’s discuss one by one.
Fuel Supply System
In fuel supply system there are one storage tank, where oil in stored.
Strainer: This oil then pump to dry tank, by means of transfer pump.
During transferring from main tank to smaller dry tank, the oil passes through strainer to remove
solid impurities. From dry tank to main tank, there is another pipe connection. This is over flow
pipe. This pipe connection is used to return the oil from dry tank to main tank in the event of
over flowing.
From dry tank the oil is injected in the diesel engine by means of fuel injection pump.
Air Intake System
This system supplies necessary air to the engine for fuel combustion. It consists of a pipe for
supplying of fresh air to the engine. Filters are provided to remove dust particles from air.
Exhaust System
The exhaust gas is removed from engine, to the atmosphere by means of an exhaust system. A
silencer is normally used in this system to reduce noise level of the engine.
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Cooling System
The heat produced due to internal combustion, drives the engine. But some parts of this heat
raise the temperature of different parts of the engine. High temperature may cause permanent
damage to the machine. Hence, it is essential to maintain the overall temperature of the engine to
a tolerable level. Cooling system of diesel power station does exactly so. The cooling system
requires a water source, water source, water pump and cooling towers. The pump circulates
water through cylinder and head jacket. The water takes away heat from the engine and it
becomes hot. The hot water is cooled by cooling towers and is re-circulated for cooling.
Lubricating System
This system minimizes the water of rubbing surface of the engine. Here lubricating oil is stored
in main lubricating oil tank. This lubricating oil is drawn from the tank by means of oil pump.
Then the oil is passed through the oil filter for removing impurities. From the filtering point, this
clean lubricating oil is delivered to the different points of the machine where lubrication is
required the oil cooler is provided in the system to keep the temperature of the lubricating oil as
low as possible. Starting System
Unit runs with its own power. For small DG set, the initial rotation of the shaft is provided by
handles but for large diesel power for starting a diesel engine, initial rotation of the engine shaft
is required. Until the firing start and the station. Compressed air is made for starting.
Therefore in this industry there three diesel power plant of different ratings
Unit: 1 of 4 MW
Unit: 2 of 6 MW
Unit: 3 of 2 MW.
GAS TURBINE:
Gas Turbines are one of the most efficient equipment for converting fuel energy to mechanical energy. How does a Gas Turbine work? What are auxiliary systems? This article explains in simple terms the working of the main parts of the Gas Turbine.
Gas turbine functions in the same way as the Internal Combustion engine. It sucks in air from the atmosphere, compresses it. The fuel is injected and ignited. The gases expand doing work and
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finally exhausts outside. The only difference is instead of the reciprocating motion, gas turbine uses a rotary motion throughout.
This article details the three main sections of the Gas Turbine.
1. Compressor. The compressor sucks in air form the atmosphere and compresses it to pressures in the range of 15 to 20 bar. The compressor consists of a number of rows of blades mounted on a shaft. This is something like a series of fans placed one after the other. The pressurized air from the first row is further pressurized in the second row and so on. Stationary vanes between each of the blade rows guide the air flow from one section to the next section. The shaft is connected and rotates along with the main gas turbine.
2. Combustor. This is an annular chamber where the fuel burns and is similar to the furnace in a boiler. The air from the compressor is the Combustion air. Burners arranged circumferentially on the annular chamber control the fuel entry to the chamber. The hot gases in the range of 1400 to 1500 °C leave the chamber with high energy levels. The chamber and the subsequent sections are made of special alloys and designs that can withstand this high temperature.
3. Turbine The turbine does the main work of energy conversion. The turbine portion also consists of rows of blades fixed to the shaft. Stationary guide vanes direct the gases to the next set of blades. The kinetic energy of the hot gases impacting on the blades rotates the blades and the shaft. The blades and vanes are made of special alloys and designs that can withstand the very high temperature gas. The exhaust gases then exit to exhaust system through the diffuser. The gas temperature leaving the Turbine is in the range of 500 to 550 °C.
The gas turbine shaft connects to the generator to produce electric power. This is similar to
generators used in conventional thermal power plants.
Performance More than Fifty percent of the energy converted is used by the compressor. Only around 35 % of the energy input is available for electric power generation in the generator. The rest of the energy is lost as heat of the exhaust gases to the atmosphere.
Three parameters that affect the performance of a of gas turbine are
The pressure of the air leaving the compressor. The hot gas temperature leaving the Combustion chamber. The gas temperature of the exhaust gases leaving the turbine.
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The above is a simple description of the Gas Turbine. Actually it is a very sophisticated and complex equipment which over the years have become one of the most reliable mechanical equipment. Used in combined cycle mode gives us the most efficient power plant.
Therefore the rating of this gas power plant is 7.2 MW.
Fig. Diesel engine
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INTRODUCTION TO SPINNING DIVISION
The spinning division serves as the first and one of the most crucial divisions in any textile industry. In this unit of 37235 spindles capacity, the raw fiber is converted into yarns through series of processes. The main fiber spun in this unit is cotton and its blends along with some other special fibers that include polyester modal, bamboo, static; etc.the cotton is mainly blended with polyester in the ratio depending on the end use and requirement. The capacity of the spinning division is approximately 55-60 tons per day.
There are mainly three types of spinning processes that are perfumed.
1. Ring spinning
2. Open end spinning
3. Combed spinning
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Spinning Department
It starts with the blow room.
BLOW ROOM:
Blow room is the starting of the spinning operation where the fiber is opened, cleaned, mixed, micro dust removed and evened thus passed to carding machine without increasing fiber neps, broken seed particles and without removing more good fibers.
The basic function of blow room is opening, cleaning, dust removal, blending and evenly feeding the material on the card.
There are various varieties of cotton as well as other special fibers that are spun here. The types of fibers that are spun here are:
Types of fiber Price range (Rs. Per kg)
Procured from Used in
Shankar-6 70-75 Gujarat Towels, rugs Organic cotton 65-70 Maharashtra, Orissa Towels Pima 114-118 USA Towels Wool Noils 70-75 Imported Towels, rugs Egyptian Giza 102-106 Egypt Towels PVA 144-148 Imported Towels, rugs Bamboo 148-152 China Towels
o
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o
Opening is the first operation within the blow room in which the goal is always a high degree of openness of material with gentle treatment with and a fiber loss as less as possible. By keeping view of this concept in mind, a project work has been carried out in sequence of different machines in blow room like varioclean, ASTA, MULTIMETER, DUSTEX and the subsequent process carding, by conducting trials with different process parameter at each stage.
The main object of this study is to achieve better sliver and yarn quality by implementing different settings at different machines cited above.
Process description of spinning is given below:
OPENING & CLEANING COTTON:
The raw cotton bales are fad into blenmoat for opening and then cleaning of cotton is done in blow room line
SLIVER MAKING:
Clean cotton for blow room is again clean card and converted into the form of silver. The draw frame also make silver.
CARDING (TEXTILE) PROCESS PARMENTS:
INTROCDUCTION:
Carding is most process in spinning it contributes a lot to the year quality. The flowing process parameters and specification are to be selected properly to produce a good quality yarn with a lower manufacturing cost.
Cylinder wire flat tops specification liker –in wire specification doffer wire specification feed weight draft between feed roller and doffer grinding flat tops grinding cylinder, flat tops, doffer wire life licker-in wire life cylinder speed flat speed licker – in speed setting between cylinder and flat top between licker – in and feed plate between licker in and under casing elements like, mote knife, combing segments etc.
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CYLINDER WIRE AND CYLINDER SPEED:
Cylinder Wire selection is very important, it depends upon cylinder speed, the raw material To be process and the production rate .the following characteristic of cylinder wire should be consider
1. Wire angle 2. Tooth depth 3. Wire production 4. Rib thinness 5. Tooth profile 6. Tooth pitch 7. Tooth point 8. Overall wire height
Wire front angle depends on mainly cylinder speed and coefficient of friction of raw material .higher the cylinder speed, lower the angle for a given fiber. The cylinder speed in turn depends upon the production rate.
Higher production means more working space for the fiber is required it is the wire that keeps the fiber under its influence during carding operation. Therefore the space within the wire should also be more for higher production
MATERIAL PRODUCATION RATE CYLIDER SPEED Cotton Low 360 to 400 Cotton Medium 430 to 470 Cotton High 500 to 550 Synthetic Low 300 Synthetic Medium 380 Synthetic high 460
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ROVING MAKING:
The speed frame converts the slivers into the Roving Bobbin.
SPEED FRAME: It is an intermediate process in which fibers are converted into low twist lea called roving. The sliver which is taken from draw frame is thicker so it is not suitable for manufacturing of yarn. Its purpose is to prepare input package for next process. This package is to prepare on a small compact package called bobbins. FUNCTION OF SPEED FREME: Attenuation of drawn sliver to form roving of required count by drafting. Insert small amount of twist to give required strength of roving. Wind the twisted roving on to the bobbin. Build the roving in bobbins RING FRAME: Function of ring frame:
To draft the roving until the required fineness is achieved.
To impart strength to the fiber, by inserting twist
To wind up the twisted yarn in a form suitable for storage, transportation and further processing. Advantages of ring spinning frame:
It is universally applicable, i.e. any material can be spun to any required count.
It delivers a material with optimum characteristics, especially with regard to structure and strength.
It is simple and easy to master.
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YARN MAKING:
The roving is converts into the yarn by ring frame and then cheese is prepared in the auto
Conner.
The slivers from draw frame are also fed into the open-end spinning where the cheese is prepared from sliver.
This prepared yarn is dispatched for sales after packing and also for own captive consumption.
COMBING MACHINE:
The combing machine is located in the spinning process between the drawing frame and the flyer. Combing is a method for preparing carded fiber for spinning. The combing process is carried out in order to improve the quality of the sliver combing out of the carding process eliminates short fibers. Combing is divided into linear and circular combing. French comb is an example of linear combing. Combing separate out the short fibers by means of a rotating ring or rectilinear row of steel pins. Its use is optional, and it is use to improve the yarn quality. The goal is achieved by combing out the shorter fibers, thus increasing the effective fiber length.
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Objective of combing:-
To remove naps in the carded sliver.
To make the fiber more parallel and straight.
To produce a uniform sliver of required per unit length.
To remove remaining impurities in comber lap. Advantage of combing machine: High drive dynasmics. Individual drive for the pilgrim step motion. The minimum requirements are 1 servo motor for the feeder and 1 asynchronous motor for the rotary comb as the main drive .Both motors are located on the converter.
WARPING:-
The process of warping consists of collecting predetermined number of ends from a set of wound package and transforming them in a sheet form on to warper’s beam.the warping process lays the foundation of the quality of a weaver’s beam.
There are two types of warping.
1. Direct warping
2. Sectional warping
1. Direct warping:-
The direct warping consists of preparing a full width warper’s beam in one step. High speed warping is also called as the direct warping/beam warping. All the yarns are wound at once and simple flanged beam is used. It is a very high speed process and is used for making fabric of single color.
There are 2 types of direct warping machines in the company-
1) Benninger -2 machines 2) Jupiter -2 machines
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FLOW CHART OF DIRECT WARPING:
Features:
1. It is used to make common fabrics in large quantities.
2. The production is high.
3. Large amount of yarn is required to produce a weaver’s beam.
4. It is used to produce weavers beam from single yarn.
5. Simple flanged beam is used and drums are not required.
creel
beam for sizing
weaver's beam
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2. SECTIONAL WARPING:-
In sectional warping equal length of yarn is first wound in small sections on a drum. Then from the drum it is transferred to the beam. This is two stage method and is used for making fancy fabrics. Sectional warping consists of preparing only one section at a time and then such sections make a full width weavers beam. Sectional warper is mainly used for colored yarn and also for doubled yarn if sizing process is to be eliminated.
There are 5 machines used in sectional warping:-
1) Sucker Muller 2) Benninger 3) Karl Mayer 4) Prashant Gamatax 5) Vama tax
FLOW CHART OF SECTIONAL WARPING:
Creel
Drum
Beam
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Working principle:
1. Sectional warping is used for short runs especially for fancy pattern fabrics.
2. In this section of warp which may contain up to 1000 ends are first wound onto a drum tapered with a given cone angle.
3. So cross wound sections are combined on the drum & thus each layer of warp contains the same number of ends on the drum.
4. Then the warp threads altogether are transferred onto a weavers beam by unwinding the drum.
Features:-
1. This is suitable for making stripped, checked or other fancy fabric.
2. The production is less in sectional warping.
3. The yarn tension is less uniform.
4 .It is less efficient then direct warping.
DIFFERENCES BETWEEN SECTIONAL AND DIRECT WARPING:
DIRECT WARPING SECTIONAL WARPING
1. Beam warping is used for runs of grey fabrics & simple pattern.
1. Sectional warping is used for short runs especially for fancy pattern fabrics.
2. The amount of colored yarn is less than 15% of the total.
2. Greater amount of colored yarn is used.
3. High production. 3. Low production. 4. Less expensive. 4. More expensive. 5. Beam warping is more widely used. 5. Sectional warping is not widely used.
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SIZING:-
Sizing of the warp yarn is essential to reduce breakage of the yarn and thus production stops on the weaving machine. With sizing the strength, resistance of the yarn will improve and hairiness of yarn will decrease. The degree of improvement of strength depends on adhesion force between fiber and size. Sizing is the process of applying the size material on yarn. Starch, gelatin, oil, wax and manufactured polymers such as polyvinyl alcohol, polystyrene, poly acrylic acid, and polycetates are employed.
There are 3 types of sizing machines in the company:-
1) Benninger- 2 machine 2) Jupiter- 1 machine 3) Sucker Muller- 1 machine
Details Benninger Jupiter Sucker Muller No. of warper beam (input)
12 8 8
No. of ends in warper beam
656 576 576
No. offends in weaver beam
7872 4608 4608
Speed of sizing 100-140m/min 50m/min 50m/min No. of drying cylinder
12 8 8
No. of creels 3 2 2
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Object of sizing:
1. To protect the yarn from abrasion.
2. To improve the breaking strength of the yarn.
3. To increase smoothness of yarn.
4. To increase yarn elasticity.
5. To decrease the generation of static electricity.
Disadvantages of sizing:
Cost of land and machine is high.
Required lots of labors.
Requires utility like gas, electricity etc. and their cost is high.
The process is long and it takes times
There is a risk of pollution.
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WEAVING SECTION:
In Rapier and Air jet,
For lifting, there are two types of loom,
1. Jacquard loom 2. Dobby loom
For terry weaving special type of looms are required where two sets of beams.
1. Pile beam 2. Ground beam
These two types of beams are required. The tension on ground warp is high while on that of pile is less, which forms loop. The formation takes place by two different methods.
1. By Reed movement: Every 3rd pick full beat up takes place and less tensioned pile end forms loop.
2. By cloth movement: Cloth moves towards the reed for full beat up and loops are formed by less tensioned pile warp.
WEAVING SECTION
AIRJET LOOM
RAPIER LOOM
WATERJET LOOM
LOOM
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Except the above modifications the rest of the loom mechanism are similar to normal loom and depending upon requirement dobby mechanism, for bigger floral design jacquard attachments are provided. The process sequence attached shows the various stages through which yarn passes to form ultimately a terry fabric.
Microcontrollers: There are three types of microcontroller that are use in weaving looms 2. Series 250 3. Series 500 4. Series 800
Series 500 is compact than series 250. It uses hard disk and static RAM.
In series 800 we can provide the design through the pen drive also.
AIR-JET LOOM:
A loom using a jet of air to carry the yarn through the shed. A jet of air is projected across the shed forcefully, that takes the filling yarn to the other side i.e. a jet of air is used to propel the weft yarn through the shed at speeds up to 600 ppm.
To makes fabrics on this latest types of looms available in the market place today, one needs to use uniform weft yarns.
Though heavier yarns are suitable for air-jet looms, lighter yarns are very difficult to control through the shed.
It has also been noticed that two heavy yarns also can’t be carried across the loom by air-jet. Despite these limitations, air-jet looms can produce a wide variety of fabrics.
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Tsudakoma developed new ZAX9100 air-jet loom. Advantages of the ZAX9100 are: Loom rpm: increase 20% Air consumption: reduced 10% Floor vibration: reduced 35% Accessibility: increase 20%
With all these new designs the ZAX9100 thoroughly pursues high-speed ability.
Thus, Tsudakoma succeeded in reducing style change time 20%.
A Toyota industry develops and manufactures air jet looms, which insert the weft yarn using air. It provides speedy and reliable performance.
Toyota air-jet looms can weave ultra-wide home furnishings fabric, stretch fabric, and fabric of different tarn types.
Production- 1 million meters per year. electronic cam, dobby and jacquard shedding
Weft insertion- automatic pick controllers synchronizes weft yarn travel and prevents weft yarn breaks.
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JACQUARD LOOM:
Jacquard loom is a mechanical loom, invented by Joseph Marie jacquard that simplifies the process of manufacturing textiles with such complex patterns as brocade, damask and matelassé.
BONAS machine company Ltd launched the first electronic jacquard at ITMA in 1983.
The loom was controlled by a “chain of cards”, a number of punched cards, laced together into a continuous sequence.
Multiple rows of holes were punched on each card, with one complete card corresponding to one row of the design.
Jacquard weaving makes possible in almost any loom the programmed raising of each warp threads independently of the others.
The term “jacquard loom “is a misnomer. It is the “jacquard head” that adapts to a great many dobby looms that allow the weaving machine to then create the intricate patterns often seen in jacquard weaving.
Jacquard looms, is relatively common in the textile industry, are not as ubiquitous as dobby looms which are usually faster and much cheaper to operate.
However, unlike the jacquard looms, they are not capable of producing so many different weaves from one warp.
Modern jacquard looms are controlled by computers in place of the original punched cards, and can have thousands of hooks.
Jacquard weaving of course uses all sorts of fibers and blends of fiber, and it is used in the production of fibers for many end uses.
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RAPIER LOOM:
Rapier weaving machine are known for their reliability, performance and versatility, i.e. ability to weave wide range of fabrics.
In the field of rapier weaving, the number of manufactures is unbelievably high.
It is therefore realistic to consider only the principals involved.
Although, all rapier machines can be classified as a single group for convenience, they can be sub-classified in several ways.
Newer rapier machines are built with two distinct weaving areas for two separate fabrics. On such machines, one rapier picks up the yarn from the center, between the two fabrics and carries it across one weaving area, as it finishes laying that pick, opposite end of the rapier picks up another yarn from the center, and the rapier moves in the other direction to lay a pick for the second weaving area, on the other half of the machine.
Classification of the rapier: Type of rapier: rigid, flexible, and telescopic No. of rapiers: single, double or twin Method of weft insertion: gabler, dewas Positioning of the picking mechanism.
An important Advantage of rapier machines is their flexibility, which permits the laying of picks of different colors.
They also weave yarns of any type of fiber and can weave fabrics up to 110 inches in width without modification.
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DOBBY LOOMS:
Dobby looms first appeared around 1843, roughly 40 years after Joseph Marie jacquard invented the jacquard device that can be mounted atop a loom to lift the individual heddles and warp threads.
In dobby looms, dobby magnets are used. A dobby loom is a type of floor loom that controls all the warp threads using a device called a dobby.
A dobby loom is an alternative to a treadle loom. Both are floor looms in which every warp threads on the loom is attached to a single shaft using a device called a heddle.
A shaft is sometimes known as a harness. Each shaft controls a set of threads.
Raising or lowering shafts at the same time gives a huge variety of possible sheds (gaps) through which the shuttle containing the weft thread can be thrown.
A manual dobby uses a chain of bars each of which has pegs inserted to select the shafts to be moved.
A computer-assisted dobby loom uses a set of solenoids or other electric devices to select the shafts. Activation of these solenoids is under the control of a computer program.
Industrial dobby loom detail:
Fabric: Light, medium, and even heavy-weight fabrics of virtually all yarn types; natural spun, and filament are all capable of being woven on the IDL. The wide range of applications extends from plain weaves to complex 24 harness dobbies.
Yarn: Spun yarns of natural and man-made fibers as well as filament yarns in a very wide range of yarn counts are all possible. The loom performs well medium density cotton, heavy novelty yarns (chenille), and super-fine silk among others.
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Advantage:
Dobby loom becomes even more pronounced on looms with 12 shafts, 16 shafts or more. It reaches its peak on a jacquard loom in which each thread is individually controlled.
Another advantage to a dobby loom is the ability to handle much longer sequences in the pattern.
Dobby looms expand a weaver’s capabilities and remove some of the tedious work involved in designing and producing fabric.
GREY INSPECTION:-
After weaving cloth is removed from the loom and before sending it to processing it is inspected if any defects are seen corrective action is taken in weaving, otherwise fabric is sent to
process house.
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PROCESS SECTION:-
Dyeing process:
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 materials. After dyeing, dye molecules have uncut chemical bond with fiber molecules. The temperature and time controlling are two keys factors in dyeing. There are mainly two classes of dye, natural and man-made.
There are two types of dyeing process.
1. Yarn dyeing 2. Fabric dyeing
YARN DYEING:
There are many forms of yarn dyeing. Common forms are the package form and the hanks form. Cotton yarns are mostly dyed at package form, and acrylic or wool yarn are dyed at hank form.
The common dyeing process of cotton yarn with reactive dyes at package form is as follows:
1. The raw yarn is wound on a spring tube to achieve a package suitable for dye penetration 2. These softened packages are loaded on a dyeing carrier’s spindle one on another. 3. The packages are pressed up to a desired height to achieve suitable density of packing. 4. The carrier is loaded on the dyeing machine and the yarn is dyed. 5. After dyeing, the package is unloaded from the carrier into a trolley. 6. Now the trolley is taken to hydro extractor where water is removed. 7. The packages are hydro extracted to remove the maximum amount of water leaving the
desired color into raw yarn. 8. The packages are then dried to achieve the final dyed package. 9. After this process the dyed yarn packages are packed and delivered.
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FABRIC DYEING:
1. First take the material and load it in the eco soft machine. Start with the first process that is scouring main objective of scouring is to remove the PVA and chemical used is EM clean CP. In this section bleaching and washing of fabric is done.
2. After this treatment add bleaching chemical, which include miratols WA etc. HYDRO EXTRACTO MACHINE is used to remove the excess water of the wet fabric. ROPE OPENING is used after the bleaching, washing, and dyeing stations. It is used to remove fabric twisting. Then it is applied for dryer. Dryer is used for drying the textile fabrics. Steam is used in this process, blowing hot air for drying the fabrics.
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SHEARING MACHINE:
The function of shearing machine is to cut the yarn, present on a fabric surface, at a constant level of height. This operation can be applied to a wide range of fabrics and for a wide range of applications. The machine is provided with section knives with sliding blades which can be adjusted by hand to make 90 cuts on angles and T-sections of different sizes as well as with openings for cutting round and square bars.
FINISH-FOLDING DEPARTMENT:
The process of finish-folding department:
AQL
packaging
1.polybag
2.carton
Dispatch
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length slitting
length hemming
cross cuttinglength
hemming alteration
cross cutting
embroidery cross hemming
checking
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EFFLUENT TREATMENT PLANT
PROPOSED FACILITIES
Sr. No.
Unit
Capacity
Quantity
1. Manual Screen Chamber 1.2 m3 1 2. Mechanical Screen Chamber 1.92 m3 1 3. Oil trap tank 105 m3 1 4. Equalization Tank 5000 m3 1 5. Cooling tower basin 54 m3 1 6. De nitrification tank 650 m3 1 7. Selector Tank 650 m3 1 8. Aeration Tank 10000 m3 1 9. Secondary settler 1350 m3 1 10. Quartz filter feed tank 1600 m3 1 11. Quartz filter 2.2 m dia X 2 m ht. 5 12. Backwash water tank 126 m3 1 13. Treated water storage tank 1050m3 1 14. Ozone System 2 nos./ 6.4 kg/hr 1 15. Ultra-filtration System /
Membranes Area / Quantity 2 nos. / 50 m2 each 44
16. Reverse Osmosis System / Membrane Area / Quantity
2 nos. / 400 sq.ft each
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17. Sludge Thickener 275 m3 1 18. Filtrate collection sump 15.6m3 1 19. Thickened sludge sump 9.68m3 1 20. Belt press 12 m2/hr 1
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PRIMARY TREATMENT:
Bar Screen Chamber & Oil Trap tank:
Raw effluent will be collected into Equalization tank after passing through manual coarse bar screen of 10 mm clear spacing and Rotary Fine screen 4 mm perforation provided for the removal of coarse floating suspended matter and fine suspended matter to avoid clogging of rotating equipment at downstream side of the treatment. Then the effluent enters into the Oil Trap tank for the removal free floating oil then effluent enters into the Equalization tank.
Equalization tank & Cooling Tower:
The effluent after passing through oil trap tank collected in the equalization tank provided with12 hrs retention time, suitable SS 304 SCH 10 grid for air agitation shall be provided to keep the contents of the tank in mixed condition, the effluent shall be homogenized properly in this tank, and this tank will avoid shock loads on downstream operations. The effluent shall be pumped for cooling in the series of two stage cooling towers, online pH correction provided at discharge of cooling tower – II feed pump and then the cooled effluent sent for further treatment in the two stage biological treatment. De nitrification Tank:
The de-nitrification process, as electrons acceptor, uses a part of the incoming carbon as BOD; therefore the BOD consumed in the de-nitrification must be excluded from the calculation of the following oxidation section.
If there are no Nitrogenous compounds to remove, then there is no de nitrification, it means that the entire incoming BOD must be removed in the following phase. But if the de-nitrification tank could be transformed into a pre-oxidation tank, with the aim to remove that part of BOD related to the de-nitrification, it should be possible to have at disposal a bigger total volume for the oxidation of the organic load. It means it will be possible to utilize a volume of the plant that, if there is no de--nitrification should be unusable.
For these reasons the de-nitrification tank is provided of aeration net, equipped with diffusers on the bottom formerly foreseen in the selector.
During its functioning as pre-oxidation tank the installed mixer is switched off.
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Selector Tank: The SELECTOR, with the aim to control the filamentous biomass presence will be maintained, operating in anoxic condition, under mixing by a mechanical mixer. In fact, the previous foreseen aeration had e only the task to maintain the effluent mixed, as referred in the above mentioned text. Furthermore, as our process is a complete mix type, the filamentous control is achieved by mixing the recirculation sludge with the incoming effluent into an anoxic contact section.
Aeration Tank:
Effluent after cooling tower enters into two stage biological treatment (Extended
Aeration) tanks where soluble organics are degraded aerobically by microorganisms. In order to ensure required population of bacteria in aeration System, i.e., Mixed Liquor Suspended Solids (MLSS) and also Food to Micro-organisms ratio (F/M), part of the settled sludge from Lamella Clarifier will be re circulated back to Aeration tank. The organic wastewater is introduced into the Extended Aeration Tank where aerobic bacterial culture is maintained in suspension in the form of bio-sludge. The reactor contents are referred to as the mixed liquor. In the reactor, the bacterial culture carries out the conversion in general accordance with the stoichiometry as under:
Reaction:
Diffused Aeration system shall be used to provide desired oxygen to microorganisms, which also serves to maintain the reactor contents in a completely mixed regime & Dissolve Oxygen (DO) level of 2 ppm.
Secondary Settler:
The Mixed Liquor from Aeration Tank enters the central well of secondary settler for Separation of Sludge and liquid.
Quartz Filter Feed Tank:
The treated effluent from Secondary settler will enter in the Quartz filter Feed Tank. The effluent from the Quartz Filter Feed Tank will be then pumped to Quartz Filter for filtration.
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Quartz Filter:
The effluent, from treated water tank is pumped into Quartz filter. Quartz filter would be provided complete with filter backwash arrangement to ensure reduction & Suspended solids & turbidity at the outlet of the Quartz Filters. This
Filtration step reduces the suspended solids, before taking it to downs stream membrane systems. This unit works on the phenomenon of surface filtration. The unit offered consists essentially of a mild steel rubber-lined pressure vessel. It is externally fitted with necessary pipe work, valves, pressure gauges, and sampling points at the inlet and outlet. The filtration bed consists of fine sand of specified size over a layer of gravels. Water flows downwards through the filter bed and the suspended solids are retained on the sand surface and between the sand grains immediately below the surface. The filtered water is evenly collected by header lateral type bottom collecting system.
Backwash Water Tank:
At a pre-determined pressure drop the backwash of filter is initiated to clean the filter bed. The backwash water at high flow rate is pumped through the filter bed in upward direction to facilitate expansion of the filter bed. The particles are kept in suspension and are washed and dirty water is sent to Equalization tank from the upper side of the vessel. Once the backwash cycle is completed, filter is taken online for service after a final rinse with service flow rate. All the applied steps Collected in Backwash water Tank.
Treated Water Storage Tank:
The Final service water outlet of Quartz filter collected in treated water storage tank which can be further feed in to Ultra-filtration.
Ozone system:
Ozone is the highest oxidative substance that causes a chemical oxidation breaking complex molecules into pieces. Ozone is produced as a gas, starting from compressed air under electric discharge. Then it is blown into the effluent to be treated, through special ceramic diffusers that produce micro-bubbles giving an intimate contact with pollutants. This reaction produces oxygen again, and it arises to the upper part of the reaction tank together with some not yet reacted ozone. This gases flows through an ozone breaking device to eliminate it before the emission to the open air. The treated water, after this ozone process, can be discharged according to the requested law limits.
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Ultra-filtration system:
The filtered Part of treated effluent from UF feed Tank will be further treated in an Ultra filtration system. Ultra-filtration system is a low-pressure membrane process in which particulate colloidal and high molecular weight material is filtered from the effluent. Ultra-filtration consists of Hollow Fiber Membranes. The pore size of the membranes is such that it allows water to flow through but retains bacteria, other macromolecules and Turbidity (SDI). The effluent flows from the inside of the fibers, permeates through the membrane and is removed as the product from the shell side. The reject from UF is continuously removed from the other end of the membrane from the reject stream, which is typically 12 to 15 % of the feed. The Back flushing shall be done by UF permeate water.
Reverse Osmosis system:
Reverse osmosis is the finest level of filtration available. The RO membrane acts as a barrier to all dissolved salts and inorganic molecules, as well as organic molecules with a molecular weight greater than approximately 100. Water
Molecules, on the other hand, pass freely through the membrane creating a purified product stream. Rejection of dissolved salts is typically 95% to greater than 99%. The applications for RO are numerous and varied, and include desalination of seawater or brackish water for drinking purposes, wastewater recovery, food and beverage processing, biomedical separations, purification of home drinking water and industrial process water. Also, RO is often used in the production of ultra-pure water for use in the semiconductor industry, power industry (boiler feed water), and medical/laboratory applications. Utilizing RO prior to ion exchange (IX) dramatically reduces operating costs and regeneration frequency of the IX system. Tran’s membrane pressures for RO typically range from 75 psig (5 bar) for brackish water to greater than 1,200 psig (84 bar) for seawater.
Sludge Thickener:
The bridge, with peripheral traction, is placed over a rising-flow sedimentation tank with an upturned-cone-shaped bottom. The mixture of water and solids flows through the system and the solids which drop due to effect of gravity tend to sediment on the bottom, where scrapers placed on a beam anchored to the center of the sedimentation tank draw them from the sides towards the middle of the cone, from where they are extracted by a pump. The separated water overflows from a channel outside.
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Thickened Sludge sump:
The thickened sludge from sludge thickener is transferring in to sludge sump to further more treatment in Belt press for removal of suspended solids from the feed of water. We get minimum 2 to 3 % sludge concentration in sludge sump.
Filtrate collection Sump:
The overflow of sludge thickener and center of belt press get collected in this tank. This collected filtrate water again pumping to equalization tank for re processing.
Belt Press system:
The belt press entirely made in STAINLESS STEEL AISI 304 has a double belt which dewaters a sludge conditioned by chemical reagents by gradual pressing between two permeable belts crossing each other in a “S” way made by rollers with decreasing diameter. The washing water and the filtrate are discharged into the storage tank, while the dehydrated sludge is removed from
The cloths using scrapers. Then the dewatered sludge is deposited in the outside of the machine. Components: The bearing structure is manufactured in STAINLESS STEEL AISI304 and the rollers are also in stainless steel. The clothes stretching is carried out using pneumatic pistons and the cloth roller centering is controlled with pneumatic sensors, solenoid valves, pneumatic pistons and self-cleaning nozzles for clothes cleaning. The filter clothes are manufactured in polyester fabric. The unit is completed with: - belt press drive unit - stainless steel pre-dewatering cylinder - two sludge feeding mohno pumps.
- Counter washing pump - air compressor - filtered water pump
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Conclusion:
The one month internship was a journey through the ocean of knowledge and industrial exposure. This was the first major long term industrial project which enlightened us with the complete functionality of a composite textile firm. We witness some of the world’s best technologies and state of the art infrastructure that were explained by some of the great intelligentsia. The main aspects of learning in depth process understanding, technical details and the involvement of machinery, human capital and information technology. Thus, by providing us the great opportunity to take this precious internship welspun India limited has contributed a lot for building up a good knowledge base and hands on experience for the development of our carrier in this field. Thus, we would like to say that Welspun has trained us well. “Welspun …..Well-Trained”