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Journal of Research in Engineering and Applied Sciences

JREAS, Vol. 05, Issue 01, Jan 2020

DETAILS THERMOGRAPHY AUDIT OF RINGSPINNING MACHINE IN TEXTILE INDUSTRY

Abstract

In this paper Energy Audit of Electrical Installations is an integral part of the overall energy audit of complex technical systems, and infrared thermography is one of the non-destructive testing (NDT) methods for that type of analysis of power distribution subsystems. During the energy audit of the Ring Spinning Machine in Textile Industry by means of a thermal camera, it is necessary to carry out some additional measurements of electrical quantities which are often not performed easily. The paper provides an overview of the standards in the field of thermography and safety criteria of main motor of ring frame ,belt of main motor ,doffer motor, Cylinder bearing housing LHS, Opening roller bearing, cylinder bearing and card feed motor based on a thermal image and measured electrical parameters. The procedure of the audit and decision making for future maintenance is described in detail. Recommendations of corrective actions in the maintenance procedure based on the absolute temperature criterion .

Keywords:- Electrical power installations; thermography, ring frame

1. Introduction

ISSN (Print) : 2456-6411, ISSN (Online) : 2456-6403

Infrared Thermography is a science of using electronic optical devices to detect and measure radiation and correlating that to surface temperature. Thermal imagers can convert infrared radiation being emitted from the body into electric signals and thus present them visually. Infrared Thermography is the latest analysis tool for the detailed energy audit as the thermal cameras are powerful tool in viewing wall cavity insulation, ceiling insulation, moisture related problems. Several areas in electrical installations are not easily identified using conventional methods but these are able to locate with Thermal Imaging. Infrared Thermography is one solution for diagnosis used to determine the most effective plan of action to make the electrical installation more energy efficient. Energy Audits include– Walk through, preliminary, detailed Energy Audits and Infrared Thermography Assessments in the various industries such as Electrical, Construction etc.,[1-2]

Thermography Energy Audit by URS indicates organization's adherence to efficient energy saving technologies and measures using thermal cameras and as truly Auditing Firm, offers Value Auditing Services in Energy Auditing by suggesting energy efficient measures within the deep insulation, wall cavity etc. Auditing Services of URS are designed to meet Global Standards that deliver Credibility in adoption of Energy Saving Measures using thermal imaging. To achieve this objective, professionally trained auditors having expertise in thermal imaging are deputed to identify 'Opportunities and Measures for Improvements' in Energy Auditing.

1 2 3P. B. Joshi , P. S. Shete and R. B. Nagpure1,2Electrical Engineering Department, YCCE ,Nagpur India

3MSTCL,Nagpur India 1Email:{ joshiprasad1985@gmail.com}

2. Ring frame2.1 Ring spinningSpinning process is done by machine called ring

frame. It converts the bobbin into a yarn. The bobbin taken from the previous process fly frame is mounted on ring frame either automatically or manually. The ring frame stretches the material using a drafting 2s and 140s. Ring yarn is finer and more hairy when compared to open

2.2. Need of advancementIn ring spinning a large number of changes had

occurred for continuous improvement in production, quality and efficiency Air suction, Air pipes and Additional air conditioning requirements. The advantages and disadvantages are mention below [ 4-7]

Advantages are as follows:1. Production of high strength yarns. 2. Spinning of fine yarn count. 3. Proper for special yarns. 4. It is flexible as regards quantities (blend & lot

size) 5. The speeds in drawing section are best

controlled, yarn evenness is excellent. But if short fibers are too much, yarn unevenness occurs.

Fine yarns can be produced as compared to open-end spinning system

20 JREAS, Vol. 05, Issue 01, Jan 2020ISSN (Print) : 2456-6411, ISSN (Online) : 2456-6403

Disadvantages are as follows

1. Process stages are more numerous. Roving stages exists as an extra process compared to other systems.

2. The high speed of the traveler damages the fibers.

3. Capacity of the cops is limited. 4. Energy cost is very high. 5. Low production rate.

2.3. Main Parts of Ring Frame: The main parts of ring frame are as follows [8]

1. Roving Bobbin: Inserted in holders. 2. Roving Guide: To feed roving correctly. 3. Creel: To hold the roving bobbin over the

roller beam. 4. Guide Rail: Guide the roving into the drafting.

2.4. Zones in Ring Frame

There are totally four types of zones. 1. Creel zone 2. Drafting zone 3. Twisting zone 4. Winding zone

3. Thermography Result3.1. Main motor

Fig.3.1. Belt motor found heated condition at bale plucker a) IR Image b) Visible Image

Fig.3.1.shows the Belt motor found heated condition at bale plucker after thermography audit it's found following observation as shown in Table 3.1

Table 3.1. Thermography Report of Main motor

Component Temperature 83.6 °C Background Temperature

31.7 °C

Emissivity

0.95

Transmission

1.00

Average Temperature 83.0 °C Calibration Range -20.0 °C to 250.0 °C

Remark:- Conveyor drive belt motor at bale plucker found heated condition Suggested to check the following things 1) Motor winding condition and bearing condition 2) Lubrication schedule 3) Belt alignment 4) Cleaning condition

3.2. Doffer Motor

Fig.3.2. Doffer Motor Found Heated Condition At Card No-2 a) IR Image b) Visible Image

Fig.3.2.shows the Doffer Motor Found Heated Condition At Card No-2 after thermography audit it's found following observation as shown in Table 3.2

Table 3.2. Thermography Report of Doffer motor

Component Temperature 70.8 °C Background Temperature

37.6 °C

Emissivity

0.95

Transmission

1.00

Average Temperature 70.0 °C Calibration Range -20.0 °C to 250.0 °C

Remark - Doffer motor at card no-2 found heated condition. Suggested to check the following things 1) Motor winding condition and bearing condition 2) Lubrication schedule 3) Cleaning condition 4) Belt Tension

3.3. Doffer Motor at card

Fig.3.3. Doffer motor at card no-4 found heated condition a) IR Image b) Visible Image

Fig.3.3.shows the Doffer Motor Found Heated Condition At Card No-2 after thermography audit it's found following observation as shown in Table 3.3

Table 3.3. Thermography Report of Doffer motor at card

Component temperature 69.4 °c

Background temperature

35.9 °c

Emissivity

0.95

Transmission

1.00

Average temperature 69.0 °c Calibration range -20.0 °c to 250.0 °c

Remark- Doffer motor at card no-4 found heated condition . Suggested to check the following things 1) Motor winding condition 2) Lubrication schedule 3) Cleaning condition

21 JREAS, Vol. 05, Issue 01, Jan 2020ISSN (Print) : 2456-6411, ISSN (Online) : 2456-6403

3.4. Cylinder bearing

Fig.3.4. Cylinder bearing housing lhs at card no-1 found heated condition a) IR Image b) Visible Image

Fig.3.4.shows the Cylinder bearing housing lhs at card no-1 found heated condition after thermography audit it's found following observation as shown in Table 3.4

Component temperature 76.4 °c Background temperature

35.0 °c

Emissivity

0.95

Transmission

1.00

Average temperature 76.0 °c Calibration range -20.0 °c to 250.0 °c

Remark- Cylinder bearing housing LHS at card no-1 found heated condition. Suggested to check the following things 1) Lubrication schedule 2) Cleaning condition

3) Check bearing condition

3.5. Opening Roller

Fig.3.5.opening roller bearing housing at card no-3 a) IR Image b) Visible Image

Fig.3.5.shows the .opening roller bearing housing at card no-3 after thermography audit it's found following observation as shown in Table 3.5

Table 3.5. Thermography Report of Opening Roller

Component temperature 66.0 °c Background temperature

34.0 °c

Emissivity

0.95

Transmission

1.00

Average temperature 66.0 °c Calibration range -20.0 °c to 250.0 °c

Remark- Opening roller bearing housing LHS side at card no-3 found heated condition. Suggested to check the following things 1) Check side frame jamming 2) Lubrication schedule 3) Cleaning condition

4) Check bearing condition.

3.6. Cylinder bearing housing

Fig.3.6. Cylinder bearing housing at card no-3 found heated condition a) IR Image b) Visible Image

Fig.3.6. shows the Cylinder bearing housing at card no-3 found heated condition audit it's found following observation as shown in Table 3.6

Table 3.6. Thermography Report of Cylinder bearing housingComponent temperature 66.0 °c Background temperature

34.0 °c

Emissivity

0.95

Transmission

1.00

Average temperature 66.0 °c Calibration range -20.0 °c to 250.0 °c

Remark- Cylinder bearing housing LHS at card no-3 found heated condition . Suggested to check the following things 1) Lubrication schedule 2) Cleaning condition

3) Check bearing condition

3.7. Card feed motor

Fig.3.7. Card feed motor at card no-5 found heated condition a) IR Image b) Visible Image

Fig.3.7. shows Card feed motor at card no-5 found heated condition audit it 's found following observation as shown in Table 3.7

Table 3.7. Thermography Report of Cylinder bearing housing

Component temperature 73.1 °c Background temperature

35.8 °c

Emissivity

0.95

Transmission

1.00

Average temperature 73.0 °c Calibration range -20.0 °c to 250.0 °c

Remark- Card feed motor at card no-5 found heated condition Suggeted check the following things 1) Bearing condition and motor winding condition. 2) Motor servicing schedule 3) Lubrication schedule 4) Cleaning schedule

4. Thermography data of cardFollowing table 4.1 shows the Thermography data of card

Table 3.4. Thermography Report of Cylinder bearing

22 JREAS, Vol. 05, Issue 01, Jan 2020ISSN (Print) : 2456-6411, ISSN (Online) : 2456-6403

Table 4.1. Thermography data of card

Doffer Bearing Housing

Cylinder bearing housing

M/C no

Doffer motor

Brush motor

Main motor

L.H.S R.H.S M/C pulley

Cylinder pulley

L.H.S R.H.S Fan motor

1 63.3 62.3 51 38 44.3 51.1 40.9 76.4 66.2 42.1 2 70.8 61.7 53.2 42.8 43.9 49.6 42.1 59 55 42.5 3 67.8 61 55 39.9 41.6 51 39.3 78.3 60.5 48.1 4 69.3 65.1 46.4 46.9 47 45.3 42.8 69.1 65.5 43 5 65.7 62.7 47.8 51 42.1 46.8 46.5 62.6 61.4 43.3 6 67 55.8 47.1 39 47.8 45.7 43 41.3 49.8 40.8 7 62 57.2 48 38.5 45.4 45 41.6 53.9 67.4 41.1

Following Table 4.2 shows the Thermography data of card

Table 4.2. Thermography data of card

Opening roller frame

M/C no

Opening roller motor

L.H.S R.H.S Chute feed motor

Card feed motor

Philipson Brush motor

Delivery motor

Can changer

Lickerin Bearing housing

(LHS)

Lickerin

Bearing Housing

(RHS)

1 48.1 43.8 47.9 49.6 69.4 60.6 67 39.2 58 53.2

2 56.3 44 46 53 60.9 52 57.6 39.2 61 58

3 55 66.2 48 53 62.7 69.5 52.1 39.4 70.2 65

4 51.8 43.7 44.6 48.4 55.7 64.3 53.1 39 59.3 70.3

5 54.8 47.2 64.8 52.2 73.1 58.6 53.5 38.9 58.4 56.9

6 59.7 46.5 42 49.8 61.9 56.2 58.1 38.2 60 73.3

7 55.5 44.2 45.5 55.3 64.2 67.5 50.9 39.8 52.9 64.4

Following Table 4.3 shows the Thermography data of ring card

Table 4.3. Thermography data of Ring card

Drafting Motor/Gear box H.S

Drafting Motor/Gear box

Head Stock Gearing

RHS LHS RHS LHS LHS RHS 85.6/72.4 95.3/75.2 83.4/75.7 74.4/69.3 65.4 65.4 79.8/66.8 80.6/68.5 77.5/70 73.4/68.1 65.1 63.4 66.2/77.5 84.1/73.2 74.6/68.2 69.8/65.7 63.1 63 87.5/74.4 92/79 89.4/78.2 89.3/77.3 54.6 63.1 86.3/75.7 82.2/75.2 78.3/72.1 72.4/68.1 62.3 54.6 88.9/75.3 86.7/75.3 77.3/72.1 73.2/65.8 65.1 62.3 89.4/78.8 85.2/73 83.7/74.2 78.5/72.1 65.9 65.1 92.1/79.7 91.7/71.3 81.1/73.2 89.7/74.8 53 65 89.2/75.3 93.6/78.1 91.9/71.1 87.2/69 62.7 53 92.5/75.4 98.2/78.1 80.1/72 84.4/70 63.1 62.7

23 JREAS, Vol. 05, Issue 01, Jan 2020ISSN (Print) : 2456-6411, ISSN (Online) : 2456-6403

5. CONCLUSION

As a non-destructive method of testing electrical installations, infrared thermography is a simple way to quickly spotting the potential problems. Training and experience of the operator are crucial for a correct interpretation of thermograms. The complexity of the field is evident in the fact that there is no single technical standard in thermal imaging. From above paper we say that idea operating temperature is in rage from 600 C to 800 in above section the temperature goes beyond safe range .Hence remedial action is suggested. Thermography is a very practical method for the energy audit and maintenance of electrical installations, but it is very complex for evaluation and making judgments. The thermal imaging camera operator has to continuously broaden his or her knowledge in a relatively wide area of technical expertise.

References[1] ISO 9712:2012 Non-destructive testing -

Qualification and Certification of NDT personnel

[2] Glavaš, H., Józsa, L. and Barić, T., 2016. Infrared thermography in energy audit of electrical installations. Tehnički vjesnik, 23(5), pp.1533-1539.

[3] Http://www.ursindia.com / thermography _audit.aspx

[4] Www.reiter.com (REKIPEDIA)

[5] Http://www.rieter.com

[6] Http://textilelearner.blogspot.com/2013/05/an-overview-of-ring-spinning.html4

[7] BS ISO 18436-7:2014 Condition monitoring and diagnostics of machines - Requirements for qualification and assessment of personnel Part 7: Thermography

[8] Infraspection Institute, "Standard for Infrared Inspection of Electrical Systems & Rotating Equipment", 2008.