360 Quality Code. Recommendations for Container Pre-Trip Inspections February 2015

Transcription

1 Preface These Recommendations relate to the 360 Quality Code prepared and released by the 360 Quality Association. The recommendations provide more detailed information in order to assist the specialized reefer industry. Conduct of Inspections PTI inspections are part of the supply chain of cargo in reefer containers. These inspections are executed to ensure the proper working of the reefer machinery and can differ per shipping line. The PTI inspection is valid for 30 days when the reefer container passes the inspection. In case reefer containers fail on the PTI, repairs should be executed before cargo can be carried inside the container. PTI inspections are mostly executed on terminal or depot locations. PTI companies (hereafter called service suppliers ) are responsible for an accurate execution of the PTI inspections. 1

2 1. VISUAL INSPECTION The purpose of the visual inspection is to verify if the unit is in apparent good order and condition before switching on the unit to carry out the automatic PTI test. 1.1 Are all fixing bolts present and properly tightened? The engineer checks the presence of all fixing bolts securing the reefer machinery to the container and of various panels. 1.2 Is the fresh air ventilation cover in a proper condition and not leaking? The engineer checks if leakage is present on the fresh air ventilation cover. 1.3 Is the refrigeration unit free of any damage, which can affect the proper working? The engineer checks the unit for damage or wear and tear. 1.4 Is the electrical plug and power cable in proper condition and does the cable have the minimum required length? The engineer checks if the reefer plug is undamaged and if the rubber ring and cam on the plug are present. The standard length of the cable is at least 15m (20ft container) and 18 m (40HC container). The cable should not have more than two repair splices. 1.5 Are all electrical cables properly connected? The engineer checks if all electrical cables are properly connected and that no signs of improper repairs are present. Special attention should be given to the cables in the control box. 1.6 Are all relays and contactors fitted correctly? The engineer checks if relays and contactors are correctly fitted. Switch on unit 1.7 Are evaporator and condenser fan motors free of abnormal noise? The engineer checks if abnormal noise is present (such as from fan motor bearings). In case abnormal noise is present the engineer checks if fan motors and fan blades are damaged. To check this some panels should be dismantled. 2

3 2. PREPARATIONS FOR AUTOMATIC PTI The purpose of this preparation is to verify if some components are working correctly before the automatic PTI test is initiated as otherwise the test will Fail on any of the below mentioned issues. 2.1 Are the indication-led s and display screen(s) working correctly? The engineer checks if all LED s and display screen(s) of the controller are working correctly. 2.2 Are the correct container number and date & time set in the data recorder? The engineer checks if the correct container number and date & time (UTC) is set in the data recorder. 2.3 Are all sensors & pressure transducers working correctly at ambient conditions? When the container is connected to the power supply the engineer checks if temperatures and pressure transducers indicate ambient temperature and pressure. 2.4 Is the latest software update and configuration installed according to the customers requirements? The engineer checks if the latest software is installed in the controller according to the customers requirements. 2.5 Are all default settings according to the customers demands in range? The engineer checks the in range tolerance, defrost interval and current limit requested by the particular customer. 2.6 Have all relevant modifications been carried out? The engineer checks if all relevant modifications according to manufacturers instruction (such as by a service bulletin) have been carried out. 2.7 Are spindles and protection caps of the manual service valves in good condition? The engineer checks if spindles are undamaged and free of corrosion. All spindles should have protective caps. 2.8 Is the compressor oil level sufficient? The engineer checks if the oil level of the compressor is within the range recommended by the manufacturer. 3

4 2.9 Is the condenser free of dirt? The engineer checks that less than 10% of the condenser area is dirty Are the condenser and refrigerant pipes free of oil traces? The engineer checks for the presence of oil traces on the condenser and the refrigerant pipes. Oil traces could indicate that there is a leakage in the cooling system Is the condenser fan and motor without damage or bad wiring? The engineer checks the condenser fan for damage and loose or bad wiring Is the drain hose free of obstruction or damage? The engineer checks if drops of water are present from the drain hose. In case no drops are present water has to be poured into the drain system to verify proper drainage Is the refrigerant free of moisture? The engineer checks if the indication glass indicates dry (centre is green) Is the system history free of alarms and are previously registered alarms cleared? The engineer checks the active alarms in the data recorder Is the unit free of abnormal noises? The engineer checks for the presence of abnormal noises from the complete reefer unit. Set unit temperature set point at 0 o C 2.16 Are all sensors & pressure transducers working correctly at 0 o C? The engineer checks if temperature sensors and pressure transducers indicate the temperatures and pressures present in the container. Temperatures should be in line with each other Is there sufficient airflow from the reefer unit inside the container? The engineer checks the presence of sufficient airflow and that the baffle plate is in correct position inside the container Are the container drains clear and can they be closed? The engineer checks proper functioning of the container drains Are the partial cool functions at 0 o C working correctly? 4

5 The engineer checks that the partial cool functions and capacity control (modulation, unloading, hot gas and/or bypass) are working correctly and temperature settings are maintained Is a megger test executed on compressor, condenser fan motor, evaporator fan (high & low speed), heater rods and is resistance minimum 0.5 MOhm? The engineer checks the resistance of the above mentioned components against earth. Initiate an automatic PTI test. 3. RESULT OF AUTOMATIC PTI 3.1 Does the container pass the requested PTI test? The engineer checks if the reefer container passes the PTI test according to customer requirements. 3.2 Are drip pan and refrigerant pipes free of oil traces after running the PTI? The engineer checks if drip pan is clean and if no oil traces are present on refrigerant pipes. 3.3 Is the system free of any active or inactive alarms? The engineer checks if alarms have become active in the controller of the reefer container. Set unit temperature set point at -20 o C 3.4 Are all sensors & pressure transducers working correctly at -20 o C? The engineer checks if temperatures and pressure transducers indicate the temperatures and pressure present in the container. Temperature sensor indications should be in line with each other. 3.5 Is the level of the refrigerant sufficient at -20 o C (full capacity)? The engineer checks the level of refrigerant when temperature is in range, compressor is running and condenser fan is switched off. 5

6 Attachment No.1 Carrier Transicold Pre-trip diagnosis provides automatic testing of the unit components using internal measurements and comparison logic. The program will provide a PASS or FAIL display to indicate test results. The testing begins with access to a Pre-Trip selection menu. The user may have the option of selecting one of two automatic tests. These tests will automatically perform a series of individual Pre-trip tests. The user may also scroll down to select any of the individual tests. When the short sequence is configured, it will appear as AUTO in the display. AUTO1 (Short PTI) will also indicate the short sequence and run tests P0 through P6. AUTO2 will indicate the long sequence and run tests P0 through P10, while AUTO3 is a mid-sequence (Perishable PTI) and run tests P0 through P8. Full description of each "P" test can be found in appendix 1. Thermo King Brief PTI pre-trip test (short PTI) automatically checks unit refrigeration capacity, heating capacity, temperature control, and individual components including the controller display, contactors, fans, protection devices and sensors. The test includes measurement of component power consumption and compares test results to expected values. Function Test automatically tests individual components including the controller display, sensors, condenser fan, evaporator fan, compressors, etc. The test includes measurement of component power consumption and compares test results to expected values. Full PTI (Long PTI) is a special Full PTI pre-trip test that automatically checks unit refrigeration capacity, heating capacity, temperature control, and individual components including the controller display, contactors, fans, protection devices and sensors. The test includes measurement of component power consumption and compares test results to expected values. StarCool StarCool has a Function test, PTI (Pre-Trip Inspection/ Long PTI) test and a PTI short (optional/ perishable PTI ). Function test (short PTI) is a unit component test. The test is based on a GO/NO GO procedure. All tests must be executed without failure one by one for the function test result to PASS. Function test includes the following items: 1. PTI init 2. Controller test 3. Power check 4. Evaporator fan (Mevap) 5. Condenser fan (Mcond) 6. Heating element (Hevap) 6

7 7. Probe check. 8. Compressor/FC/valve test (Vexpansion, Vhotgas and Veconomizer) PTI (Pre-Trip Inspection/ Long PTI) test. The purpose of the PTI test is to verify the presence of cooling performance. The test is based on a GO/NO GO procedure. All tests must be executed without failure one by one for the PTI result to PASS. 1. Function test (see Function test) 2. 5 C (41 F) test 3. 0 C (32 F) test C (-0.4 F) test 5. Defrosting 6. Test completion / status PTI short (optional/ perishable PTI ) Short PTI includes the following test items: 1. Function test 2. 5 C (41 F) test 3. 0 C (32 F) test 4. Defrosting 5. Test completion / status Daikin For S-PTI (Short PTI) the components are inspected for abnormalities. Even if any abnormal components are found, all processes are executed. F-PTI (long PTI) is an S-PTI + a test of the unit cooling capacity. The cooling capacity check is executed only if any abnormal components are not found with S-PTI. If any abnormality is found during the cooling capacity inspection, F-PTI is terminated. Test results of PTI inspections are archived in the data recorder. Downloads can be taken from the container to track history results, including temperature results during voyages. The shipping line has to inform their service suppliers which of the above tests should be implemented in the PTI procedure. 7