Super Freezer Refurbishment
17 July 2013
Super Freezer Refurbishment Guide (Draft) 1.0.1 1.0.2 1.0.3 1.0.4 1.0.5 1.0.6 1.0.7 1.0.8 1.0.9 1.0.10 1.0.11 1.0.12
General and process chart Basic requirements on spare parts storage Visual inspection Gas sample flame testing (R134a) R134a system cleanup procedure Function and operational Check: Buffer tank modification Unit cannibalization Estimation and repairs Unit reinstallation Full PTI Quality managements by shop
1.0.1 GENERAL The purpose of this manual is to standardise the SuperFreezer Containers’ Refurbishment and reporting thereof. Process chart
Working in MCIQ
Working in depot/shop
Gate in
R40 great than 0.05% R134a less than 99% Visual inspection Failed
Lab GCMS test
R40
R40 less than 0.05% R134a Great than 99%
Without R40
R134a Flame test Vacuum & cleaning
Pass
Function check
Pass
Second flame test Buffer tank mod modification Y/N
Disposal
New box production
Above repair limit
Estimation Below repair limit
Repair Parts cannibalization from disposed unit for further units’ repairs Truck unit to MCIQ
Unit installation onto new box
Cannibalize unit from box
Full PTI
Quantity controlling by MCI
Truck new container to depot/shop
RCD installation Y/N
Releasing
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1.0.2 Basic requirements on spare parts storage The shop will at least have following parts in storage before the refurbishment programme starts along with a good inventory level during the refurbishment process. Item
1 2 3 4 5 6 7
Part No:
Part description
66-8811 102-796 506-431 41-4523 506-421 504-1529 66-9877
Moisture Indicator , CRR-40 Compressor, R-23 Super Freezer TXV, R-23 Super Freezer HP-Switch , 470 PSIG , R-23 Filter Drier, R-23 Sensor for Deep freezer ONLY Orifice for R-23 TXV 506-431 Adapter Unitor R23 bottle - 1/4 3/8 flare (Refer to following pictures)
8 9 10 11 12 13 14 15 16 17 18 19 20 21
104-759 1710812-01 66-3015 506-161 66-9873 1201125-02 66-1916 66-3942 33-2805 78-1167
R-23/KG 9,1KG Bottle Buffer mod pipes (3/8, 9.52mm, 1.2mm copper) (Refer to following pictures) 4x6mm2 Cable Condensor motors
Quantity
10 10 10 10 20 20 10
Remark
SF SF SF SF SF SF SF
kit kit kit kit kit kit kit
5 2 bottles
Prepared by shop From Sinochemlt
50 3000 ft 10
Prepared by shop From HF SF using
CAP,SV VLV (PLAST) VALVE CAP ON R23(BRASS) CAP-DISCHARGE VALVE, R134A ADAPTER-SERV-PRESS-HIGH
30 10 20 20
R23 GAUGE VALVE-SUCTION-R23 VALVE-DISCHARGE-R23 GASKET-R23 COMPRESSOR CONDENSER FAN
20 10 10 10 10
PLASTIC BRASS
From Carrier
Remarks Adapter Unitor R23 bottle - 1/4 3/8 flare, it is used on R23 cylinder for the connection type change to link with gauges.
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Buffer mod pipes - 3/8, 9,52mm(O.D), 1.2MM (W.T) copper pipe
Orifice for R23 TXV, P/N 66-9877, we shall select the new type from ThermoKing with flat head (in the green bottle) into this refurbishment project.
Old type
New type
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The Circuit breaker to be changed to 7.5 A Fuse during the refurbishment then the shop shall have following parts in storage at least in following level before the project. More details of that Fuse modification you can refer to Example A) below. Part description TERMINAL STOP CLIPFIX 35.. FUSE, TERMINAL BLOCK...... FUSE 7.5AMP 32VDC.........
Part No: 41-3687 41-5105 44-9359
Remark
Quantity 100 50 50
Old Circuit breaker
New parts
Parts listed in above are mostly used on R23 system side but these standard parts on R134a side and consumable parts shall be purchased in a proper sourcing channel and kept in a good inventory level during the refurbishment program, like following ones, Part description TXV-R134A MOTOR-EVAPORATOR CONDENSER COIL EVAPORATOR COIL VALVE-DISCHARGE-R134A VALVE-SUCTION-R134A EVAPORATOR FAN BEARING BEARING VALVE-BALL COIL VALVE LIQ SWITCH-HPCO VALVE SERVICE Section (R134a)
Part No: 66-9900 104-691 67-1589 67-1591 66-9377 66-9149 508-165 W6203MSL W6205MSL 66-9125 41-2399 41-3250 66-9149
Remark
From SKF From SKF
Quantity 5 10 5 5 5 5 5 5 5 5 5 5 5
1.0.3 Visual inspection Please use Appendix I of “Super Freezer refurbishment function inspection form” (Part A) on to record following checking/inspection actions
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Before performing RUN TEST the heading of the report must be filled in. Container ID Number. Prefix always to be included Unit Serial Number. Read the serial number plate on the reefer unit in order to identify type of unit and then follow the manual, which cover the particular type of unit. UNIT manufactured year. Read the month and year of unit manufactured from unit serial plate. RUN TEST Date. Actual date when this RUN Test performed. Ambient temperature. In degree Celsius (C) Visual checck Perform visual check on the machinery to ensure all parts are there Check unit for leakage and cleanliness. Inspect the unit for refrigerant leaks (trace of oil, low refrigerant level, and lowpressure indication on R23 gauges and if any leak point at R-23 receiver inletoutlet). Inspect condenser coil for excessive dirt, clean if necessary. Inspect the control box including the controller door (that it fits), key pad, main relay board, display, relays and controller. Open Evap motor access door to see if any gasket missed or damaged. Check these three motors are there. Cleaning only to be done with fresh water at a maximum pressure of 30 Psig or pressurised air at maximum of 60 Psig. Check fasteners. Check that unit mounting bolts compressor suspension bolts and all brackets are in place and tightened properly. Check power cable and plug. 1. Visual check power cable and power plug for physical and electrical damages. 2. The section of the cable shall be 4G6.0mm2 from HF (Folsgaard) and length of cable shall be at least 18 meters and 0 splice. 3. A new one shall be placed with total length of 20 meters connected all way to CB1 (32 Ampere) in the control box if the unit has one of following, - Wrong cable used which is not 4G6.0mm2 from HF - Less than 5 m (16 ft) of the cable is left. - One or more than 1 splice kits were placed on the cable. 4. The plug shall the brand of “Mennekes” with type of “2175A” or “2175B”. Replaced with the one from MCI via consumable list where required, P/N 818559A. 5. Power plug must be without any electrical or corrosion damages to the phase legs and with gasket/safety pin and locking ring intact. 1.0.4 Gas sample flame testing of R134a Carry out the sample test of R134a system, please refer to Appendix II of “Guide to Taking a Refrigerant Sample”.
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1.0.5 R134a system cleanup procedure Those units which have failed the flame test but have passed the lab test for R40 or with limited R40 (has less than 0.05% R40 in system), it is agreed repairs should carry on in order to get the units back in to service as following steps. NOTE: Gauges and hoses used for recharging system MUST be confirmed clean via Halide flame testing a known clean sample of R134a before using. If the units that contain at least 90% 134a gas and are contaminated with 5% or less 142b 1. Open the container doors, run unit for 30 minutes, and then full cooling mode (close doors) for at least one hour (-30’C). Monitor compressor temperatures and shut down if temps exceed normal operating temps. 2. Attach gauge set to low and high side connections and recover all refrigerant in a labeled (chlorine various) recovery cylinder. After 3rd shutoff on recovery unit vacuum switch, close connections and remove recovery machine and cylinder (gas to be disposed in complying with all applicable regulations, laws, ordinances and best industry practices in local). 3. Disconnect contaminated gauge set (labeled) and fit clean R134a gauge set (labeled). 4. Clean R134a system by adding Pressurized dry Nitrogen (N2) used manifold service gauges from service ports of both section pipe and discharge pipe, then evacuate N2 from drier inlet and outlet tube. 5. Install new filter drier. 6. Evacuate system using high and low side connectors and leave active for a minimum 4 hours @ 30 inHg of vacuum. 7. Using virgin R134a refrigerant, certified and tested, scale in the charge as indicated on unit ID plate. 8. Run the unit for minimum 2 hours in full cool (-25C). 9. Turn off unit and allow stand idle for one hour. 10. Perform flame halide test and advise results. After that, the STS code of 8936 (with max 6.5 man hours and gas cost as material cost) would be used into the work order via MERC+. If the units that contain less than 90% 134a gas and/or more than 5% 142b 1. Open the container doors, run unit for 30 minutes, and then full cooling mode (close doors) for at least one hour (-30’C). Monitor compressor temperatures and shut down if temps exceed normal operating temps. 2. Attach gauge set to low and high side connections and using refrigerant recovery machine, recover all gas into a labeled (chlorine various) recovery cylinder. After a minimum of three (3) shutoffs on recovery cycling switch, close connections and remove recovery machine and cylinder. Note: reclaimed gas to be disposed in complying with all applicable regulations, laws, ordinances and best industry practices in local. 3. Remove compressor drain plug and drain oil from sump, flush sump to remove as much residue as feasible.
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4. Refresh system with POE per machine specification (Polyol Ester Based type, TK P/N 203-433). 5. Disconnect contaminated gauge set (labeled chlorinated) and fit clean R134a gauge set (labeled virgin 134a). 6. Clean R134a system by adding Pressurized dry Nitrogen (N2) used manifold service gauges from service ports of both section pipe and discharge pipe, then evacuate N2 from drier inlet and outlet tube. 7. Install new filter drier. 8. Evacuate system using high and low side connectors and two vacuum pumps and leave active until gauge reads 30 inHg of vacuum, minimum operation should be 4 hours. 9. Using virgin R134a refrigerant, certified and tested, scale in the correct system charge as indicated on the ID plate. 10. Run the unit for a minimum of 2 hours in full cool (-25C). 11. Turn off unit and allow standing idle for one hour. 12. Perform flame test and advise customer of results. After that, the STS code of 8936 (with max 6.5 man hours and gas cost as material cost) and other STS codes, such as 8933 for Compressor oil adding, would be used in the work order via MERC+. 1.0.6 Function and operational Check: Please use Appendix I of “Super Freezer refurbishment function inspection form” (Part B) to guide and record following checking/inspections to ensure fol -
There shall not be any loosing or crack or deformation on the fastener components or structures. The painter and primer on the structures, such as copper pipes shall be in one piece without any damage or loss or missing in accordance with industry standard. Refrigeration system shall be in functional condition The wires and circuits shall be in functional condition and without corrosion or loss or missing.
Turn unit on, Set/select temperature to a set point that puts the unit in full cool/pull down mode. Allow unit to start up and run for 15 minutes. Checklist: 1. 2. 3. 4. 5. 6.
Ensure proper rotation of condenser and evaporator fans Ensure R23 compressor suction and discharge pressures are correct Unit is cooling - sensor showing temperature trend towards set point Ensure controller is updated with correct Container number, configuration. No abnormal noise Perform a manual defrost - should unit temperature not be low enough for defrost to start manually force the heater relay and check the current draw. 7. Check alarm list (and alarms in message) to ensure all alarms to be recorded and clear
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8. Carry out a full datalog downloading from the unit and save them in a folder with the current container ID. Further inspections, 9. Inspection of the evap and cond motor, to ensure they are free and they are not noisy or have adverse bearing wear. (Replace the bearing or motor where required). 10. Ensure all wire harnesses are free from damage and secure. Reworks would need to be carried out on those units with improper repairs. 11. Inspection of the front Evap service hatch, to ensure that it is serviceable, shuts firmly and that the seals are in place and serviceable. Replace where required. 12. Make sure d/frost drainage tubes are clear and cleaned. 13. Ensure “cork” tape insulation is in place and secure. (Please refer to example T) 14. Check that the Evap coil heaters are fitted correctly to the Evap coil, and the wiring is correctly secured. 15. All control sensors are correctly mounted. 16. Ensure the air baffle plate is in place and free from damage. 17. Check the all Switchs, Liq Coil, drier if they are free from damage or corrosion 18. All valve caps, are in place, replace where required. Install boot in switch ON/OFF and CB. Install cap retrieve connector if it’s missed. 19. Check R23 gauges are in place and free from damage. 20. Inspect the condition of the R134a compressor terminal box and valve plate. Replace with the new plastic box and stainless steel cover (old type terminal box) where required. Check R134A valve plate and replaced with cylinder head bolt, if the bolt is heavy rusty. 21. Check regulators are adjusted correctly. They have been unadjusted in the majority of the cases and should been check again according procedure. At least crankcase pressure regulator to keep R-23 compressor with constant pressure. Operate in Cool for 10 minutes and calibrated gauge, the pressure in low side of R23 compressor should read from 40 psi to 45 psi. 22. If the R134a compressor was heavy rusty, a repainting with primer and coating will be needed. The function testing together with visual inspection would be estimated into MERC+ by STS0950 under MODE44 (FUNCTION TEST FOR SF REFURB) with 0.6 man hours and a material cost under MODE43. Examples, A) Circuit breaker to be changed to 7.5 A Fuse
Old Circuit breaker
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41-3276 to be changed to 41-3687, 41-5105, 44-9359
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B) CB Before
After Breaker modification
C) ELEC CIRCUIT Before
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After
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D) Sensor Wire Reconnection Before
If the wrong sensor wire splicing found, we shall resplice it again by bushing with hot melt adhesive inside as follows.
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After
But if we shall replace a new supply sensor, the wire shall be connected from the connect point insider controller box.
E) HEATER CONTACT Before
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After
F) MRB
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If the MRB connect port has Copper oxide, please use following cleaner to clean it. But please replace the connect port if corrosion.
G) R134A HP Switch Before
If there is any rotating or shake on the bolt, the replacement is need.
After
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H) Relay Before
After
I) Condensor motor and Coil Before
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1140 RPM, Wrong motor
After
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1750 RPM, P/N: 104-759 Correct motor
J) EVAP ACCESS DOOR (Heater access plate) Before
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Proper sealing and air tightness are very important for heater access panel, evaporator access panels. Ensure door lock and sealing of controller door panel are good. Repair if necessary.
After
K) EVAP FAN MOTOR
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crack on evaporator fan mounting
L) LIQ COIL
LSV (Liquid line Solenoid Valve) is frequent failure part. Ensure to check/replace new one if necessary. Before
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After
M) R23 COMPRESSOR Before
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After
N) R134a Compressor terminal box Before
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After
O) R134A Compressor Gasket
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P) R134a DRIER Before
There are two different types of R134a compressor gaskets, shops shall purchase both of them from TK on this project.
After
Q) Evaporator Coil Section
Ensure no screws/metal parts left on evaporator coil. Surprisingly in some cases, one screw which was left behind had been knocking evaporator coil due to vibration, caused serious leak. Always check/ensure all screws /bolts/nuts are tightened, nothing left on evaporator section.
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R) R23 Gauge
Found bolt drop down to evapopator coil between the unit frame, will cause the evaporator coil broken.
Before
If there are any cracks, pulverization or leakage, the R23 gauge shall be replaced.
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High pressure in R23 discharge pressure gauge most of the time. Thus, it is easy to get leaks at small capillary tube. Ensure to check/repair/ replace new gauge and capillary tubes to prevent leak.
After
The pipes shall be protected and fasted by both Heat Shrink and protect Tubes to avoid shake damage. Page 27 of 42
Both discharge and suction gauge on R23 system shall use P/N 12-01125-02 for 500 psig from Carrier.
S) R23 HP/LP SVC VALVE Before
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After
T) R134a LP Service valve
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Before
after
U) Service cap Before
After
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V) Tube Before
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After
These “cork” tape insulation shall be supplied by shops.
W) Power Cable and plugs Before
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After
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4G6mm2
The cable shall be 4G6.0mm2 from HF (Folsgaard), P/N.
The plugs shall be supplied by MCI via consumable parts lis, P/N 818559A. X) USDA sensors Before
After These USDA sensors shall be supplied by MCI via consumable parts list, P/N 818556B (USDA Temperature Sensor, Ø6,0 PT100)
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Y) Evaporator fan motor bearings
Special grease type such as “lithium-soap greases” has been used successfully at the temperatures of minus 60ºF (-51 deg C). However, the grease type used in evaporator fan motor may not be good enough for minus 60 deg C range. We experience frequent evaporator fan motor bearing failure, probably due to grease type which could not work well in very low temperature range for long run. Ensure to check/replace new evaporator fan motor/ball bearings
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Z) Grounded heaters , poor connection at heater cables
Poor insulation/grounded heaters are caused by improper wire connections. Check, replace new heaters (if necessary) and insulate connection wires properly.
1.0.7 Buffer tank modification 1. 2. 3. 4. 5. 6.
Removal and weighing back in of the R134a gas to ensure the correct charge. (This action shall be carried out in above mentioned function inspection and repair process) Removal and weighing back in of the R23 gas to ensure the correct charge. When R23 systems are empty, to perform a leak test with N2. (Nitrogen is under 15,170 kPa, 151.70 bar, 2200 psig pressure in a full cylinder at 21 C (70 F). Replace R23 Filter driers. (The R23 unit is a sweat in type, P/N 506-421). That R23 compound gauges are in place and are working. Inspection of all pipework and paying attention to the known weak areas.
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Another weak point which could suffer further fracturing in the future, please take inspection on that as well.
7.
If the buffer tank modification was not carried out on the unit before, a rework of loop into buffer tank shall be conducted to increase the diameter and number of loops as follows. - As part of the rework, change the angle of the pipe from the valve leading into the loop to the buffer tank. - Suggested angle is approx 30 degrees instead of 40-45 degrees to alleviate stress, using 3/8, 9,52mm copper pipe. - Have the new pipe brazed in to as a posed to on to the buffer tank. - Straighter pipe entering the buffer tank as opposed to the current angle - The dry nitrogen (N2) be used to purge the system during any solder operations and also for the leakage checking after welding. - Remark in the machinery side with words of “Buffer tank mod done” with the date and location information.
8.
A STS code 8219 can be used into MERC+ with 8 man hours and a material cost of RMB3000. That material cost will include, a full charge of R23 gas (worse case) leak testing, N2, R23 f/drier (P/N 506-421) in fact everything to carry out the repair.
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- There is NOT be any further R23 gas cost or R23 f/drier accepted by other STS codes in the same one unit if it requests the buffer tank modification. - R23 F/drier (P/N 506-421)’s price (list price USD94.18, about RMB600) shall be cut off from total material cost with the filter direr part number inputs. - Each unit has 3.2 kg R23 inside and if the system need full R-23 adding once leakage, then the material cost shall be 3000 - 600 = 2400 RMB - If the system has full R23 without any leakage and you just recharge the gas after recovery, then the material cost shall be input at 3000-600-1500 = 900 RMB to cover other material cost like system recovery/re-charge actions, N2 using, etc.
Finishing
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1.0.8 Unit cannibalization Remove the unit from the old box with proper equipments and a forklift. Suggest referring to the manufacturer’s instructions for this risk assessment. Unit cannibalization can also be carried out before buffer tank modification checking. That will depend on the repair cost in above compared with repair limit set in MERC+.
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1.0.9
Estimation and repairs Submit estimation into MERC+ with current (old) container ID under MODE43 for Maersk /MCI’s evaluation and then arrange repairs after approval. The repair action would be conducted together with buffer tank mod modification. MCI will conduct the evaluation on these to be disposed units to see if any old parts would be removed from them for further repair using. Shop would use them with a material cost at 1/5 of list price rather than the part number in MREC+ to cover their additional action of parts removal and testing. All these R134a used onto the unit shall be tested by flame halide tester of each new cylinder. Each Gas usage records shall and filled into Gas Logbook. Please refer to Appendix III of “R134a flame test guide” for more details on the cylinder gas flame test. Shop shall at least have 3 separate Freon recovery machine & cylinders for the gas recovery and collection. All clean (good) R134a from the unit, which passed unit samples flame test, would be re-used during repair works by one set of recovery machine & cylinder. The second set is used for contaminated R134a. The last one set shall be working for R23 recovery and re-using. Do not mix gases pulled from different system or cleaning/contaminated units. Mounting Bolts Unit mounting bolts should be tightened to a torque value of 204 N.m (150 ft-lb). Compressor and fan motor mounting bolts should be tightened to a torque value of 20 to 21 N.m (15 to 20 ft-lb). Cleaning of machinery After repairs, a cleaning of the machinery side should be carried out and remove all old labels/stickers, oil smear and impurity. Cleaning only to be done with fresh water at a maximum pressure of 30 Psig or pressurised air at maximum of 60 Psig. Insulation TK recommend the insulation value of compressor and fan motors and heaters to ground is minimum 1M Ω or more when measure with Mega Ohm meter with 500V output
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Before
After
1.0.10 Unit reinstallation This action shall be done in MCIQ 1.0.11 Full PTI
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Check the unit and box ID to ensure they are in the same. Change the container number in controller to align with box. The correct software (120608) is in installed along with the correct Date, Time and Container ID. Install RCD onto the unit if it was not fitted before. Remove the back up battery together with wiring inside control box and mounting brackets during RCD installation. Please refer to Appendix IV of “Maersk RCD Installation Guide Hand-out for more details. The normal full PTI process would be followed. Please refer to Appendix V of “SuperFreezer PTI form”. The estimation shall be submitted with new container ID into MERC+ for PTI and RCD installation. STS8940 (FULL PTI FOR SF REFURB ) under MODE44 can be used for that. Each work order shall be recorded with old container number in the remark filed for further checking. 1.0.12 Quality managements by shop Shop should have its own Quality controlling and management team to record and check each step carried out in the refurbishment. Then the QA documents from the depot/shop on their work shall be signed off by the person in charge finally.
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