Packaging Solutions Project title - gov.uk · OFFICIAL Page3of29 Operating and Maintenance Specification for Type P-i Package Design No. TC1 1, Transport Handling Frame History sheet

LLW Repository Ltd OFFICIAL

Page 1 of 29

Operating and Maintenance Specificationfor Type IP-1 Package Design No TCI I,Transport Handling Frame

Project title: Packaging Solutions — TCJ I

Project number: 34109227

Bldg name/number: B786

Document ref: OM-3409227-M ECH-0000I -B

Purpose ofissue: For Operational Use

Date ofissue: 14 December 2015

Author: B Mellor

Department: Engineering

Group: LLW Repository Ltd

Checked by: M Elliott

Level ofchecking: Level 3

Checker’s signature:

Date: A a2...Approvedby: R E Millington

Approver’s position: Packaging Design Authority, LLWR Ltd

Approver’s Q Date: 4t2I’signature:

“Copyright NDA 2015, this document contains proprietary information, permission to copy, or use suchinformation, should be sought from the Intellectual Property Manager, LLW Repository Ltd.”

OFFICIAL

c Nudear Decnrisicnq Auth1y

OFFICIAL Page 2 of 29

Operating and Maintenance Specification for Type P-i Package Design No. TC1 1 Transport Handling Frame

C I rcu lation list Purpose of issue: I For comment

2 For action3 For information

Name Location No of Remarks Purposecopies of issue

R Millington LLWR I 3M P Flynn LLWR I 3K Quilter LLWR 1 3IcePac Document Controller LLWR I Original for Archiving 3

OFFICIAL

c Nucar Deornrrsscfling Aiitho1y

OFFICIAL Page3of29

Operating and Maintenance Specification for Type P-i Package Design No. TC1 1 , Transport Handling Frame

History sheet

Rev Date Reason for revision Revised by

A 09 Mar2015 First Issue B Mellor

B 14 Dec 2015 IcePac Document Controller added to B MellorCirculation List.Section 4, point 2 amended to includereference to use of an OQP sectionSections 5.2, 8.4 & Reference 13, -

OM/3409227/MECH/00006/A amended toOM-3409227-MECH-00006Table I formatting corrected.Section 6.4, Table 2 and Section 7.1amended to include HP monitoring of theTH F/fittings.Section 14 — Design Authority replaced withContract Authority.Section 14.3 — new sentence addedregarding disposal of damaged web lashingcomponents.Figure 2 (photograph) replaced withI Ilustration.App. A — (0.75m3) added to Table title

0F FICIAL OM-3409227-M ECH-00001 -B

OFFICIAL Page4of29

Operating and Maintenance Specification for Type P-I Package Design No. TC1 1 , Transport Handling Frame

Contents Page

I Introduction 6

2 Scope 6

3 Compflance 6

4 Responsibilities 6

5 Package Descripfion 7

6 Package Handling Operations 7

7 Pre-loading Checks 10

8 Loading and Unloading of the Transport Handling Frame II

9 Pre-dispatch Checks 13

10 Storage 13

11 PlannedMaintenance 14

12 SQEPRequirements 16

13 Record Requirements 16

I 4 Acceptance Criteria 17

15 References 20

Figure 1 - General View of Transport handling frame 21

Figure 2 — General View of Soft Sided Package 22

Figure 3 — SSP lifted with attachment 23

Figure 4 — SSP lifted with forks 23

Figure 5 — Trailer Support 24

Figure 6 — Lifting Using Fork Lift Truck 25

Figure 7 — Lifting Using Bottom Fittings 26

Figure 8 — Lifting Using Top Fittings 27

Figure 9 — Twist lock System on Trailer 28

Appendix A: Transport Handling Frame and soft sided package data 29



Operating and Maintenance Specification for Type IP-1 Package Design No. TC1 1 , Transport Handling Frame

Deli n itionslGlossaryALARP

ACEP

ADR

Approving Authority

CFA

Consignor

Contract Authority

CSC

Design Authority

El

EIM&T

IAEA

lP-1

ISO

LLW

LLWR

Manufacturer

MQP

0I

OQP

QA

SQEP

SSP

THE

WAC

WLL

As Low As Reasonably Practicable.

HSE Approved Continuous Examination Programme.

European Agreement concerning the carriage of DangerousGoods by Road.

LLWR Container Approval Authority is responsible for the issueof Certificates of Approval for IAEA self-assessment containertypes on behalf of LLWR.

Conditions Eor Acceptance.

Consignor according to the provisions of ADR.

LLW Repository Ltd.

(International) Convention for Safe Containers.

Package Design Authority, LLW Repository Ltd., Holmrook,Cumbria.

Emergency Instructions.

Examination, Inspection, Maintenance & Testing

International Atomic Energy Agency.

Industrial Package Type 1.

International Standards Organisation.

Low Level Waste.

Low Level Waste Repository.

The organisation responsible for producing hardware inaccordance with the requirements of the Contract Authority.

Maintenance Quality Plan.

Operating Instructions.

Operational Quality Plan.

Quality Assurance.

Suitably Qualified and Experienced Person.

Soft Sided (Inner Containment) Package.

Transport Handling Erame.

Waste Acceptance Criteria.

Working Load Limit.

OFFICIAL OM-3409227-MECH-00001 -B


Operating and Maintenance Specification for Type P-i Package Design No. TC1 , Transport Handling Frame

I IntroductionThis document provides the Package Design Authorities guidance regarding the Operating andMaintenance requirements for the transport handling frame which forms part of the Type IP-1TCI 1 packaging system. The transport handling frame is designed to carry soft sided innercontainment packages containing low level radioactive waste material in solid form. The softsided packages form the inner containment system of the TCI I package.

2 ScopeThis document identifies the design intent for the operation and maintenance of the transporthandling frame and is to be used as an aid to producing detailed Operating and MaintenanceInstructions. It provides an outline of the O&M tasks to be carried out at specified intervalstogether with the acceptance requirements that must be satisfied to ensure compliance with therequirements of reference [3]. Adherence to the Operating and Maintenance requirements willensure that the equipment remains in a serviceable and safe condition to meet the designparameters and maintain regulatory compliance within the safety justification.

The O&M guidance addresses the following issues:

a) Handling operations including turn-round inspection to be carried out as required onloading and unloading, consisting of minor tasks only, which can be carried out by theoperational staff under the Operational Quality Plan (OQP).

b) Planned maintenance and periodicity as performed by maintenance staff in accordancewith a Maintenance Quality Plan (MQP).

c) Acceptance criteria requirements (norms and tests).

3 ComplianceThe Consignor is responsible for ensuring that the regulatory requirements governing the useof the transport package are complied with, such as current editions of:

. Health and safety at work act.

. Personnel protective equipment at work regulations.

. Provision and use of work equipment regulations (PUWER).

. Manual Handling Regulations.

. lonising radiation regulations.

. Control of substance hazardous to health (COSHH).

. Machinery (Safety) Regulations.

. IAEA Regulations for the Safe Transport of Radioactive Material.

. Lifting operations and lifting equipment regulations (LOLER).

. International convention for safe containers (CSC).

. The Package Certificate of Approval.

4 ResponsibilitiesIt is the responsibility of the Consignors to ensure that:. All local and regulatory requirements governing radioactive materials and transport

packages are complied with;. Package operating and inspection activities are carried out in compliance with a quality

management system that meets the requirements of ES EN ISO 9001 Reference [4],which shall include the use of an Operational Quality Plan (OQP);

. Reference is made to the Certificate of Approval for the package identifying informationon approved contents and other shipment and operating requirements;

0F FICIAL OM-3409227-MECH-00001 -B

OFFICIAL Page7of29

Operating and Maintenance Specification for Type IP-1 Package Design No. TCI I , Transport Handling Frame

. The material to be consigned satisfies the regulatory requirements for transport within anIP-1 package and complies with the waste acceptance criteria (WAC) for the receivingfacility; and

. Personnel associated with packing, loading, unloading and carrying out inspections of thepackage are instructed to carry out the required operations as quickly as safelypracticable in order to ensure personal radiation dose is ALARP.

5 Package Description5.1 GeneralThe transport handling frame is uniquely identified by the LLW Repository Ltd IP-1 packagedesign number TCI I . The transport handling frame (which is shown in Figure 1 ) is essentiallya half height, open top, series I ISO freight container which is primarily designed to transportsolid waste items contained within soft sided packages which form the inner containmentsystem.

The transport handling frame measures 6.058m x 2.438m x I .325m high and consists of acarbon steel external frame incorporating three stainless steel lined inner compartments.Installed in each of the three inner compartments is a removable, stainless steel, cruciformdivider which is used to sub-divide each compartment into four smaller eq ui-sizedcompartments to accommodate the I m3 soft sided inner containment packages as shown inFigure 2.

A cargo net cover fitted with ratchet tensioners spans across each of the three large innercompartments to retain the soft sided inner containment packages within the transport handlingframe. Each cargo net is permanently attached on one side of the transport handling frameand is detachable on the opposite side to facilitate loading.

5.2 PayloadThe maximum rated payload for the transport handling frame is I 5000 kg, i.e. a 5000 kgpayload per large compartment. However with the 3 cruciform dividers (i.e. 3 x 280kg) installedto provide 1 2 smaller load compartments, the payload capacity for each smaller compartmentis limited to I I 80 kg giving a total payload capacity of I 41 60 kg.

The TCI I transport handling frame shall only be used to transport Soft Sided InnerContainment Packages. The operation of the SSP is described in Operating and MaintenanceSpecification OM-3409227-MECH-00006, Reference [131.

NOTE: Only Soft Sided Inner Containment Packages approved by LLWR may be used as theinner containment system for the TCI I package.

6 Package Handling Operations6.1 GeneralThe consignor shall have a documented QA system in place covering the packaging systeminspection, handling, loading and dispatch activities as identified in this document, which shallconsider all operational hazards and limits including but not limited to the following:

. Package inventory;

. All lifting operations;

. Payload size, weight, geometry, Working Load Limit (WLL), etc.; and

. Radiation and contamination levels.


OFFICIALPage 8 o129

Operating and Maintenance Specification for Type P-i Package Design No. TC1 I , Transport Handling Frame

Table I shows the main activities required to be addressed for safe handling of the Packageduring turn-round.

Package Handling Activity Reference Docs.(OQP’s, 01’s, El’s CFA etc.)

I . Package Receipt OQP, 01 & CFA2. Package Preparation Unloading OQP, 01Including Turn-round Maintenance (see Section 8)3. Package Preparation Loading OQP, 01Including Turn-round Maintenance (see Section 7)4. Package Preparation For Dispatch (see Section 9) OQP, 01, El & CFA

Table I : Package Handling Activities

6.2 Package Handling Methods

6.2.1 General

WARNING: BEFORE COMMENCING LIFTING OPERATIONS THE OPERATOR MUSTENSURE:

. ALL LIFTING AND HANDLING EQUIPMENT IS RATED TO HANDLE THE LOAD TOBE LIFTED SAFELY;

. ALL LIFTING AND HANDLING EQUIPMENT IS TAGGED AND IN DATE; AND,

. THE TRANSPORT HANDLING FRAME AND ITS LIFTING FEATUES ARESTRUCTURALLY SOUND.

CAUTION: Before commencing lifting operations to lift the transport handling frame offthe conveyance ensure all four twist locks used to secure the package to the transporttrailer are unlocked (See Figure 9).

The transport handling frame is based on a Series I ISO freight container conforming to ISO1496-1 [1] and features standard corner fittings and forklift pockets. The recommendedhandling methods which comply with BS ISO 3874 [5] are detailed below.

The transport handling frame is to be secured to the conveyance using twist locks at thenominal spacing of 5855mm (longitudinal) and 2260mm (lateral) which engage with the fourbottom corner fittings in compliance with BS ISO 3874 [5]. For any other method of restraint,assessment must be carried out by SQEP personnel and submitted to the Contract Authorityfor endorsement.

The vehicle securing devices will be rated to carry the package as designed under routineconditions of transport.

Before any lifting the transport handling frame must be free to be lifted by ensuring the twistlock mechanisms or any other securing systems are removed or disengaged (See Figure 9).

6.2.2 Lifting using a Fork Lift Truck

WARNING: THE PACKAGE MUST ONLY BE LIFTED WITH THE LIFTING FORK TINESALIGNED AND FULLY INSERTED IN THE FORK POCKETS.

Forklift pockets, which are rated for the gross weight of the fully laden package, are an integralfeature of the transport handling frame’s base structure. They are positioned at 2050 mmcentres. The forks must be fully inserted in the fork pocket as shown in Figure 6.




6.2.3 Lifting using Bottom Fittings

CAUTION: The angle between the container base and the sling leg must be 45 degrees orgreater.

CAUTION: The bottom sling attachment shall bear on the corner fitting only and must notexcerpt a lifting force more than 38mm away from the outer face of the corner fitting.

This method of lifting can be used to lift the transport handling frame when laden or unladen.The method, as illustrated in Figure 7 — Lifting Using Bottom Fittings, employs two twin-leg wireor chain slings attached to a beam which spans the full width of the transport handling frame.Each leg of the sling is attached to the side of the appropriate base corner fitting using eithershackles or mono-blocks.

6.2.4 Lifting using Top Fittings

CAUTION: The use of a four-leg sling applied to the top corner fittings is NOT permittedfor lifting a laden package although it can be used to lift the empty transport handlingframe.

With the transport handling frame in the laden condition, this method of lifting requires aspreader frame (See Figure 8) designed to ensure that only a vertical lift is applied to the topcorner twistlock fittings. The attachment to the corner fitting must be as shown in Figure 8.This method of lifting is suitable for use on both loaded and empty containers.

When in the unladen condition, a four-legged sling can be used where each leg of the sling isattached to the side or top of the top corner fitting using either shackles or mono-blocks to lift.However, this must not be used when in the laden condition.

6.3 Maximum Stacking HeightCAUTION: The ground upon which the containers are stacked must be flat and level andcapable of supporting the accumulated gross weight of the containers.

The maximum stacking height for a fully laden transport handling frame is five (5) highincluding the base container. Where the transport handling frames are to be stacked, it isrecommended that ISO intermodal connecting twist locks are used to aid stack stability.

6.4 Turn-round Inspections and Maintenance (OperationalActivities)

On package turn-round (i.e. loading and unloading at consignor and consignee facilities), thefollowing visual inspections shall take place, where applicable. Record of these inspectionsshall be kept and any defects or difficulties shall be reported using the Container DamageAssessment Sheet [16] to the Contract Authority.

1 . Inspect general condition of package and components. This may require intrusivesurveys to monitor contamination, corrosion and damage or defect.

2. Inspect lifting and fastening features. Report and record any defects or difficulties.

3. Inspect other safety related features (cargo nets, webbing straps and ratchettensioners)

4. Ensure required markings, identification labels/plates and warning labels are in placeand free from damage.

5. Inspect the cruciform divider for signs of damage.

6. Check for debris inside package.

7. Confirm Package functionality.

8. Confirm Package licence validity.


OFFICIALPage 10 of 29

Operating and Maintenance Specification for Type IP-1 Package Design No. TC1 I , Transport Handling Frame

Ref. Inspection Requirement Record Requirement Acceptance

____________________________

Criteria Ref

1. General condition Contamination, corrosion, damage, 7.1defectandwear 74

2 Lifting and securing features Corrosion, damage, defect or 7.4difficulties and wear

3. Other safety related features.ie Damage, defect, wear or 7.4Cargo net operational difficulties

4. Markings All regulatory markings/labels are 7.4present and legible.

5 Cruciform divider Security, corrosion. Damage defect 7.5and wear.

6. Check container internally No debris, damage, corrosion, 7.5pooling water or sharp edgespresent.

7 Functionality Malfunctions 7.4

8 Package license validity Confirm validity of Package 7.2Certificate of Approval.

Table 2: Turnaround Inspection Requirements

All appropriate operational and maintenance defects/incidents and abnormalities are to bedocumented and reported to the Contract Authority.

7 Pre-loading Checks7.1 GeneralThe transport handling frame should be in a fit-for-purpose condition before being used andshall satisfy the inspection/checking criteria described below as a minimum.All inspections must be carried out by a Suitably Qualified and Experienced Person (SQEP). Ifany defects, incidents or abnormalities are identified then the container shall be placed on holdand it must be reported to the Contract Authority for resolution. Confirmation that all thefollowing inspections have been carried out must be recorded, signed and dated by the personperforming the operations on an OQP.Health Physics monitoring of the Transport Handling Frame and fixtures/fittings should becarried out and results recorded. If any contamination is identified and cannot be removed thenthe container shall be placed on hold and it must be reported to the Contract Authority forresolution.

7.2 Certificate of ApprovalThe package Certificate of Approval for transport issued by the Approving Authority must bechecked to ensure it is valid and will remain valid throughout the period during which thepackage is to be transported in the public domain.

7.3 CSC (Safety Approval) PlateThe CSC safety approval plate must be checked to verify that the container is in date or confirmthat a valid ACEP decal is displayed adjacent to the CSC plate and the date of the nextexamination due is valid. Re-inspection and re-plating will be required if the period of validitywill expire prior to filling or consignment. The Contract Authority shall be contacted regardingpackage re-inspections.



Operating and Maintenance Specification for Type IP-1 Package Design No. IC1 1 , Transport Handling Frame

7.4 External Visual Inspection of the Package THFWARNING: INSPECTION OF THE UNDERSIDE OF THE TRANSPORT HANDLING FRAMESHOULD BE CARRIED OUT FROM THE SIDE - DO NOT WORK UNDER THE SUSPENDEDCONTAINER.

Visually examine all the external surfaces (including the base) of the container for signs ofdamage.

i) Cracking of welded joints is unacceptable.

ii) Puncturing of the load compartment walls or floor is unacceptable

iii) Cuts or scratches in the walls or structure greater than I .5 mm deep are unacceptable

iv) Small dents in the compartment walls are acceptable (less than 25 mm)

v) A single deformation such as a bend, bow or dent in a corner post greater than 25 mm ortwo or more dents on a single corner post greater than I 5 mm are unacceptable,

vi) The external paint finish must be checked for damage/corrosion. Minor scuffing of thepaint finish is acceptable but there shall be no exposed bare metal that is not stainlesssteel. Any exposed bare metal that is not stainless steel should be reported to theContract Authority. Note: The internal walls and floors of the load compartments and thecruciform dividers (where fitted) are unpainted as the surfaces are stainless steel.

vii) All decals are present and correct including placard and address holders securely fixed.

viii) Cargo net securing bolts and nuts are in place; the nets are securely attached; the netsare free of cuts, frays or damaged/missing/loose stitching and the ratchet tensioners aresecurely attached and function correctly.

NOTE: If in any doubt contact the Contract Authority for advice.

7.5 Internal Visual Inspection Package THFVisually examine the internals for signs of damage and cleanliness. There shall be no visiblemechanical damage.

i) Cracking of welded joints is unacceptable.

ii) Internal sharp edges are unacceptable.

iii) Puncturing of the compartment walls, floor or cruciform panel walls are unacceptable.

iv) Cuts or scratches in the compartment wall and floor panels greater than I .5 mm deep areunacceptable.

v) Small dents are acceptable (less than 25 mm).

vi) There shall be no pooling water present in the load compartments and drain holes shall beunobstructed i.e. free of debris.

vii) Cruciform partitions are installed and securely retained.

8 Loading and Unloading of the Transport HandlingFrame

8.1 Positioning of THFDuring loading/unloading operations the container shall be either:

i) Positioned on a flat & level hard standing/floor such that four corner fittings transferthe load. Note: a proprietary castor wheel can be secured to each base corner twistlock to aid manoeuvrability of the transport handling frame provided that the castorwheels are rated to support the maximum gross weight of the loaded transporthandling frame and movement of the transport handling frame, supported on thewheels, is attempted only on a level hard standing/floor; or,




ii) If the transport handling frame is to be operated whilst residing on its transport trailer,then the tractor unit must be removed and an independent jacking system must beused to support the front of the trailer as shown in Figure 5.

8.2 Cargo net removalBefore the soft sided packages can be loaded into the transport handling frame the cargo netcovers must be rolled back to allow access to the load compartments.

To roll back the cargo nets, release the tensioning straps from stowage and release thewebbing straps from the ratchet tensioning devices. When safe to do so, throw the loose strapends over the top of the transport handling frame to the other side. Then from other side usethe straps to pull the cargo net clear ensuring you stand far enough away to avoid this falling onyou.

8.3 Loading of the SSPCAUTION: The Soft Sided Packages must be loaded in the transport handling framesuch that the payload is distributed evenly across all the three large load compartmentsto ensure a balanced load is achieved.

CAUTION: The dimensions of the fork tines used to lift the Soft Sided Packages mustnot exceed 150mm in width.

The soft sided packages must be prepared for loading in the transport handling frame strictly inaccordance with OM-3409227-MECH-00006, Reference [13].

The maximum gross weight of the SSP is I I 80 kg.

Before loading the SSPs into the transport handling frame ensure all the pre-loading checksspecified at Section 7 have been satisfactorily completed.

The SSPs are lifted using a fork lift truck with the fork tines fully inserted in to the lifting sockslocated on the top of the SSP (Figure 3 & 4). Once the fork tines have been fully inserted intothe lifting socks slowly lift the SSP and position over the nominated load compartment of thetransport handling frame.

Once the SSP is correctly aligned over the nominated load compartment, carefully lower theSSP into the nominated compartment ensuring that it sits correctly within the load compartmentand does not snag the transport handling frame whilst being lowered into the compartment.

Once the SSP is fully lowered and seated correctly within the nominated load compartment,disengage the fork tines from the lifting socks of the SSP.

Repeat the loading operation until all SSPs to be loaded have been loaded ensuring that theload is evenly distributed across the load compartments of the transport handling frame thenre-fit the cargo nets over the load compartments in accordance with Section 8.4.

8.4 Re-fitting cargo netOnce the soft sided packages have been loaded into the transport handling frame, position theCargo Nets on to the edge of the transport handling frame adjacent to their anchor points whilstkeeping hold of the long end of the webbing straps.

Ensuring the area on the opposite side of the transport handling frame is free of personnel,throw the straps over to the opposite side.

Move round to the opposite side of the transport handling frame and use the end of thewebbing straps to pull the Cargo Net fully over the load compartments before feeding thestraps through the ratchet tensioning devices.



Operating and Maintenance Specification for Type IP-1 Package Design No. TCI 1 Transport Handling Frame

Check the cargo nets are correctly positioned before operating the ratchet tensioners to tensionthe cargo nets. Once the cargo nets have been tensioned wrap the excess lengths of straparound the stowage bars and securely tie off, ensuring no part can flap or extend outside thecorner casting faces. Once the cargo net has been tensioned confirm the SSPs (includinglifting socks) are fully restrained beneath the cargo nets.

8.5 Unloading of the SSPTo unload the SSPs from the transport handling frame, remove the cargo net from over theload compartment in accordance with Section 8.2

Raise and lift the top section of the SSP by pulling up the lifting socks so that they protrudeabove the top rail of the transport handling frame.

Using the lifting equipment carefully engage the fork tines in to the SSP lifting socks ensuringthat the lifting tines are fully engaged within the socks. Be aware of potential wedging of SSPsdue to load settlement during transit.

Slowly lift the SSP from the compartment ensuring that no snagging takes place.

Remove the SSP to the designated set down area or disposal point.

Repeat steps for each compartment to be unloaded.

Following the removal of the SSP ensure that inspection of the internals of the transporthandling frame is carried out in accordance with section 7.5 before the cargo net is re-fitted inaccordance with section 8.4.

9 Pre-dispatch Checks9.1 Visual ExaminationImmediately prior to dispatch a visual examination of all exterior surfaces of the package(including the underside and fork pockets) must be carried out in accordance with section 7.4 toverify:

. the package has not sustained any damage whilst awaiting dispatch;

. all decals are legible and securely affixed to the transport handling frame body; and

the cargo net is adequately tensioned and the loose ends of the tensioning straps are securelystowed.

9.2 Monitoring and LabellingPrior to dispatch the Consignor shall monitor the radiation and contamination levels on theoutside of the package in accordance with the applicable requirements and affix all necessarylabels and placards in compliance with the Regulations [2] & [7].

9.3 DocumentationThe Consignor shall complete the necessary consignment documentation as required byReference [2], by the Consignors/Consignees Site Procedures and the receiving facility WAC.

10 Storage10.1 Storage of Empty THFThe transport handling frame should be stored on a hard flat surface that is well drained. Thetransport handling frame shall not be used for storage of payload. If the transport handling


Page 14 0f 29OLeSeciffcatOnfOtTeiP1Packae0 etat’fl

0sigflees site tot onget than one month then Contractframe is to rest at the 0nsigno5 or!suthoritY permissi0fl

required.

shalt be exam” accordance withfrom 5otage the tran5P0 ,and1irg frameUpon retrieVSectiofl 7

It is a regulatorY to ensure compliance with the package Desigfl SafetY RepO thatp’anned maintenance sha be peormed under a Maintenance Qua’itY plan (MQP) Theonsign0r must check the supp’ied docUmentation which wilt c\eatY define the nextmaintenance due dateS The 0sign0r must check that this date has not passed. The eve ofmaintenance and frequencY recommended in this document wi ensure that suitab’emaintenance regimes are imp’emented

ughOut the design ‘ife of the package and aconsistent

approach is taken to package maintenance acrOs5 the LLW RepositorY Ltd site.

Where the usage of a package is ‘low’ then it maY be t0 consider Risk BasedInspection and prepare a ‘Written Scheme of Examinat0n agreed with the competent personsuch that periods greater than 12 months can be specified for any ‘Statutory Examinations’.howeVer, for SO freight containers which are approved and operated under the nternati0nConvention for Safe Containers (CSC) scheme there are reguat0rY

qirement5 for someexaminations to be in accordance with a scheme or programme

approved b the eath andSafetY Executive (S

So freight contars are approved as freight containers under the provision of the CSCperiodic Examination Scheme (PES). Under this scheme al new containers are approved for aperiod of five years from the date of first registration Nter this initia’ fiveYear period thecontainers must be examined and

pproved as being suitab for another period of service,which can be up to a maximum of 30 months. Thereafter the freight container must be reexamined for additi0n periods of service up to 30 months as specified b the SE approvedContainer inspection uthoritY. NtemativelY the containers can be operated under anApproved Continuous Examination

programme (ACEP). Examinations carried out under anACEP are peormed in connection with malor repair, refurbi5hment or onhire10ffrerchange and in no case es5 than once every 30 months. A containers operated under anACEP wi’l have a deca’ fitted to the SafetY Approva’ plate 5owing the letters ACEPand the identification of the 0ntractng paY which has granted approval of the programme.NOTE The examinations carried out under either pES or ACEP are in to theroutine operatinQ inspections and maintenance activities specified herein and must becarried out b a SE approved container inspection auth0r1t*Maintenance activities are presented in the tables below for the main package items as follows:

. Tran5P0 jandling Frame -

Table 3.Table 4.. ifting and Tied0w’ Features

On pcage reCetPt -

. Review Maintenance QualitY plan (MQP)

. Record package identification.(package design and serial number).

. Check receipt dOcume1tatbon

. Carry out P survey ensuring results are within prescrd limits.

LOR package and operational defect repOt5.. Review previous maintenanceO9227ME00001OFFICIAL

jO.2 ,ft0m Storage

11 pianned Maintefl


Operating and Maintenance Specification for Type IP-1 Package Design No. TC1 , Transport Handling Frame

On commencement and during maintenance: -

. Ensure a safe system of work is in place.

. Ensure as package components are removed and when doors/hatches/compartments areopened, HP monitoring activities are carried out.

. Ensure that any spares used are inspected/certified and correctly identified. Recordusage in the LQR.

. Ensure components removed are held in a controlled area.

. Ensure defective components are labelled and are quarantined.

. Record serial numbers and calibration date of test equipment or special tools used.

. Ensure before any functional tests are carried out all necessary clearances/permits towork are in place.

. Proof load testing must be repeated, whenever new untested or repaired load bearingcomponents are fitted. If new inspected and certified components are used the packageshall be tested using the appropriate self-weight.

. Special attention shall be given to lifting features, which may be affected by corrosion.

. Ensure all necessary records are completed.

Maintenance Frequency Required (i)

Ref Maintenance Activity * cycles/months

100 500 Acceptancecycles or cycles CriteriaRef12 5yearsmonths

I . Inspect for wear, damage and corrosion V V’ I 4.1.12. Ensure all components are in place and secured “ 14.1.23. Ensure required Markings, identification “ “ 14.1.3

labels/plates and warning labels are in placeand free from damage.

4. Assess paint internal/external surfaces. Touch V 1’ 14.1.4up or repair as required. 14.1.5

5. Inspectdrainpoints/plugs/seals. “ “ 14.1.46. Inspectthreadsandinsertsforwear V’(l) v’(2) 1. 14.6.1, 14.6.3

2. 14.6.2, 14.6.37. Inspect cargo net, associated anchor points and “ “ 14.3

ratchet tensioners8. Visually check internal components “ “ 14.1.4

9. Remove cruciform divider (if fitted) and inspect “ 14.4for wear, damage and corrosion 14.6.3

Table 3: Package Body



Operating and Maintenance Specification for Type P-i Package Design No. TCI 1 , Transport Handling Frame

Maintenance Frequency Required (V)

Ref MaintenanceActivitycycleslmonths

* Acceptance100 cycles *500 .

Criteria ReforJ2 cyclesmonths 5 years

1 . Inspect lifting features for wear, damage, 14.2deformity and corrosion. Measure and record

2. Confirm testing/certification documentation for ‘ “ Review previousproof load testing of assemblies and LQR’scomponents is available.

3. Visually check that all components are in ‘ 14.1.2place.

4. Check torque settings bolts/screws *. “ 14.85. For welded component use NDT to check for v 45

cracks.6. Replace fixing features i.e. bolts/nuts if 14.6.3

damaged or over tightened.7. Self weight test body lifting features v 4.28. Proof load test body lifting features. “ 14.2

(repaired/new untested components only) 14.59. lnspectthreads for wear and damage “(J) i(2) 1. 14.6.1

2. 14.6.2Table 4: Package Lifting and Tie-down Features

Routine maintenance and annual inspections are the responsibility of the package operator andshall be carried out in accordance with the MQP and annual inspections will be carried outunder an ACEP scheme. The maintenance frequency as marked (*) shall be based onwhichever occurs first i.e. number of cycles or time period.

12 SQEP RequirementsAll personnel involved in operations and maintenance activities must have received training toensure that they meet the required competency level to perform the required tasks (SQEP).Requirements for training personnel are defined in Reference [7] and Repository SiteProcedure RSPII.02, Reference [12].

13 Record RequirementsAppropriate through life quality records shall be kept. Typically but not exclusively the LQR’Sshall include:

. Records of all EIM&T carried out on the packages.

. Copies of signed completed check lists for maintenance and operational activities.

. Operational and maintenance defects and difficulties and incidents.

. Records of all spares used including certification.

. References to original manufacture’s LQR package shall be included if available.

. Record all uses of packages (full & empty) on the LLWR database.

Requirements for keeping records are defined in Repository Site Procedure RSP 5.01,Reference [11].



çprating and Maintenance Specification for Type P-i Package Design No. TC1 I , Transport Handling Frame

14 Acceptance Criteria14.1 General Inspections

14.1.1 GeneralPackages shall be in good condition free from damage, corrosion and wear which will affectsafety and operational requirements.

There shall be no visible damage to the package structure and shall be in good workingcondition.

All mechanical interlocks shall be fully functional and free from wear. There shall be smoothengagement of movable parts.

All security features shall be fit for purpose.

14.1.2 ComponentsAll components are to be in place, securely fitted and free from damage. Refer to packagedesign drawings for details of all fitted components.

All components should be checked to confirm their operations are within the design life cycle.

14.1.3 MarkingsAll required labels I markings to be legible and securely fitted. Refer to Package designdrawing and 01’s.

14.IA InternalsPackage internals are to be free from damage and corrosion. No debris to be present anddrain holes to be free of blockages/obstructions.

14.1.5 Surface FinishesPackage surfaces both internal and external shall be in good condition free from damage andcorrosion. Where surfaces are painted they shall be in good condition. The paint should befully adhered and not flaking. Any damage to the paint finish must be made good. Care mustbe taken to ensure that the transport handling frame decals are not obliterated during any paintrepair.

Where operational records indicate excessive decontamination requirements, assess causeand consider repair options.

Where the proposed repair is not covered by a pre-approved procedure, the repair proposalshall be submitted to the Package Design Authority for review/approval.

14.2 Lifting and Tie-down FeaturesThere shall be no visible mechanical damage, corrosion, deformation, change in section orcracks evident in the main body/welds of any lifting or tie-down features.

Burrs or sharp edges shall be dressed off.

To ensure there is no wear which will have a detrimental effect when interlacing with approvedlifting accessories dimensions of lifting feature sections shall be within tolerances as detailedon the design drawing. If this is not the case Contract Authority shall be consulted.

For self-weight testing purposes the package-unladen weight can be used, unless the packageladen weight difference, is excessive (i.e. >20%) and in such a case advice is to be sought fromthe Package Design Authority via a concession. A visual confirmation of package performanceis acceptable. Weights may be obtained from the package design drawings. (See also theLLWR datasheet for the TCI 1 Transport Handling Frame.)

0F FICIAL 0M34O922Z-MECH-OOOO1 -B


Operating and Maintenance Specification for Type IP-1 Package Design No. TCI 1 , Transport Handling Frame

If the inspector chooses to use NDT to assess defects see section 14.5.

14.3 Cargo NetThere shall be no signs of damage such as tears, cuts nicks and breaks in the load bearingfibres and retaining stitches or deformations resulting from exposure to heat on the cargo nets.

There shall be no signs of any accidental contact with chemical products on the cargo nets.

Anchor points shall be complete without signs of damage, deformation, corrosion or excessivewear.

End fittings and tensioning devices should be free from deformations splits, pronounced signsof wear or signs of corrosion.

Ratchet tensioning devices should operate smoothly without application of excessive force.

Damaged or defective web lashings and ratchet tensioners shall be removed from the THE anddisposed via the appropriate route.

Any defects that are found shall be reported to the Contract Authority.

14.4 CruciformIf fitted remove the cruciform and thoroughly inspect. There shall be no signs of damage orcorrosion evident on the structure. Any defects that are found shall be reported to ContractAuthority for sentencing.

14.5 NOT

14.5.1 Magnetic Particle Inspection (for carbonlferritic steels)Inspection shall be carried out in accordance with BS EN ISO 17638 [81 with acceptance levelsin accordance with BS EN ISO 23278 [9].

Defects are not acceptable for welds associated with lifting or tie-down features. Any defectsthat are found shall be reported to the Contract Authority for sentencing.

All personnel performing MPI shall be qualified in accordance with BS EN ISO 9712 [10], PCNLevel 2 minimum or an equivalent International Standard.

14.5.2 Liquid Penetrant Inspection (for austenitic steels)Inspection shall be carried out in accordance with BS EN ISO 3452-1 [14] with acceptancelevels in accordance with BS ISO 23277 [15]

Defects are not acceptable for welds associated with lifting or tie-down features. Any defectsthat are found shall be reported to the Contract Authority for sentencing.

All personnel performing MPI shall be qualified in accordance with BS EN ISO 9712 [10], PCNLevel 2 minimum or an equivalent International Standard.

14.6 Threads

14.6.1 Visual InspectionThreads shall be continuous, have a full form and be free from burrs and sharp edges fortheir design length.

14.6.2 Gauge TestingMale Threads

Threads accept ‘GO’ gauges for the full design length.

Threads shall not accept a ‘NO GO’ threaded gauge any further than two full thread pitches.

0F FICIAL OM-3409227-MECH-0000 I -B



Threads shall accept a ‘GO’ calliper gauge at any point along the thread design length.

Threads shall not accept a ‘NO GO’ calliper gauge at any point along the thread designlength.

Female Threads

Threads shall accept ‘GO’ gauges for the full design length.

Threads shall not accept a threaded gauge for more than two full pitches.

14.6.3 Anti-GallingWhere appropriate, threads shall be lubricated (sparingly) using a dry film lubricant such asRocol DFSM.

J47 LubricationLubrication of ratchet tensioners shall be carried out using light oil such as WD4O. Excess oilshould be removed with a dry cloth. Any lubricant that comes into contact with the fabricshould be washed off with a mild detergent and allowed to dry before returning to service.

14.8 Torque SettingsThe torque setting for cruciform fasteners is 100 Nm.

14.9 Functional TestsCorrect functionality of package to be confirmed, such as fitting and removal of cruciformpartitions and operation of cargo net tensioners.




15 References[1] BS ISO 1496-1:2013, Series I Freight Containers — Specification and Testing. Part: 1:

General Cargo Containers for General Purposes.

[2] IAEA, Specific Safety Requirements No SSR-6, Regulations for the Safe Transport ofRadioactive Material, 2012 edition.

[3] International Convention for Safe Containers, 1972 (CSC).1996 Edition.

[4] BS EN ISO 9001 Quality Management Systems — Requirements.

[5] BS ISO 3874:1997, Series I Freight Containers - Handling and Securing, IncorporatingCorrigendum No.1 and Amendment Nos.1, 2 and 3.

[6] Lifting Operations and Lifting Equipment Regulations 1998 512307.

[7] The Carriage of Dangerous Goods and Use of Transportable Pressure EquipmentRegulations 2009.

[8] BS EN ISO I 7638:2009 — Non-destructive testing of welds — Magnetic particle testing (ISO17638:2003)

[9] BS EN ISO 23278:2009 — Non-destructive testing of welds — Magnetic particle testing ofwelds — Acceptance levels (ISO 23278:2006).

[10] BS EN ISO 9712:2012 — Non-destructive testing — Qualification and certification of NDTpersonnel (ISO 9712:2012).

[1 1J RSP 5.01 Records Management.

[1 2] RSP 1 1 .02, SQEP Qualification of People

[1 3] OM-3409227-MECH-00006, Operating and Maintenance Specification for the I . I 8t WLLSoft Sided Package (SSP).

[1 41 BS EN ISO 3452-1 :201 3 — Non-destructive testing — Penetrant testing

[1 51 BS EN ISO 23277:2009 — Non-destructive testing of welds — Penetrant testing of weldsAcceptance levels (ISO 23277:2006)

[1 61 TCI 1 Damage Assessment Sheet, Form 542


OF

FIC

IAL

Ope

rati

ngan

dM

aint

enan

ceIn

stru

ctio

nfo

rT

ype

P-I

Pac

kage

Des

ign

No.

TC1

1,T

rans

port

Han

dlin

gF

ram

e

Fig

ure

1-

Gen

eral

Vie

wof

Tra

nspo

rtha

ndli

ngfr

ame

Pag

e2l

of29

Cru

cifo

rm(x

3)

VT

CII

Tra

nsp

ort

Han

dlin

gF

ram

e

Car

go

Net

(x3)

I325

mm

Ten

sion

ing

Dev

ice

(x6)

J

OF

FIC

IAL

101

1T

rans

port

Han

dlin

gF

ram

e(c

argo

net

only

show

nin

Ipo

sitio

nfo

rcl

arity

)

OM

-340

9227

-ME

CH

-000

01-B


Operating and Maintenance Instruction for Type IP-1 Package Design No. TCI 1 , Transport Handling Frame

Figure 2 — General View of Soft Sided Package

Inner & outer closures

Corner loops(for loading frame)

Lifting Sleeve

1145mm

OFFICIAL

Loops for Anti TamperDevice

Bottom loops(for weather cover)

711mm

Figure 2I . I 8t Soft Sided Package

(shown with closures open)

OM-3409227-MECH-00001 -B

OFF

ICIA

LO

per

atin

gan

dM

ainte

nan

ceIn

stru

ctio

nfo

rT

ype

IP-1

Pac

kage

Des

ign

No.

TC

II,

Tra

nspo

rtH

andl

ing

Fra

me

Pag

e23

of29

OFF

ICIA

L

Fig

ure

3—

SS

Pli

fted

wit

hat

tach

men

tF

igure

4—

SS

Pli

fted

wit

hfo

rks

Lif

ting

Sock

r

TC

iNr

I

(Not

e:P

roto

type

SS

Psh

own,

Pro

duct

ion

SS

P’S

will

begr

een)

OM

-340

9227

-ME

CH

-000

01-B


Operating and Maintenance Specification for Type IP-1 Package Design No. TCI I , Transport Handling Frame

Figure 5 — Trailer Support

OFFICIAL

DANT

SUPPORTARRANGEMENTWHEN CONTAINER LOADED WHILE ON A TRAILER

OM-3409227-MECH-00001 -B

0 C,)

C (0 N)

N)

ifi

0 C C C C

T]

0 -q 0 z U)

Ri

Ri

-H Ri

0 Ri

Ri

0 Ri

Ri

-U 0 0 Ri

Ri

-H U)

‘1 C -‘ CD I- C Cl)

Co ‘1 0 I- -I 1 C 0

cD

fl

3-n

D D CD 0 CD 0)

CD 0 - 0 0 0 H CD -p -a Q) 0 CD CD C,,. z p H 0 H D C,,

0 T 0 ,1CD C)

,

CDN

)(0

0 -Ti

‘1 0 I-

0-U

00

-HR

i)U

)R

iR

iO Z 0 Ri

Ri

-H 0 -H -U



Figure 7 — Lifting Using Bottom Fittings

.

I

\:..)$

3•

2

\ CASTING ATTACHMENT

OFFICIALOM-3409227-MECH-00001 -B

0,

c%J0

I-

C

u_

C

c

C

D-.E

9

:5C

0

c

w

IH

C?

0

HozU)

Ua)a)0a)0a)

HI-

0‘I—0

—.

CD

)0

C;j

•-

4-.

0:

UD

20

Z:L

)

0U

)a)

.Ea)

0D

.

0)

a).c

—A

J:y‘

I

•Jt

-Ca)

I—

Co0)

0o

0


Operating and Maintenance Specification for Type IP-1 Package Design No. TCI , Transport Handling Frame

Figure 9 — Twist lock System on Trailer

OFFICIAL

IJI

OM-3409227-MECH-00001 -B

OFFICIALPage 29 of 29


Appendix A — Transport Handling Frame and soft sided package data

GA. Drg. No BE 2781501

2000

280

17000

1325

2438

Maximum Stacking Height:-. 5

Compartment Dimensions:

Top Length (mm)

Top Width (mm)

Bottom Length (mm)

Bottom Width (mm)

Depth (mm)

Volume (mj

With cruciforms fitted

890

1045

765

965

Without cruciforms fitted

I 830

2160

1580

2000

1150

4

Indicative Weights (kgs)

Body

Cruciform

Permissible Gross Weight

6058

1150

I

Indicative External Dimensions:

Height (mm)

Width (mm)

Length (mm)

Specific Information for the Soft Sided Package (0.75m3)

Indicative External Dimensions:

Height (mm)

Width (mm)

Length (mm)

1145

711

914

G.A. Drgs. No I BE2865624

Indicative Weights (kgs)

Weight 11

Safe Working Load I I 80

Minimum Clearance Heightrequired from Lifting Sock to Top 1500Of Transport handling frameduring loading/unloading (mm)

OFFICIALOM-3409227-MECH-00001 -B

Documents

Packaging Solutions Project title - gov.uk · OFFICIAL Page3of29 Operating and Maintenance Specification for Type P-i Package Design No. TC1 1, Transport Handling Frame History sheet