NDA A - gov.uk › government › uploads › syst… · Packing and Handling Instruction for lP-2 Design No. TC19 OM-3409278-MECH-00005-C Page 7 of 16 I Introduction 1.7 General

OFFICIALOM-3409278-MECH-00005-C

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LLW Repository Ltd Page 1 of 16

Packing and Handling Instruction for IP-2Package Design No. TCJ9(Solid Super-compactable IP-2 Drum)

Project title: Low Level Waste Drum PackageProject number: 34109278Bldg name/number: Low Level Waste Repository

OM 3409278 MECH 00005 CDocument ref: — — — —

Purpose of issue: For Operational UseDate of issue: j2th June 2017

Author: J. McNallyLLWR

Checked by: M. ElliottLLWR

Level of checking: Level 3

Checker’s signature: Date: iQ 7Approved by: R MillingtonApprover’s position: Package Design Authority LLWR Ltd

Approver’s signature: Date:

“Copyright NDA 2017, this document contains proprietary information, permission to copy, or use suchinformation, should be sought from the Intellectual Property Manager, LLW Repository Ltd.”

OFFICIALA company owned by UK Nuclear Waste Management Ltd Registered Address: Old Shore Road, Drigg

Holmrook, CumbriaUnited Kingdom, CA19 1 XP

OFFICIALPacking and Handling Instruction for IP-2 Design No. TC19 OM-3409278-MECH-00005-C

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Circulation list Purpose of issue: 1 For comment

2 For action

3 For information

Name Location No of Remarks Log-on ID Purpose ofcopies issue

R Millington LLWR 1 3M P Flynn LLWR 1 3

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History sheet

OM-3409278-MECH-00005-CPage 3 of 16

Rev Date Reason for revision Revised by

A 1gth June 2013 First Issue B Mellor

B 15th April 2016 References updated and reference 3 D Windleyadded.Section 1.2 Temperature Range addedSection 5 Chemical Nature of Contentsadded.Revised in line with TC14 Packing andHandling Instruction.

C 12 June 2017 J. McNallyAddition of Figure 2 to show lid clampbolt weld detail.Addition of c) & d) in Section 7.4.2. i) toimprove lid band removal andinspection procedure.Modification to Section 9.2.1 to includelid and clamp band assemblyinspection.

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ContentsItem Page

Circulation list 2

History sheet 3

Contents 4

DefinitionslGlossary 6

I Introduction 71.1 General 71.2 Permissions 71.3 Temperature Range 7

2 Scope 7

3 Compliance 8

4 Responsibilities 8

5 Chemical Nature of Contents 85.1 Chemical Compatibility 85.2 Dangerous Properties $5.3 Gas Generation 9

6 Drum Handling Methods 96.1 General 96.2 Lifting and Loading Equipment 9

7 Pre-filling Checks 97.1 General 97.2 Certificate of Approval 97.3 Visual Inspection 97.4 Lid Removal and Inspection 10

8 Filling the Drum — Solid Contents Only 108.1 General 108.2 Waste material being transported for high force compaction 118.3 Waste material (in solid form) being transported for incineration 118.4 Waste material in the form of VLLW being transported to authorised landfill sitesfor disposal 11

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ContentsItem

OM-3409278-MECH-00005-C

Page 50116

Page

Waste material being placed into interim storage 77

Prior to closing lid 12

Closing the lid 12

9 Pre-shipment Checks 129.1 Weight 129.2 Final Inspection 129.3 Monitoring and Labelling 129.4 Documentation 12

10 Shipment Requirements 1210.1 Load Restraint 12

11 Drum

11.1

11.2

11.3

Storage 13Storage of Empty Drums 13

Drum Retrieval from Storage 13

Storage of Loaded Drums 13

12 References 13

Figure 1: General view of Type TCI9 solid supercompactable lP-2 drum 14

Figure 2: Lid Clamp Band Assembly, showing details of the lug welds andbatch identifier stamp 15

Appendix A 16

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8.5

8.6

8.7

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Definitions/Glossary

ALARP As Low As Reasonably Practicable

Approving Authority LLWR Package Approval Authority is responsible for theissue of Certificates of Approval for IAEA self assessmentpackage types on behalf of LLWR

Consignor Consignor according to the provisions of ADR

Drum Operator Owner of the Drum

Contract Authority LLW Repository Ltd

Design Authority Head of Engineering, LLW Repository Ltd., Pelham House,Calderbridge, Cumbria CA2O 1DB

IAEA International Atomic Energy Agency.

IP-2 Industrial Package Type 2

ISO International Standards Organisation.

LLW Low Level Waste

LLWR Low Level Waste Repository

LSA Low Specific Activity

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

SCO Surface Contaminated Object

SQEP Suitably Qualified and Experienced Person

VLLW Very Low Level Waste

WAC Waste Acceptance Criteria

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I Introduction1.7 General

1.1.1 The drum covered by this instruction (See Figure 1) is a UN approved PackingGroup I (X) nominal 210 litre capacity steel drum (UN Approval1A2/X368/S/**/GB/6190) with a reduced neck diameter at the top, fitted with a fullaperture steel lid. The drum and lid are manufactured from nominal 1.0mm thickcarbon steel. The overall dimensions are approximately 585mm diameter (extendingto 600mm over the lid clamp fastening) x 867mm high. The drum lid, whichincorporates an EPDM elastomer seal is secured to the drum body by a zinc coatedsteel closure ring with a 5/8” BSW (Whitworth) heavy duty nut and bolt fastening.

1.1.2 The drum is designed for the transport of solid radioactive material in the form ofLow Level Waste (LLW) or Very Low Level Waste (VLLW), which qualifies as LowSpecific Activity (LSA) or Surface Contaminated Object (SCO) material as defined inthe International Atomic Energy Agency (IAEA) Safety Standard SSR-6, Regulationsfor the Safe Transport of Radioactive Material, 2012 Edition [Ref 1]. The explicit useand restrictions are defined in the Certificate of Approval issued to the customer byLLW Repository Ltd.

NOTE: Where it is found that any part of the Packing and HandlingInstructions cannot be complied with the container shall beembargoed and advice shall be sought from the Contract Authority.

Contact: transportandloqisticsIIwrsite.com or Telephone 019467 70301

1.1 .3 Each drum is supplied as a single use Industrial Package Type 2 (IP-2) packaging.

1.2 Permissions

1.2.1 In specific circumstances, the following table indicates where Contract Authoritypermission/authority/endorsement must be obtained.

Contact: transoortandloaisticsä)llwrsite. corn

Ref Activity Acceptance Criteria

1 Damaged drum 1.2.2

1.2.2 Damaged drum

Consignment of drums which do not satisfy the inspection criteria of sections 7 or9.2 but are considered suitable for transport.

1.3 Temperature Range

1.3.1 TC19 shall not be transported when the temperature is less than -10°C.

1.3.2 There is no maximum operating temperature limit.

2 Scope2.1 This document identifies the design intent for the packing and handling of the

package and is to be used as an aid to producing detailed consignor specificOperating and Maintenance Instructions. The purpose of these instructions is toensure that the package is safely and correctly handled and loaded prior totransportation.

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2.2 These instructions are to be used in conjunction with the Package Operator and/orConsignors local instructions governing radiological and other safety issues relatedto movement of radioactive materials, any national nuclear safety requirements andthe agreement for the supply of the drum.

2.3 This Packing and Handling Instruction details the handling methods, pre-fillingchecks, loading procedure, pre-shipment checks and shipping requirementsapplicable to the drum.

2.4 This Packing and Handling instruction is for use with the following package type:

• Type TC19 Solid “Super-compactable” IP-2 drum.

3 Compliance3.1 The Consignor is responsible for ensuring that Regulatory requirements governing

the use of the package are complied with.

4 ResponsibilitiesIt is the responsibility of the Consignor to ensure that:

• Packing and handling activities are carried out in compliance with a qualitymanagement system that meets the requirements of BS EN ISO 9001 [Ref 2].

• All local and regulatory requirements governing radioactive materials andtransport packages are complied with.

• Reference is made to the Certificate of Approval for the package identifyinginformation on approved contents and other shipment and operatingrequirements.

• The material to be consigned satisfies the regulatory requirements for transportand complies with the Waste Acceptance Criteria for the receiving facility.

• Personnel associated with filling, closing, loading and handling the drum observeALARP principles so that personal radiation dose is minimised.

• The drum is fit for purpose and the checks detailed in section 7 have been carriedout and recorded, signed and dated.

5 Chemical Nature of Contents5.1 Chemical Compatibility

5.1.1 Ensure that the waste materials carried in TC19 are chemically inert, chemicallycompatible with each other and are not chemically aggressive to the mild steelconstruction of the package.

5.1.2 No account may be taken for the internal lacquer coating since this is easilydamaged during filling.

5.2 Dangerous Properties

5.2.1 If the drum contents have other dangerous properties i.e. explosive, pyrophoric,corrosive, toxic, flammable, oxidising etc. it is the consignor’s responsibility toensure that these properties are taken into account in accordance with therequirements of the relevant Dangerous Goods Regulations.

5.2.2 Since Package Design TC19 is a Type 1A2 UN approved packages (removablehead steel drum) it may be suitable for the transport of contents having other

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dangerous properties. The consignor must ensure that the Packing Instructions ofthe relevant Dangerous Goods Regulations permit the use of Type 1A2 drums.Otherwise Package Design TC14 may be used as overpack formaterials/substances contained within suitable UN approved primary packaging.

5.3 Gas Generation

5.3.1 Substances with the potential for gas generation are not permitted to be carried inTC19.

6 Drum Handling Methods6.1 General

6.1.1 The drum is a standard 210 litre drum design which has no specific liftingattachments or handling method.

6.1.2 The drum may be lifted using standard drum handling equipment such as drumgrabs or tongs or slings or when secured on a pallet. Care must be taken particularlywhen using a drum grab to ensure that the drum is not damaged.

6.1.3 The drum may be may be secured to a pallet for ease of handling.

6.2 Lifting and Loading Equipment

6.2.1 All drum lifting and loading equipment must be suitably rated to handle the drumsafely. See Appendix A for relevant weight information applying to the packagedesign.

7 Pre-filling Checks7.1 General

7.1.1 The drum shall be in a fit for purpose condition before being used and as a minimumthe checks detailed below are designed to ensure that the packaging is fit forpurpose. All inspections must be carried out by a Suitably Qualified andExperienced Person (SQEP). Confirmation that all the following inspections havebeen carried out must be recorded, signed and dated by the person conductinginspections. If unacceptable damage is found the packaging shall not be used. If thedrum is considered suitable for use contact the Contract Authority to obtainpermission (see section 1 .3).

7.2 Certificate of Approval

7.2.1 The package Certificate of Approval tor transport issued by the Approving Authoritymust be checked to ensure it is valid and will remain valid throughout the periodduring which the package is to be transported in the public domain.

7.3 Visual Inspection

7.3.1 Ensure that the drum has the appropriate UN marking 1A2/X368/SI**1GB16190located on the side of the drum body near the bottom.

NOTE: indicates the last 2 digits of the year of manufacture.

NOTE: Drums with other UN markings or no UN marking must not be used.

7.3.2 The drum shall be fitted with a flat lid with no openings.

7.3.3 Visually inspect the external surface of the drum including the base for any damage,deformation, corrosion, dents, splits etc. likely to impair the safety or efficiency of thepackage.

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External Examination Acceptance Criteria:

i) Cracking of welded joints is unacceptable.

ii) Puncturing of the drum body or lid is unacceptable.

iii) Very small dents of no deeper than 5mm on the drum body only are acceptable,providing the dents are not located near the drum chimes or near the top andbottom rolled rings.

iv) Minor scuffing of the paintwork is acceptable.

7.3.4 Ensure the package decal is present, legible and securely affixed to the drum body(see Figure 1).

7.4 Lid Removal and Inspection

7.4.1 Unscrew the clamp band bolt using a suitable spanner or socket, remove clampband and remove lid.

NOTE: The clamp band is fitted with a 5/8” BSW (Whitworth) bolt.NOTE: The bolt head is typically 26mm across flats.

7.4.2 Visually inspect the lid, clamp band and internal surface of the drum for anydamage, deformation, corrosion, dents, splits etc. likely to impair the safety orefficiency of the package.

Examination Acceptance Criteria:

i) Clamp band

a) Superficial damage only is acceptable. The zinc coating shall be completewith no exposed steel.

b) Superficial damage only of the locking bolt and lugs is acceptable. Thereshall be no damage to the bolt or lug threads.

c) Ensure the clamp band is marked with a batch identifier (e.g. week numberand year of manufacture)

d) Ensure the threaded lug is attached to the clamp band firmly, and thesupportive fillet welds are visible (See figure 2)

ii) Lid seal

a) There shall be no damage to the integral lid seal and no foreign matteradhering to the seal surface.

b) Ensure the seal is fully secured to the lid.

iii) Drum

a) There shall be no damage (scores, dents or scratches) to the top sealingface of the drum body.

b) Minor scuffing of the internal finish is acceptable.

8 Filling the Drum — Solid Contents Only8.1 General

8.1.1 Carefully place waste items or material into the drum taking care not to damage thedrum noting the requirements of paragraphs 9.2 to 9.5.

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8.1.2 Any waste material that has the ability to penetrate the drum wall during normalconditions of transport must not be loaded adjacent to the internal surface of thedrum.

8.1.3 When filling with solid material, the top 30% of the drum (i.e. above the top rollingring) shall only be filled with material having a relative density of less than or equalto one. If suitable waste material is not available, the top 30% of the drum shall befilled with packing material. The packing material may comprise coarse granularmaterial such as polystyrene chips, wood chip or shredded cardboard.

8.1.4 Any waste material that has the ability to penetrate the drum wall during normalconditions of transport must not be loaded adjacent to the internal surface of thedrum.

8.1.5 Waste must be carefully packed into the drum to ensure that radiation levels at thedrum surface are kept as low as practicable. Consideration must be given to ensurethe maximum drum surface radiation level does not increase significantly from thatrecorded prior to transport (as per 9.3.1).

NOTE: An increase by 20% will be regarded as a reportable event to the ONR.8.2 Waste material being transported for high force compaction

The contents shall comprise solid radioactive waste material being transported forhigh force compaction meeting the relevant Waste Acceptance Criteria, subject tothe requirements of section 5 regarding chemical compatibility, dangerousproperties and gas generation being met.

NOTE: TCI9 is suitable for super-compaction at the Sellafleld WAMACsuper-compaction facility.

8.3 Waste material (in solid form) being transported for incineration

The contents shall comprise combustible radioactive waste material (in solid form)being transported for incineration meeting the relevant Waste Acceptance Criteria,subject to the requirements of section 5 regarding chemical compatibility, dangerousproperties and gas generation being met.

8.4 Waste material in the form of VLLW being transported to authorised landfillsites for disposal

The contents shall comprise VLLW for disposal meeting the relevant WasteAcceptance Criteria, subject to the requirements of section 5 regarding chemicalcompatibility, dangerous properties and gas generation being met.

All items must be reduced to typically less than house brick size.

For concrete waste forms, any rebar protruding from the concrete must be less than300mm in length.

8.5 Waste material being placed into interim storage

The contents shall comprise radioactive waste material being placed into interimstore prior to other waste routes becoming available and shall be subject to therequirements of section 5 regarding chemical compatibility, dangerous propertiesand gas generation.

The contents should typically be less than 75mm size and any heavy metal orsimilar items must be placed in the bottom 70% of the drum (i.e. below the toprolling ring).

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8.6 Prior to closing lid

Clean and dry the sealing face of the drum body and ensure that the sealing surfacehas not been damaged during filling.

If necessary clean the integral lid sealing ring to remove all foreign matter andensure that the seal has not been damaged.

8.7 Closing the lid

Fit the lid and clamp band to the drum and tighten the clamp band bolt until theclamp band is fully engaged. Ensure that the lid and clamp band are correctly fitted.Tap all around the periphery of the clamp band with a soft faced mallet to ensurethe clamp band and lid seal are fully seated and tighten the clamp band bolt to atorque of 45 Nm. Repeat this procedure (i.e. tap clamp band and torque up) until nofurther tightening of the clamp band bolt is possible. This is best done by twopeople, one tapping the clamp band while the other simultaneously tightens theclamp band bolt.

NOTE: This is an important step to ensure the drum is sealed and must be fullycomplied with.

NOTE: The clamp band bolt must not be tightened beyond 45 Nm.

9 Pre-shipment Checks9.1 Weight

Measure and record the weight of the loaded drum. This must not exceed 300kg.9.2 Final Inspection

9.2.1 Visually inspect all external surfaces of the drum, including the lid, clamp bandassembly and the base. See section 7.

9.3 Monitoring and Labelling

9.3.1 Monitor the radiation levels on the outside of the package for compliance with theIAEA Regulations [Ref 11.

9.3.2 Affix all necessary labelling in accordance with the requirements of the IAEARegulations [Ref 1].

9.4 Documentation

9.4.1 The Consignor shall complete the necessary consignment documentation asrequired by the IAEA Regulations [Ref 1].

10 Shipment Requirements10.1 Load Restraint

10.1.1 The package shall be adequately restrained during transport.

10.1.2 The Radioactive Material Code of Practice TCSC 1006, Guide to theSecuring/Retention of Radioactive Material Payloads and Packages DuringTransport [Ref 3] provides guidance on load restraint and appropriate accelerationfactors to be applied to the package. Further guidance can be found in the EuropeanBest Practices Guidelines on Cargo Securing for Road Transport [Ref 4]. Whentransporting loads within the scope of the IAEA Regulations [Ref lithe accelerationfactors from TCSC 1006 [Ref 3] shall be used.

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10.1.3 The package may be restrained using webbing straps secured to the floor or walls ofthe conveyance, cargo netting, ropes and sheeting or it may be carried in a stillage.

10.1.4 Loading may be in accordance with an LLWR Standard Waste Loading Plan, LLWRContainer Packing and Handling Instruction, or approved Customer WLP.

11 Drum Storage11.1 Storage of Empty Drums

The drum should be stored on a hard flat surface that is well drained. It is importantthat the drum paint finish is not damaged during this operation.

11.2 Drum Retrieval from Storage

Upon retrieval from storage the drum shall be examined in accordance withSection 7.3. If unacceptable damage is found the packaging shall not be shipped. Ifthe drum is considered suitable for use contact the Contract Authority to obtainpermission (see section 1 .2).

11.3 Storage of Loaded Drums

If stored prior to transport the drum must be stored in a suitable secure storagearea.

NOTE: Temporary labels shall be affixed using low tack adhesive/tape so thatthe drum paintwork is not damaged when they are removed prior totransport.

12 References[1] IAEA Safety Standard Series, Regulations for the Safe Transport of Radioactive

Material, 2012 Edition, Specific Safety Requirements No. SSR-6.

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

[3] Transport Container Standardisation Committee. Transport of Radioactive MaterialCode of Practice. Guide to the Securing/Retention of Radioactive Material Payloadsand Packages During Transport.Reference: TCSC 1006 September 2014.

[4] European Best Practices Guidelines on Cargo Securing for Road Transport.European Commission. Final version 8 May 2014.

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Figure 1: General view of Type TCI9 solid supercompactable IP-2 drum

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Figure 2: Lid Clamp Band Assembly, showing details of the lug welds and

batch identifier stamp

Manual Welds

Example ‘Batch Identifier’stamp on clamp band

NOTE - Location will vary

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Appendix A

OM-3409278-M ECH-00005-CPage 16 of 16

Indicative Weights (kg)

PACKAGE TYPETCI9

Tare weiQht (empty) 20Maximum Gross 300

Indicative External Dimensions:Height (mm) 867Diameter (mm)Maximum width over lid clamp (mm)Volume (litres)

585

600

210

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