Packaging Supplier Day May 2015

Transcription

1 Objective: To engage with suppliers who may be interested in and have the capability and capacity to manufacture various forms of packaging required, and the associated services. Date: 18 th June 2015 Location: Penrith, Cumbria Introduction LLW Repository Ltd, the Purchaser, is a waste management company that provides goods and services to Customers to treat and dispose low level radioactive waste, on behalf of the Nuclear Decommissioning Authority (NDA). We manage the national Low Level Waste Repository (LLWR) in West Cumbria and oversee the national programme for Low Level Waste (LLW) to ensure that lower activity nuclear waste is managed effectively across the UK. Our customer base consists of nuclear industry and non-nuclear industry waste producers including: Nuclear sites owned by the NDA, public sector bodies, such as the Ministry of Defence, and private sector businesses, such as power generation, medical, research or nuclear services companies. We provide goods and services to over 30 different customers at more than 50 customer sites. This note provides information on LLW Repository Ltd s packaging goods and associated services needs for the transport of waste, in advance of these requirements being issued as Tender, which will be detailed in the Official Journal of the European Union (OJEU) Contract Notice. Packaging for the Nuclear Industry is required to meet high standards. This arises, quite rightly, as any escape of radioactive material into a public area, would be a National or International event. This event would impact on the reputation of both the Purchaser and the Supplier and most likely would impact the manufacture of packaging whilst the event is investigated. For this reason very high standards apply to the manufacture/supply of goods; this includes the need for surveillance and certification confirming that the goods supplied conform fully to the agreed specification/drawings. It is expected that the Supplier will have Process Systems for Quality, and preferably Environment and Health and Safety Management. These Systems are to be certified by an independent third party (BSi, LRQA, BM Trada, DNV, etc.) In line with government guidance, LLW Repository proposes the use of the NEC suite of contracts with additional terms and conditions as required, to meet its contract with the NDA. Each contract is anticipated to commence early 2016, and be for a period of typically 4 years. ALL SUPPLIERS WILL BE REQUIRED TO BE ACCREDITED TO ISO9001 as a minimum Page 1 of 12

2 Packaging Supply and Service Support LOT 1 - IP2 ISO Container Supply & Associated Services Various forms of containers termed packaging are used by customers to transport radioactive (low and very low) waste for processing or to be disposed of in the LLW Repository or other authorised facilities. The most common variants used by customers are termed TC01, TC03, & TC08. There are other variants, such as TC02, TC06 & TC11 with some used as re useable containers, and associated ancillary equipment, including lifting frame (and testing), that may also be required. The manufacture of these to agreed programmes as well as capacity to store the units (until LLW Repository Ltd collect to deliver to customers) is a key element of the scope. The scope will also include minor repairs and refurbishment of a small number of units. Due to the importance of the quality being correct, LLW Repository Ltd will undertake Readiness Reviews of all processes and documentation prior to giving Approval for Manufacture to commence, per order placed. In addition, welding quality requirements must be in compliance with BS ENISO and all welding procedures will need to be reviewed and approved by LLW Repository Ltd/the DA, in advance of manufacture. In process and final checks will be undertaken on both hardware and final handover records, termed Lifetime Quality Records (LQR)LLWR QA team on a % basis. Full traceability is required for all materials, welding qualification and non destructive examination used etc. which forms a key element of the LQR documents. For the manufacture of each variant Type Approval is required, which consists of manufacture of a prototype and subsequent load testing at an approved test facility and witnessed by a container classification body, if not currently approved for each type of container. In addition support services are required such as ISO design assistance, to include capability to design restraint systems, assist in container optimisation studies, assist in manufacturability reviews and general design reviews. Details of TC C Half Height LLW ISO Container Dimensions (internal) Length Width Height Dimensions (external) 6058 mm 2438 mm 1320 mm 3090 kg Construction is mild steel, except for the lid flange and seal carrier which are ferritic stainless steel, and forged clamps. Page 2 of 12

3 Details of TC03 Dimensions (external) Third Height ISO (THISO) Length Width Height 6058 mm 2438 mm 880 mm 2860 kg without overlid 3200 kg with overlid Construction is mild steel, except for the lid flange and seal carrier which are ferritic stainless steel, and forged clamps. Detail of TC C Half Height LLW ISO Container Dimensions Length Width Height Dimensions (external) 6058mm 2500mm 1345mm Without Rails 2,660 kg With Rails 2,793 kg Construction is mild steel, except for the lid flange and seal carrier which are ferritic stainless steel, and forged clamps. Page 3 of 12

4 Official Packaging Supplier Day May 2015 Details of TC02 Reusable Half Height ISO Container Dimensions Length Stillage TC02/S1 envelope dimensions 2420mm Dimensions (external) 6058 mm 4,100kg Width Height 1680mm 890mm 2438 mm 1325 mm Construction is of mild steel outer frame, forged clamps with inner of stainless steel construction. Details of TC11 Soft Sided Package Transport Handling Frame Dimensions Length Width Height Dimensions (external) 6058mm 2438mm 1325mm 2000kg Page 4 of 12

5 Construction is of mild steel outer frame with inner liner of stainless steel construction. Container Type Indicative Quantity Comment TC01 TC03 TC per year per year 40 per year All quantities required are subject to customer demand which does fluctuate. Other TC variants may be required in very small quantities. Page 5 of 12

6 LOT 2 IP2 ISO Container Spares LLW Repository Ltd requires a supplier to produce (manufacture/procure), control, store and distribute consumable spares for its Packaging fleet. The fleet typically consists of Various forms of ISO IP2 containers. The technical and quantity requirements will be advised by LLW Repository Ltd. Examples of spares to be held: Seals (doors / container / o rings) Decals Touch up paint Clamps, restraining bolts, nuts, flanges, screws & washers Lubricants Container lids Etc. Storeman Expected to be required on a part time basis. Deliveries When requested by LLWR the Supplier will be required to arrange delivery to any of its customers to various locations in England and Wales. Possible LOT 3 Packaging Storage LLW Repository Ltd may require a supplier to provide a weatherproof facility for secure indoor storage of packaging. Ideally the facility needs to be within 25 miles of site (the LLW Repository) and have adequate capacity to store typically 40 off TEU ISO Containers. The facility shall be capable of maintaining temperature control, such that it does not drop below +5 0 C. Handling equipment and access doors etc. shall be large enough to accommodate a full height 20 ISO container, either on a trailer for offloading inside or the doors be wide enough to allow the containers to be placed in store after offloading outside. The facility shall be large enough to accommodate the storage and handling, to enable a first in first out principle, an area of circa 400m2 is expected to be required, or less if the facility has sufficient height to stack units. The packaging to be stored will typically consist of ISO containers, ancillary equipment such as waste boxes, stillage s etc. The supplier is expected to require equipment to be able to handle empty units up to 5Te. A fully 24hr manned facility is not necessarily expected, but it shall be secure to avoid any damage from vandalism and prevent theft. Page 6 of 12

7 LOT 4 IAEA Type A (TC16) Over Container Detailed Design, Manufacture and Testing LLW Repository Ltd. has a requirement to develop a new transport package, which is fully compliant with the requirements of the IAEA Regulations for the Safe Transport of Radioactive Material to enable the package to be licensed as a Type A/Type IP-2 package for the transport of solid form radioactive material. The package is to be used to transport the following solid form radioactive payloads by road and sea: Large unpackaged items of contaminated plant and equipment destined for waste treatment facilities; and Damaged (or non-compliant) Type IP-2 ISO freight containers containing low level radioactive waste. Following optioneering and outline design by others, LLW Repository Ltd requires a supplier to be able to complete the detailed design, manufacture, test, and provide the LQR records. In addition to standard structural design, the design will involve all the above topics and impact assessment involving Finite Element Analysis (FEA).These works will need to take due cognisance of applicable National and European Regulations and in particular: IAEA Safety Standards: Regulations for the Safe Transport of Radioactive Material, Specific Safety Requirements No SSR-6, 2012 Edition IAEA Safety Standards: Advisory Material for the IAEA Regulations for the Safe Transport of Radioactive Material (2012 Edition), Specific Safety Guide No SSG-26 Supply of Machinery (Safety) Regulations 2008 Lifting Operations Lifting Equipment Regulations 1998 (LOLER) Pressure Equipment Regulations 1999 (SI 1999/2001) (PER) Provision and Use of Work Equipment Regulations 1998 (PUWER) Road Vehicles (Authorisation of Special Types) (General) Order 2003 (STGO) Due to its size and method of operation it requires specialist elements such as: Radiometrics Electrics Hydraulics Use of lightweight/exotic Steels Programmable logic control Appreciation of ergonomics (operator safety) These works are to take due cognisance of applicable National and European Regulations and in particular: IAEA Safety Standards: Regulations for the Safe Transport of Radioactive Material, Specific Safety Requirements No SSR-6, 2012 Edition IAEA Safety Standards: Advisory Material for the IAEA Regulations for the Safe Transport of Radioactive Material (2012 Edition), Specific Safety Guide No SSG-26 Supply of Machinery (Safety) Regulations 2008 Lifting Operations Lifting Equipment Regulations 1998 (LOLER) Pressure Equipment Regulations 1999 (SI 1999/2001) (PER) Provision and Use of Work Equipment Regulations 1998 (PUWER) Road Vehicles (Authorisation of Special Types) (General) Order 2003 (STGO) Contract is expected to commence during Page 7 of 12

8 LOT 5 IA2/IA1 Steel Drums LLW Repository Ltd requires a supplier to provide IA2/IA1 and 6HA1 Drums UN approved packaging Group X or Y. Ideally a single design is sought to suit all forms of waste and disposal method. It will typically have a capacity of 200ltr. for the transport of solid and liquid radioactive waste. They shall be tested to demonstrate IP-2 compatibility with decommissioning arrisings. Due to the nature of materials to be shipped it is essential that a robust quality control is in place. The supplier is required to have a capacity to respond to orders as short notice or with a storage area available to stock items, to minimise lead in time to release units to LLW Repository Ltd customers. There are three variants in use today, however, a single multiuse design option is preferred: TC14 Liquid/Solid variant TC14 Liquid/Solid IP-2 Drum Dimensions (External) Diameter Maximum Width (with clamping bolt fitted) Height 606mm 634mm 885mm Payload Capacity Material 280kg 20kg Mild Steel TC19 Variant Dimensions (External) TC19 Solid Supercompactable IP-2 Drum Diameter Maximum width (with clamping bolt fitted) Height 585mm 600mm 867mm Payload Capacity Maximum Gross Weight Material 280kg 20kg 300kg Mild Steel LLW Repository will review and accept all manufacturing records prior to acceptance of the goods. An indication of quantities required is: TC14-1,800 & TC19 2,500. These are subject to change as customers demand. Page 8 of 12

9 LOT 6 UN Approved Fibreboard Drums As a variant for waste that is sent for combustion, LLW Repository Ltd is seeking a 200ltr capacity fibreboard or similar drum that can be disposed of by combustion with the waste. It shall be UN approved to packaging group X or Y. It will typically have a capacity of 200ltr. for the transport of solid radioactive waste, and shall be tested to demonstrate IP-2 compatibility with decommissioning arrisings. Due to the nature of materials to be shipped it is essential that a robust quality control is in place. LLW Repository Ltd is seeking a supplier with a capacity to respond to orders as short notice or with a storage area available to minimise lead in time for LLW Repository Ltd customers. Page 9 of 12

10 LOT 7 UN Approved IP-1 Soft Sided Packages (FIBC) To support ongoing innovations, for the diversion of Very Low Level Waste (VLLW) to landfill sites LLWR has, designed and manufactured a prototype package system, known as the TC11 Transport Handling Frame (THF). This is designed to restrain and transport Soft Sided Packages (SSPs) for the transport of VLLW. The TC11 THF is based on a 20 ISO container footprint (as indicated in Lot 1) and has been designed to be transported by road, rail or sea. The SSP will form the inner containment system to the TC11 and the THF outer forms the payload restraint system (longitudinally, laterally and vertically). The package stacking capability, the conveyance restraint capability and the combination of the SSP and the THF satisfy all the requirements for an IP-1 package, with no modal restrictions. The TC11 package will primarily be used for the transport of VLLW to landfill (as LSA-I/SCO-I or Excepted Packages). However, subject to successful implementation of the TC11, and adoption of the SSP as an IP-1 package design, LLWR has designed the TC11 with LLW (as LSA-II/SCO-II) transport in its scope. The required dimensions of the SSP, providing a clearance fit into the split bays, are L 915mm x W 710mm x H 1145mm (approximately 0.73 m 3). The packaging shall be UN Approved Group X or Y. The SSP design shall incorporate features to minimise human intervention during handling, such as a lifting sock system. The Socks are to be self supporting to enable the equipment operator to engage the package directly using a FLT forks, with no need for dedicated lifting frames or use of SQEP lifting riggers and to avoid contents compaction. The SSP s shall conform to ISO 21898; 2004, and are required to prevent water ingress for up to 60 days, and ideally also conform to ISO 16495:2013 for carrying asbestos. The SSP, including the outer fastening system, will form the containment system, and must be able to withstand forces, vibrations, and temperature and pressure changes to be expected during Routine Conditions of Transport (RCT). Each consignment will require a respective Suppliers declaration of conformity conforming to ISO17050 parts 1 and 2. LLW Repository Ltd is seeking a supplier with a capacity to respond to orders as short notice or with a storage facility available to minimise lead in time for LLW Repository Ltd customers. Other variants may be required subject to customer demand such as flexible liners Page 10 of 12

11 Engineering Consultancy Support LOT 8 TC16 Over Container Optioneering and Concept Design We have a requirement to develop a new transport package, which is fully compliant with the requirements of the IAEA Regulations for the Safe Transport of Radioactive Material to enable the package to be licensed as a Type A/Type IP-2 package for the transport of solid form radioactive material. The package is to be used to transport the following solid form radioactive payloads by road and sea: large unpackaged items of contaminated plant and equipment destined for waste treatment facilities; and damaged (or non-compliant) Type IP-2 ISO freight containers containing low level radioactive waste. The initial task is to conduct an engineering study and develop concept design options for the new transport package; then to conduct a design optioneering study to determine the preferred option through down selection and; finally once the preferred option has been selected, produce a set of design proposal drawings with underpinning calculations/analyses which will then be used to initiate the detail design phase of the project. Note: The detail design is not included in this scope The scope of work is limited to the following tasks which, when completed, will be used to facilitate the detail design phase of the project by others: Conducting an engineering study to identify and develop preliminary concept design options for presentation at design optioneering study; Conducting a design optioneering study to determine preferred option through down selection and production of study report; Participation in HAZOP 1 study of preferred option; Production of a set of design proposal drawings for the preferred option with supporting calculations and analyses, which form the preliminary design package that will be used to initiate the detail design phase; and Production of a Mechanical Flow Diagram (MFD) and Sequence and Interlock Definition Document (SIDD) for the operation of the container door. These works are to take due cognisance of applicable National and European Regulations and in particular: IAEA Safety Standards: Regulations for the Safe Transport of Radioactive Material, Specific Safety Requirements No SSR-6, 2012 Edition IAEA Safety Standards: Advisory Material for the IAEA Regulations for the Safe Transport of Radioactive Material (2012 Edition), Specific Safety Guide No SSG-26 Supply of Machinery (Safety) Regulations 2008 Lifting Operations Lifting Equipment Regulations 1998 (LOLER) Pressure Equipment Regulations 1999 (SI 1999/2001) (PER) Provision and Use of Work Equipment Regulations 1998 (PUWER) Road Vehicles (Authorisation of Special Types) (General) Order 2003 (STGO) Due to its size and method of operation it requires specialist elements such as: Radiometrics, Electrics Hydraulics Use of lightweight/exotic Steels Programmable logic control Appreciation of ergonomics (operator safety) Page 11 of 12

12 Expected Timescale: to commence late in 2016 Page 12 of 12