Technical Operating Directive TPo-1140-2026-A: Technological Process for

Filling 155 mm M107 Shells

1. Cover Page and Administrative Identification
ZVS holding, a.s.

OPERATING DIRECTIVE I

Number: TPo-1140-2026-A Product: Filling 155 mm M107 obj. 507

Approval Block:

Title Signature
Head of TPV Special ____________________
BT (Safety Technician) ____________________
Production Director ____________________
Technical Director ____________________
Authorized Person ____________________

Administrative Information:

 Location: Dubnica nad Váhom

 Date: 26.03.2026
 Prepared by: Bc. Martin Šaray
 Total Sheets: 70
 Document ID: E300-ZVH-FO002

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2. Training and Record of Changes

MSM GROUP Attendance List / Record of Briefing

Subject: Filling 155 mm M107 obj. 507 Duration: 8 Hours Date: 26.03.2026

By signing below, I confirm that I have participated in the training, fully understood the subject matter concerning the briefing, and undertake to follow the
rules and principles presented in this directive during the performance of my duties.

Seq. No. Name Surname Signature

1. — — —
2. — — —
3. — — —

Instructor: Bc. Martin Šaray Organization: ZVS Holding

Overview of Changes

No. Date Change Recorded by

1. 26.03.2026 Initial Release Bc. Martin Šaray

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3. Production Flow and Equipment List

 Production Flow Sketch (Náčrt toku výroby obj.)
 List of Machines and Equipment 507 (Zoznam strojov a zariadení 507)

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4. Personnel Requirements for Laboratory Groups

Required personnel for laboratory operations on objective 507:

Number of
Laboratory Group Operation
Workers
Group 2: Shell Transport of shells/chemical materials, preparation of asphalt lacquer, internal
4
Preparation cavity spraying, inspection, and repair of non-conforming shells/threads.
Group 3: TNT TNT transport/tempering, shell unloading, batch formation, screw filling,
7
Screw Filling density/volume control, waste TNT preparation and disposal.
Group 4: Post- TNT face cleaning/milling, cavity painting, fuse cavity inspection, thread gauging,
3
Filling Cleaning pallet marking, and transport to final assembly.
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5. Personal Protective Equipment (PPE) Inventory

TPo
PPE Name Description / Standard Requirements / Alternatives
Desig.
ESD Trousers IEC 61340-5-1:2016 Required Resistance R < 1.0 x 10⁹ Ω
ESD T-shirt IEC 61340-5-1:2016 Required Resistance R < 1.0 x 10⁹ Ω
ESD Blouse IEC 61340-5-1:2016 Required Resistance R < 1.0 x 10⁹ Ω
ESD Long-sleeve IEC 61340-5-1:2016 Required Resistance R < 1.0 x 10⁹ Ω
ESD Footwear IEC 61340-5-1:2016 Required Resistance R < 1.0 x 10⁹ Ω
Anti-cut ESD Tegera 803 / EN 388:2016+A1:2018
1 Resistance R < 1.0 x 10⁹ Ω
Gloves (4X42B)
Chemical Half-
3M with filters 3M ABEK16059 8 Mask: EN 136 / Filter: EN 14387+A1
mask
Protective Apron Red - Struve 9 EN ISO 13688 / EN 340
Clear ESD
E 4012 (anti-impact/chemical/heat) 10 EN 166
Goggles
Face Shield Polycarbonate 11 Anti-impact and chemical protection
Hearing
3M Optime II (SNR 31 dB) 12 EN 352-1
Protection
Antistatic EN 139 82-1, EN 13034, EN 1149-5, EN 14126,
For spraying operations 13
Clothing EN 1073-2
Foam Earplugs Disposable (SNR 35 dB) 14 EN 352-2 / EN 13819

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6. Operational Procedure: Laboratory Group No. 1 - Incoming Inspection

Op. Execution
Precise Name and Procedure Executed by
No. Object
Quality
0100 Incoming Inspection 507
Controller
Incoming inspection of components is performed in accordance with Quality
0101 507
directive H540-ZVS-QMA-VS001. Controller

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7. Operational Procedure: Laboratory Group No. 2 - Shell Preparation

Op.
Procedure Description Tools / PPE Executed by
No.
Ordnance
0100 Delivery of Shells to the Facility PPE: 1
Storekeeper
Transport shells in pallets or gitterboxes to the exterior of Object 507. Verify Explosion-proof Storekeeper /
0101
quantities against the delivery note. Forklift Operator
Inspect pallets/gitterboxes for damage; report defects to the foreman immediately.
0102 Pallet truck Storekeeper
Unload shells and place in Room 120 for tempering.
0103 Remove empty pallets/gitterboxes from the workspace after unloading. — Storekeeper
Separate and load shell packaging material into designated waste collection
0104 Waste containers Operator
containers.
0200 Chemical Material Delivery — Storekeeper
0201 Transport required chemical materials (lacquer, solvents) to the site. Forklift Storekeeper
0300 Preparation of Asphalt Lacquer PPE: 5, 10/11, 8 Operator
Mixing Procedure: 1. Open A1010 container and clean the filling hole. 2.
4mm Viscosity
Remove any dry skin from the lacquer surface and lid. 3. Thoroughly stir the
cup, Wooden
0301 entire contents. 4. Transfer A1010 to the supply tank in Room 122. 5. Dilute with Operator
stirrer, Stop-
S6006 solvent as required. Check viscosity with a 4 mm flow cup (Target: 28–30
watch
seconds). 6. Fill the secondary tank with pure solvent for spray gun cleaning.
0302 Transfer diluted lacquer to individual reservoirs in Room 122. — Operator
0400 Internal Cavity Spraying PPE: 1 Operator
Prepare shells, 100% cotton rags, and 2" thread covers at the workplace (Room
0401 Cotton rags Operator
121).
0402 Insert the manipulation/centering device into the 2" fuse thread. Centering device Operator
0403 Place the shell into the spraying machine basket using the manipulator. Basket / Table Operator
0404 Remove the centering device and install the protective thread cover. Thread cover Operator
Automatic
0405 Initiate the automatic cycle. The table rotates while the internal cavity is coated. Operator
sprayer
After spraying, hold the black panel buttons to stop the table and open the safety
0406 Control panel Operator
cover.
0500 Inspection and Drying PPE: 1 Operator
 Inspect the internal coating with an ATEX flashlight. Verify no leaks, bubbles, Flashlight,
0501 Operator
bare spots, or foreign bodies. Wooden rod
0503 Shells must dry for approximately 24 hours in Room 123. — Operator
PPE: 1/4/5, 8, 9,
0600 Repair of Non-conforming Shells Operator
14
Manual taps,
Thread Repair: Use manual taps (2"-12 UN-2B) to repair damaged fuse threads.
0601 Thread gauge, Operator
Repair base threads as needed. Use fine files to smooth burrs on driving bands.
Fine file

Note on Shell Tempering: a) Empty shells must be tempered in Room 120 for a minimum of 24 hours during winter months. b) WARNING: When
transporting with a forklift, unload the top gitterbox first if stacked to prevent pallet instability. Maximum 3 empty pallets or 2 gitterboxes may be stacked.

Note on Chemicals: c) Chemical materials must have valid laboratory approval. d) Materials must be tempered for 24 hours at room temperature. e) Lacquer
that has frozen during transport or storage must be discarded and excluded from production.

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8. General Technical Requirements for TNT Filling

1. 155 mm shells are filled with TNT manufactured and accepted per technical conditions. Quality must be confirmed by a laboratory certificate and
chemical report.
2. Only two batches of TNT from the same production year are permitted per filling series unless TP-Dc-185-20 specifies otherwise.
3. Health and safety regulations per instruction TP-Dc-175-19 must be strictly observed.
4. TNT is delivered in marked boxes (series, batch, sequence number).
5. Enterprise laboratory inspections are mandatory for every TNT series.
6. Incoming TNT must undergo chemical laboratory testing for conformity.
7. Shells from the mechanical plant must undergo incoming inspection prior to filling.
8. TNT must be stored in dry, unheated warehouses and tempered at +16 °C to +30 °C for at least 24 hours before processing.
9. Filling is performed strictly according to current technical conditions.
10. Shells must be tempered to +40 ± 5 °C before filling begins.
11. Before starting (or after a 1-hour pause), the equipment must be tested with 3 "divided" shells to verify density.
12. All internal cavities must be coated with asphalt lacquer.
13. Shells are organized into batches, including control shells (divided and volume shells).
14. TNT quality and structure are monitored using control shells.
15. Required TNT Density (Screw/Auger Filling):
o Actual average density of the whole charge: min 1.50 [Link]⁻³.
o Density at cut 6, 11: min 1.49 [Link]⁻³.
o Density at cut 16: min 1.52 [Link]⁻³.
o Density at cut 19: min 1.56 [Link]⁻³.
16. Charge evaluation is performed per TP-Dc-185-20.
17. If density fails to meet requirements, the entire batch must be re-processed.
18. Automatic thermohygrographs must record temperature and relative humidity in all TNT workspaces.

Prepared by: Bc. Martin Šaray | Date: 26.03.2026

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9. Operational Procedure: Laboratory Group No. 3 - TNT Filling (Screw/Auger Method)

Op. Executed
Procedure Description Tools / PPE
No. by
0100 TNT Transport and Tempering PPE: 1 Storekeeper
Temper TNT in Room 508 for at least 24 hours at a minimum temperature of
0105 Thermohygrograph Operator
+16 °C.
0200 Delivery to Workplace PPE: 1, 8, 10/11 Operator
0202 Transport a maximum of 300 kg TNT to Room 104 on Euro-pallets. Pallet truck Operator
Open boxes, visually check TNT, and record temperatures in the daily log Non-contact
0203 Operator
H430-ZVS-VYR-FO012-A. thermometer
0400 Batch Formation PPE: 1 Operator
Mark shells with batch and sequence numbers on the ogive using a permanent
0401 Marker Operator
marker.
Standard Batch (34 shells): Shell No. 1 is divided, No. 8 and 25 are volume
0402 — Operator
shells.
High-Volume Series (102 shells): Permitted after 5 laboratory series. Shell
0403 — Operator
No. 1 is divided, No. 16, 31, 66, and 81 are volume shells.
0700 Filling via Screw Machine PPE: 1 Operator
Perform filling using the single-spindle screw filling machine. Control is
0701 Screw machine Operator
managed by trained personnel at the desk.
1100 Density Control (Divided Shells) PPE: 1, 10/11, 8 Operator
1109 Calculate average density (\zeta_o) using the formula: — Operator

Density Formula: \zeta_o = \frac{m_p - m_t}{m_v - m_t} \cdot \zeta_v \text{ [kg/dm³]} Where:

 m_t: mass of empty shell

 m_v: mass of shell filled with water
  m_p: mass of shell filled with TNT
 \zeta_v: density of water

Op. Executed
Procedure Description Tools / PPE
No. by
1110 Record the calculated density. Required result: min 1.53 kg/dm³. Logbook Operator
1113 Use brass scrapers to open the divided shells for inspection. Brass scraper Operator
1200 Volume Shell Preparation PPE: 1/4 Operator
Fill the shell with water to a depth of 57.5–58.5 mm. Determine internal volume
1205 Depth gauge Operator
using a depth gauge.
1300 Waste TNT Handling and Labeling PPE: 8 Operator
Collect contaminated TNT (from filters/sweepings) into boxes labeled Non-sparking
1301 Operator
"Contaminated TNT". shovel
Collect clean waste TNT (from hoppers/overflow) into boxes labeled "Clean Used
1302 — Operator
TNT".

Safety Warnings:

 Maximum storage load in Room 508: 3,600 kg TNT.

 Maximum TNT load in Room 104: 300 kg.
 Filled shells must cool for at least 6 hours at room temperature before being opened for density checks (Op 1110).
 Filling workspace must be cordoned off and marked with warning signs. Access is restricted to authorized personnel.

Prepared by: Bc. Martin Šaray | Date: 26.03.2026

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10. Operational Procedure: Laboratory Group No. 4 - Post-Filling Cleaning and Final Inspection
I. Technical Requirements for TNT Face:

1. Fuse Cavity Shape:

o Depth must be between 57.5 mm and 58.5 mm.
o Face must be free of irregularities; surface finish must not exceed a milling depth of 3 mm.
2. Surface Finish: The TNT face must be coated with 40% shellac lacquer.
3. Tolerances: Small bubbles on the TNT surface are permitted only if they do not exceed 1 mm in diameter and are scattered.

II. Safety Measures:

 Mobile phones, matches, or any fire-producing items are strictly prohibited in the workspace.
 PPE must be worn at all times as designated for each operation.
 Escape routes and fire-extinguishing equipment must remain unobstructed.
 Daily maintenance checks of milling/cleaning machinery are mandatory before the shift starts.

III. Special Safety Regulations for Milling:

 TNT must only be transported in approved packaging.

 Spilled TNT must be swept up immediately using non-sparking tools and placed in waste containers.

 No foreign objects (tools, parts) are permitted in the immediate milling area.

Prepared Op. Executed by: Bc. Martin

Procedure Description Tools / PPE
Šaray No. by
| Date: 26.03.20 0300 Final Cavity and Thread Inspection PPE: 1, 10/11, 8 Operator 26
0301 Visually check the shellac coating. Ensure no bubbles, peeling, or bare spots. ATEX Flashlight Operator
Gauge DL-Ema
0302 Verify fuse cavity depth (57.5–58.5 mm) using the specified gauge. Operator
2754
Ensure no TNT residues remain in the fuse threads. Cleaning must be performed
0304 Thread cleaner Operator
with non-sparking instruments.
0400 Pallet Marking and Transport PPE: 1 Operator
Attach identification labels to each pallet including: Shell type, Card number,
0401 Labels Operator
Batch, Series, TNT manufacturer, and Date.
0402 Secure pallets with steel strapping for transport to final assembly. Steel strapping Operator
0501 Waste TNT Disposal — Storekeeper
Consolidate waste TNT for destruction following the procedures established in
0501 — Storekeeper
Group 3, Op 1400.

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11. Document Footers and Sign-off

Prepared by: Bc. Martin Šaray Date: 26.03.2026

Approved by:
  Head of TPV Special: ____________________
 BT (Safety Technician): ____________________
 Production Director: ____________________
 Technical Director: ____________________
 Authorized Person: ____________________

END OF DIRECTIVE TPo-1140-2026-A