ML23213A145
| ML23213A145 | |
| Person / Time | |
|---|---|
| Site: | 07001113 |
| Issue date: | 08/02/2023 |
| From: | Mathis R NRC/RGN-II/DFFI |
| To: | Huth R Global Nuclear Fuel - Americas |
| References | |
| IR 2023002 | |
| Download: ML23213A145 (1) | |
Text
August 2, 2023 Ryan Huth Facility Manager Global Nuclear Fuel - Americas, LLC P.O. Box 780, Mail Code J20 Wilmington, NC 28402
SUBJECT:
GLOBAL NUCLEAR FUEL - AMERICAS, LLC - CORE INSPECTION REPORT 07001113/2023002
Dear Ryan Huth:
On June 30, 2023, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection at Global Nuclear Fuel - Americas, LLC. On May 25, 2023, the NRC inspectors discussed the results of this inspection with Mr. Scott Murray and other members of your staff. The results of this inspection are documented in the enclosed report.
No violations of more than minor significance were identified during this inspection.
This letter, its enclosure, and your response (if any) will be made available for public inspection and copying at http://www.nrc.gov/reading-rm/adams.html and at the NRC Public Document Room in accordance with Title 10 of the Code of Federal Regulations 2.390, Public Inspections, Exemptions, Requests for Withholding.
Sincerely, Signed by Mathis, Robert on 08/02/23 Robert Mathis, Chief (Acting)
Projects Branch 1 Division of Fuel Facility Inspection Docket No. 07001113 License No. SNM-1097
Enclosure:
As stated cc w/ encl: Distribution via LISTSERV
ML23213A145 Non-Sensitive Publicly Available SUNSI Review Sensitive Non-Publicly Available OFFICE RII: DFFI RII: DFFI RII: DFFI RII: DFFI NAME P. Startz G. Goff J. Rivera R. Mathis DATE 08/01/2023 08/01/2023 08/02/2023 08/02/2023 U.S. NUCLEAR REGULATORY COMMISSION Inspection Report Docket Number: 07001113 License Number: SNM-1097 Report Number: 07001113/2023002 Enterprise Identifier: I-2023-002-0063 Licensee: Global Nuclear Fuel - Americas, LLC Facility: Global Nuclear Fuel - Americas, LLC Location: Wilmington, NC Inspection Dates: May 22, 2023, to May 25, 2023 Inspectors: G. Goff, Fuel Facilities Inspector J. Grice, Fuel Facilities Inspector (In-Training)
P. Startz, Fuel Facilities Inspector Approved By: Robert Mathis, Chief (Acting)
Projects Branch 1 Division of Fuel Facility Inspection Enclosure
SUMMARY
The U.S. Nuclear Regulatory Commission (NRC) continued monitoring the licensees performance by conducting a core inspection at Global Nuclear Fuel - Americas, LLC, in accordance with the fuel cycle facility inspection program. This is the NRCs program for overseeing the safe operation of licensed fuel cycle facilities. Refer to https://www.nrc.gov/materials/fuel-cycle-fac.html for more information.
List of Violations No violations of more than minor significance were identified.
Additional Tracking Items Type Issue Number Title Report Section Status WER 07001113/2023-001-00 Concurrent Report - Fire 88020 Closed Door Malfunction (EN 56523) 2
INSPECTION SCOPES Inspections were conducted using the appropriate portions of the inspection procedures (IPs) in effect at the beginning of the inspection unless otherwise noted. Currently approved IPs with their attached revision histories are located on the public website at http://www.nrc.gov/reading-rm/doc-collections/insp-manual/inspection-procedure/index.html. Inspections were declared complete when the IP requirements most appropriate to the inspection activity were met consistent with Inspection Manual Chapter (IMC) 2600, Fuel Cycle Facility Operational Safety and Safeguards Inspection Program. The inspectors reviewed selected procedures and records, observed activities, and interviewed personnel to assess licensee performance and compliance with Commission rules and regulations, license conditions, site procedures, and standards.
SAFETY OPERATIONS 88020 - Operational Safety The inspectors evaluated selected aspects of the licensees Operational Safety program to verify compliance with selected portions of 10 CFR 70, including 70.24, 70.61, 70.62, and Chapter 11, Management Measures, of the facilitys license application, and applicable licensee procedures.
Identification of Safety Controls and Related Programs (IP Section 02.01)
The inspectors selected specific process areas for inspection based on the safety basis information of the facility, the risk/safety significance of the process areas, the description of plant changes submitted to the NRC, and past plant performance documentation. For the process areas of interest, the inspectors selected a sample of accident sequences in nuclear criticality safety, radiation safety, fire safety, and chemical safety based on the information provided in the integrated safety analysis (ISA) summary. The inspectors conducted a general plant tour of each major plant operating area. The accident sequences selected for review are listed below:
5.1.5.1 - Cylinder High Temperature 5.1.5.2 - Heating an Overweight Cylinder 5.1.5.3 - Heating a Pressurized Cylinder 5.2.5.1 - Cylinder High Temperature 5.2.5.8 - Loss of Containment Inside the Autoclave 5.5.3.2 - Powder Outlet Loss of Containment 5.5.3.3 - Moderator Leaks into Process Equipment - Powder Outlet 5.6.3.4 - Moderator Leaks into Homogenizer Equipment 5.8.3.1.4 - Excess Moderator Leaks into Process Equipment 5.8.3.1.5 - Loss of Containment Powder Pack (Un-controlled area) 5.8.3.2.2 - Excess Moderator Leaks into Process Equipment 5.10.5.4.2 - Buildup of Uranium in the Press Base 5.10.5.5.2 - Buildup of Uranium in the Scrap Press Base 5.10.5.6 - Breach of Feed Tube Outside Hood (loss of containment) 5.10.5.8 - Moderator Leaks into UO2 Press Room and the Gadolinium (GAD)
Area 5.10.5.13 - Scrap Press Feed Material Contains Wrong Constituents 3
5.11.5 12 - Hydrogen Explosion External to Furnace Review of Safety Controls and Related Programs (IP Section 02.02)
The inspectors reviewed information related to administrative, engineered, and passive safety controls or items relied on for safety (IROFS) for the accident sequences selected in Section 02.01, including the identification of the licensees assumptions and bounding cases as they apply to each of the selected accident sequences, safety controls, or IROFS. This review was performed to verify that the controls or IROFS were available and reliable to perform their intended safety functions and that the design basis assumptions were reflected in the actual conditions in the field. The specific safety controls selected for review are listed below:
IROFS 201-01, Vaporization Cylinder Temperature and Pressure Control System, active engineered control for Chemical Safety, and is bounded as described by QRA-201 IROFS 201-01, Vaporization Cylinder Temperature and Pressure Control System IROFS 201-02, Vaporization Autoclave Pressure Vessel IROFS 201-05, Autoclave Leak Detection System IROFS 201-06, Vaporization Sense and Flee IROFS 201-07, Vaporization Room Hydrogen Fluoride (HF) Alarm and Auto Shutdown System IROFS 201-03, Pigtail Leak Check IROFS 204-04, Process Equipment Barrier - Powder Outlet IROFS 205-08, Process Equipment Barrier - Homogenizer IROFS 207-02, Safe Geometry Powder Pack Process IROFS 207-08, FSB Control of Mass of Uranium - Powder Receipt IROFS 207-09, Process Equipment Barrier - Receipt Transfer Hood IROFS 207-10, Safe Geometry - Receipt Transfer Hood and Conveyor IROFS 401-04/503-01, Free Draining Press Base and Press Oil Catch Pan IROFS 401-05/503-02, Routine Inspection of Press Base IROFS 401-06/503-03, Pellet Press Area, Safe Geometry IROFS 401-07/503-04, Retooling Pellet Verification IROFS 402-01, Free Draining Press Base and Press Oil Catch Pan IROFS 401-08/503-05, Process Equipment Barrier, Pellet Press IROFS 401-09/503-06, Press Pellet Counter IROFS 401-10/503-07, Press Hood Level Sensor IROFS 402-11 Scrap Press Operator Present Floor Sensor IROFS 405-13, Hydrogen Supply Flow Restriction IROFS 405-14, Disassociated Ammonia (DA) Supply Flow Restriction IROFS 405-15/504-10, Furnace Area Flammable Gas Survey IROFS 405-16/504-11, Furnace Area Flammable Gas Line Inspection IROFS 405-17/504-12, Hydrogen Gas Leak Detection and Response IROFS 401-06/503-03, Pellet Press Area - Safe Geometry IROFS 401-08/503-05, Process Equipment Barrier - Pellet Press IROFS 401-09/503-06, Press Pellet Counter IROFS 401-10/503-07, Press Hood Level Sensors (Optical Sensor)
IROFS 401-11/503-08, Process Equipment Barrier - Press Conveyor 4
IROFS 401-12/503-09, Take-Off Table Storage Control IROFS 900-03, GNF-A Facility MRA IROFS 900-06, Safe Geometry - Transportable Container IROFS 900-07, Process Equipment Barrier - Transportable Container Implementation of Safety Controls (IP Section 02.03)
For the selected safety controls listed above, the inspectors reviewed management measures to verify proper implementation in accordance with 10 CFR 70 and applicable sections of the license application. This review was performed to verify that selected safety controls or IROFS were present, available, and reliable to perform their safety function and that the design basis assumptions were reflected in the actual conditions in the field. The inspectors conducted the following activities to verify the implementation of selected safety controls:
performed walkdowns of:
o vaporization process equipment o sintering furnaces in UO2 and GAD o ceramics process area o pellet press area o hydrogen and DA supply tanks and supply lines reviewed the implementation of IROFS 201-01 (pressure and temperature controls on an autoclave) reviewed the following quantitative risk assessments:
o QRA-406/505, Fabrication-Grind, Revision (Rev.) 19 o QRA-204A, Dry Conversion Process: Powder Outlet, Rev. 4 o QRA-207, Powder Pack/Receipt, Rev. 15 o QRA-401/503, Fabrication-Press, Rev. 21 o QRA-405a/504a, Fabrication-Sinter-Hydrogen Gas Release, Rev. 11 reviewed and walked down the following piping and instrumentation drawings (P&IDs):
o A26-ME50, Fuels Manufacturing Dry Conversion Process UDD Hydrogen System, Rev. 6 o P&ID, DA Building New Equipment Room, Rev. 1.0 o P01 1331, Dry Conversion Process (DCP) Vaporization (Line 2) P&ID, Rev. 18 reviewed procedures pertaining to DCP Vaporization and UO2 Sintering (See the listing in the Documents Reviewed section of this inspection report.)
Safety Control Support Programs (IP Section 02.04)
The inspectors assessed additional management measures that support the availability and reliability of the selected safety controls to verify these were implemented in accordance with 10 CFR 70 and applicable sections of the license application. Specifically, the inspectors conducted the following activities:
reviewed the following condition reports (CRs) entered in the corrective action program (CAP) for IROFS-related issues:
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o CR 39458, 05/01/2022 o CR 40219, 08/01/2022 o CR 40288, 08/01/2022 o CR 40297, 08/23/2022 o CR 40599, 09/27/2022 o CR 41038, 11/18/2022 o CR 41381, 01/09/2023 o CR 41422, 01/14/2023 o CR 41584, 02/02/2023 o CR 42106, 03/24/2023 o CR 42232, 04/06/2023 o CR 42246, 04/07/2023 o CR 42547, 05/14/2023 o CR 42551, 05/18/2023 o CR 42637, 05/25/2023 reviewed NRC License SNM 1097, Triennial Audit - 2022 reviewed work orders/functional test instructions for maintenance and calibrations for IROFS (see the "Documents Reviewed" section of this inspection report) observed control room operators perform remote verification functions for IROFS associated with the autoclaves conducted interviews with operators in processing/production areas regarding their responses to accidents and other off-normal conditions INSPECTION RESULTS WER Concurrent Report - Fire Door Malfunction (EN 56523) 88020 (Closed) WER 07001113/2023-001-00
Description:
On May 18th, 2023, the licensee submitted a concurrent notification to the NRC per 10 CFR 70, Appendix A(c), for a notification made to the New Hanover County Deputy Fire Marshal. The notification was associated with a fire door of the DCP elevator shaft that failed in the open position. The DCP elevator is located on the south wall of the DCP which is a credited fire barrier. The licensee initiated and maintained a fire watch until the elevator door was closed at approximately 1030 EDT on May 18th. The elevator was restored to full operation at approximately 1330 EDT on May 18th. The licensee submitted a written event report (WER) to the NRC on July 14, 2023 (ADAMS ML23195A094).
The inspectors interviewed licensee staff, walked down the affected process area, and reviewed the short term corrective actions for this issue during the Operational Safety inspection conducted under IP 88020. No violations of NRC requirements were identified.
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EXIT MEETINGS AND DEBRIEFS The inspectors verified no proprietary information was retained or documented in this report.
On May 25, 2023, the inspectors presented the operational safety (IP 88020) inspection results to Scott Murray and other members of the licensee staff.
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DOCUMENTS REVIEWED Inspection Type Designation Description or Title Revision or Procedure Date 88020 Calibration WO#: 5204751 F8A11310 Calibration (IROFS 201-07) 07/29/2022 Records 88020 Calibration WO#: 5204752 F8A11330 Calibration (IROFS 201-07) 07/29/2022 Records 88020 Calibration WO#: 5204753 F8A11350 Calibration (IROFS 201-07) 07/29/2022 Records 88020 Calibration WO#: 5204775 F8P11101 Calibration (IROFS 201-01) 07/28/2022 Records 88020 Calibration WO#: 5204777 F8P11121 Calibration (IROFS 201-01) 07/28/2022 Records 88020 Calibration WO#: 5219576 F8A11309 Calibration (IROFS 201-05) - HF Detector 09/16/2022 Records 88020 Calibration WO#: 5219577 F8A11329 Calibration (IROFS 201-05) - HF Detector 09/16/2022 Records 88020 Calibration WO#: 5264049 F8S11000 Calibration (IROFS 201-01) 04/05/2023 Records 88020 Calibration WO#: 5264050 F8S11020 Calibration (IROFS 201-01) 04/05/2023 Records 88020 Calibration WO#: 5264053 F8S11101Calibration (IROFS 201-01) 04/05/2023 Records 88020 Calibration WO#: 5264054 F8S11121 Calibration (IROFS 201-01) 04/05/2023 Records 88020 Calibration WO#: 5264056 F8S11309 Calibration (IROFS 201-05) 04/05/2023 Records 88020 Calibration WO#: 5264057 F8S11310 Calibration (IROFS 201-07) 04/05/2023 Records 88020 Calibration WO#: 5264058 F8S11329 Calibration (IROFS 201-05) 04/05/2023 Records 88020 Calibration WO#: 5264059 F8S11330 Calibration (IROFS 201-07) 04/05/2023 Records 88020 Calibration WO#: 5264060 F8S11350 Calibration (IROFS 201-07) 04/05/2023 Records 8
Inspection Type Designation Description or Title Revision or Procedure Date 88020 Calibration WO#: 5264258 FMACX002 Calibration (IROFS 405-15) 04/26/2023 Records 88020 Corrective Action Condition Report HF Leak 05/01/2022 Documents # 39458 88020 Corrective Action Condition Report Acrawax Buildup in Bicone 08/01/2022 Documents #40219 88020 Corrective Action Condition Report HF Leak 08/1/2022 Documents #40288 88020 Corrective Action Condition Report Powder Leaking form Tumbler 08/23/2022 Documents #40297 88020 Corrective Action Condition Report Storage Conveyor Geometry 09/27/2022 Documents #40599 88020 Corrective Action Condition Report Fire barrier surveillance 11/18/2022 Documents #41038 88020 Corrective Action Condition Report HF Leak 01/09/2023 Documents #41381 88020 Corrective Action Condition Report GAD furnace pilot light 01/14/2023 Documents #41422 88020 Corrective Action Condition Report Ceramics storage area can lid seal 02/02/2023 Documents #41584 88020 Corrective Action Condition Report Incorrect Enrichment Blend 03/24/2023 Documents #42106 88020 Corrective Action Condition Report BPG oil gearbox 04/06/2023 Documents #42232 88020 Corrective Action Condition Report DSR Virbromil Water Spill 04/07/2023 Documents #42246 88020 Corrective Action Condition Report Line 2 Arm motor 05/14/2023 Documents #42547 88020 Corrective Action Condition Report Malfunctioned Fire Door 05/18/2023 Documents #42551 88020 Corrective Action SACR #40219 Safety Assessment for Condition Report 40219 08/01/2022 Documents 88020 Corrective Action SACR #40288 Safety Assessment for Condition Report 40288 08/01/2022 Documents 9
Inspection Type Designation Description or Title Revision or Procedure Date 88020 Corrective Action SACR #41107 Safety Assessment for Condition Report 41107 11/30/2022 Documents 88020 Corrective Action SACR #41381 Safety Assessment for Condition Report 41381 01/09/2023 Documents 88020 Corrective Action SACR #41584 Safety Assessment for Condition Report #41584 02/02/2023 Documents 88020 Corrective Action SACR #42246 Safety Assessment for Condition Report #42246 04/07/2023 Documents 88020 Corrective Action Condition Report IROFS 405-13, Hydrogen Flow Restriction 05/25/2023 Documents #42637 Resulting from Inspection 88020 Drawings A26-ME50 Fuels Manufacturing Dry Conversion Process UDD Rev. 6 Hydrogen System 88020 Drawings P&ID DA Building New Equipment Room Rev. 1.0 88020 Drawings P01 1331 Dry Conversion Process Vaporization (Line 2) P&ID Rev. 18 88020 Miscellaneous License Renewal Application 11/2008 88020 Miscellaneous IRS 201-01 IROFS 201-01 Vaporization Cylinder Temperature and Rev. 2 Pressure Control 88020 Miscellaneous IRS 201-07 IROFS 201-07 Vaporization Room HF Alarm and Automatic Rev. 02 Shutdown System 88020 Miscellaneous IRS 201-07 Vaporization Room HF Alarm and Automatic Shutdown 12/14/2016 System 88020 Miscellaneous QRA - 406/505 Fabrication - Grind Rev. 19 88020 Miscellaneous QRA-204A Dry Conversion Process: Powder Outlet Rev. 4.0 88020 Miscellaneous QRA-207 Powder Pack/Receipt Rev. 15 88020 Miscellaneous QRA-401-503 Fabrication - Press Rev. 21 88020 Miscellaneous QRA-405a/504a Fabrication - Sinter - Hydrogen Gas Release Rev. 11 88020 Miscellaneous SPM 23-003 Update ISA Summary for the Global Nuclear Fuel Facility Rev. 26 M230006 88020 Miscellaneous TD 405-13 Hydrogen Supply Flow Restriction Rev. 0 88020 Procedures OP 201.00.203 DCP Vaporization - Autoclave Loading Rev. 6 88020 Procedures OP-1020.13.100 3B, 4B, and 6B Rotary Presses - General Information Rev. 1 ADMIN 10
Inspection Type Designation Description or Title Revision or Procedure Date 88020 Procedures OP-1020.13.201 3B, 4B, and 6B Rotary Presses - Startup Rev. 3.0 88020 Procedures OP-1020.13.203 3B, 4B, and 6B Rotary Presses - Normal_Operations Rev. 9 88020 Procedures OP-1020.13.203 3B, 4B, and 6B Rotary Presses - Normal Operations Rev. 9.0 88020 Procedures OP-1030.00.200 UO2 Sintering Furnace Room Flammable Gas Leak Rev. 00 88020 Procedures OP-1030.10.100 UO2 Sintering Furnaces 1,3,4,6 - General Information Rev. 6 88020 Procedures OP-1030.10.207 UO2 Sintering Furnaces 1, 3, 4, 6 - Basic Operator Rev. 7 Maintenance 88020 Procedures OP-1030.20.100 UO2 Sintering Furnace #2 - General Information Rev. 7 88020 Procedures OP-1030.20.207 UO2 Sintering Furnace #2 - Basic Operator Maintenance Rev. 5 88020 Procedures OP-1070.35.100 GAD Shop Rotary Press - General Information 88020 Procedures OP-1070.35.201 GAD Shop Rotary Press - Startup Rev. 3.0 88020 Procedures OP-1070.35.203 GAD Shop Rotary Press - Normal Operations Rev. 6.0 88020 Procedures OP-1070.40.200 GAD Sintering Furnace Room Flammable Gas Leak Rev. 0 88020 Procedures OP-201.00.201 DCP Vaporization-Pre Startup Rev. 1 88020 Procedures OP-201.00.204 DCP Vaporization-Vaporization Process Rev. 2 88020 Procedures OP-201.00.210 DCP Vaporization-Alarm Response and Emergency Rev. 2A Operations 88020 Procedures OP-204.00.100 DCP Powder Outlet General Info Rev. 2 88020 Procedures OP-2200.00.100 Powder Receipt Facility-General Information Rev. 6 88020 Procedures OP-2200.00.202 Powder Receipt Facility-Normal Operations (Outer Area) Rev. 4 88020 Self-Assessments NRC License SNM 1097, Triennial Audit-2022 88020 Work Orders ID#: 3059399 IROFS Surveillance - Monthly - IROFS 405-15 & IROFS 04/10/2023 504-10 88020 Work Orders ID#: 3063046 IROFS Surveillance - Annual - IROFS 405-16 & IROFS 504- 04/27/2023 11 88020 Work Orders ID#: 3120095 IROFS Surveillance - Annual - IROFS 401-06 03/09/2023 88020 Work Orders ID#: 3120104 IROFS Surveillance - Annual - IROFS 503-05 & IROFS 503- 03/09/2023 08 88020 Work Orders ID#: 3120107 IROFS Surveillance - Annual - IROFS 401-08 & IROFS 401- 04/27/2023 11 11