ML25329A005
| ML25329A005 | |
| Person / Time | |
|---|---|
| Site: | Westinghouse |
| Issue date: | 11/25/2025 |
| From: | Eric Michel NRC/RGN-II/DFRSS/FOB2 |
| To: | Stutts R Westinghouse |
| References | |
| IR 2025003 | |
| Download: ML25329A005 (0) | |
Text
Roy Stutts Site Director Westinghouse Electric Company 5801 Bluff Road Hopkins, SC 29061
SUBJECT:
WESTINGHOUSE COLUMBIA FUEL FABRICATION FACLITY - INTEGRATED INSPECTION REPORT 07001151/2025003
Dear Roy Stutts:
This letter refers to the U.S. Nuclear Regulatory Commission (NRC) inspection activities conducted from July 1 to September 30, 2025. On September 25, 2025, the NRC inspectors discussed the results of these inspections with you and other members of your staff. The results of the inspections are documented in the enclosed report.
No violations of more than minor significance were identified during this inspection.
Due to the temporary cessation of government operations, which commenced on October 01, 2025, the NRC began operating under its Office of Management and Budget-approved plan for operations during a lapse in appropriations. Consistent with that plan, the NRC operated at reduced staffing levels throughout the duration of the shutdown. However, the NRC continued to perform critical health and safety functions. On November 13, 2025, following the passage of a continuing resolution, the NRC resumed normal operations. However, due to the 43-day lapse in normal operations, the Office of Nuclear Materials Safety and Safeguards granted the Regional Offices an extension on the issuance of the calendar year 2025, 3rd quarter integrated inspection reports normally issued by November 15, 2025, to December 31, 2025. The NRC will resume the routine cycle of issuing inspection reports on a quarterly basis beginning with the calendar year 2025, 4th quarter integrated inspection reports, which will be issued 45 days after the 4th quarter ends on December 31, 2025.
November 25, 2025
R. Stutts 2
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, Eric C. Michel, Branch Chief Projects Branch 2 Division of Fuels, Radiological Safety, and Security Docket No. 07001151 License No. SNM-1107
Enclosure:
As stated cc w/ encl: Distribution via LISTSERV Signed by Michel, Eric on 11/25/25
SUNSI Review x
Non-Sensitive
Sensitive x
Publicly Available
Non-Publicly Available OFFICE RII/DFRSS RII/DFRSS RII/DFRSS NAME T. Vukovinsky B. Bout E. Michel DATE 11/25/2025 11/25/2025 11/25/2025
Enclosure U.S. NUCLEAR REGULATORY COMMISSION Inspection Report Docket Number:
07001151 License Number:
SNM-1107 Report Number:
07001151/2025003 Enterprise Identifier:
I-2025-003-0063 Licensee:
Westinghouse Electric Company Facility:
Westinghouse Columbia Fuel Fabrication Facility Location:
Hopkins, SC Inspection Dates:
September 22, 2025, to September 25, 2025 Inspectors:
T. Sippel, Branch Chief (acting)
C. Ubben, Fuel Facilities Inspector Approved By:
Eric C. Michel, Chief Projects Branch 2 Division of Fuels, Radiological Safety, and Security
2
SUMMARY
The U.S. Nuclear Regulatory Commission (NRC) continued monitoring the licensees performance by conducting an integrated inspection at Westinghouse Columbia Fuel Fabrication Faclity, 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 None.
3 PLANT STATUS The Westinghouse facility converts uranium hexafluoride (UF6) into uranium dioxide using a wet conversion process and fabricated fuel assemblies for use in commercial nuclear power reactors. During the inspection period, normal production activities were ongoing.
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 88015 - Nuclear Criticality Safety The inspectors evaluated selected aspects of the licensees Nuclear Criticality Safety program to verify compliance with selected portions of 10 CFR 70, including 70.24, 70.61, 70.62, and Appendix A, Chapter 6, Nuclear Criticality Safety (NCS) Program, of the facilitys license application, and applicable licensee procedures.
Criticality Analysis (IP Section 02.01)
The inspectors interviewed licensee staff and reviewed nuclear criticality safety evaluations (CSEs), and associated assumptions and calculations, to verify compliance with 10 CFR 70 and applicable sections of the license application, including 6.1.1, 6.1.2, 6.1.3.2, 6.1.3.4, 6.1.4, 6.1.5.2, 6.1.6. Specifically, the inspectors interviewed licensee staff and reviewed the following CSEs:
CN-CRI-07-18, "UF6 Cylinder Storage," Revision (Rev.) 1, which was reviewed because it contained a variety of calculations and information supporting the licensee's evaluation of accident sequences and IROFS in CSE-3-N.
CN-CRI-18-001, "MCNP6.1 Benchmark Calculations and Bias Determination for Homogeneous and Heterogeneous Systems at the CFFF Containing Uranium," Rev. 1, dated September 11, 2025; portions of which were reviewed because they had recently been changed.
CSE-3-N, "Criticality Safety Evaluation (CSE) for UF6 Cylinder Receipt and Handling," Rev. 12, including the review of what-if analysis, credible and incredible accident sequences; including scenarios involving vehicle accidents and fires.
CSE-5-A, "Criticality Safety Evaluation (CSE) for Ammonium Diuranate (ADU)
Bulk Blending System," Rev. 6; including the review of the changes, and the
4 what-if analysis, and credible accident sequences, including scenarios involving moderator introduction.
Additionally, the inspectors reviewed CN-CRI-20-003, "NCS Manual," Rev. 9, which contains guidance on the contents of CSEs, including what sequences can be determined to be incredible.
Criticality Implementation (IP Section 02.02)
The inspectors selected engineered and administrative controls from the licensees integrated safety analysis (ISA) summary to verify proper implementation through a review of process and system descriptions, plant walkdowns, and operator interviews to verify compliance with 10 CFR 70 and applicable sections of the license application, including 6.1.2, and 6.1.7. Specifically, the inspectors interviewed licensee staff and reviewed the following controls, and selected management measures, associated with the CSEs listed above and other selected areas:
ADUFZE-104, an administrative control on mass, including observing operators perform the control and reviewing their records PELPREP-915, an administrative control on moderator, including observing operations PELPREP-921, an administrative control on moderator, including observing operations UF6CYL-102, an administrative control on weight, including reviewing the posting UF6CYL-105, an administrative control on moderator and enrichment, including reviewing runsheets UF6CYL-901, an administrative control on moderator, including observations in the field, and reviewing log sheets UF6CYL-902, a passive engineered control (PEC) on moderator, including observing the control in the field and reviewing log sheets UF6CYL-903, an administrative control on moderator, including observations in the field and reviewing the posting UF6CYL-904, a PEC on moderator, including reviewing preventative maintenance records (e.g., Dispatch 302349)
UF6CYL-906, an administrative control on moderator, including reviewing the posting VENT-IFBA-125 and -126, administrative controls on concentration, including observing samples being taken, reviewing procedure steps, and reviewing log sheets Criticality Operational Oversight (IP Section 02.03)
The inspectors assessed the NCS staffs oversight of plant operators, procedures, and operations of systems involving special nuclear material to verify compliance with 10 CFR 70 and applicable sections of the license application, including 6.1.9. Specifically, the inspectors performed the following activities:
interviewed two IFBA operators about NCS controls and hazards, including long-term accumulation of Uranium in the IFBA scrubber
5 interviewed UF6 Area and ADU Pellet Press operators concerning criticality controls, including the use of IROFS during operations observed a licensee NCS engineer conduct a facility walkthrough assessment (FWA) in the ADU Pelleting Area and reviewed records of recent FWAs, including:
o "Conversion - Bulk Blending Operations," dated September 16, 2025 o
"URRS Bay Operator," dated September 15, 2025 o
"Pelleting - Powder Prep / Press Operator," dated September 16, 2025 o
"Conversion - Chief Operations and Various Containers," dated September 16, 2025 o
"Conversion - Conversion Operations and Various Containers," dated September 15, 2025 o
"IFBA FA3," dated September 16, 2025 Criticality Programmatic Oversight (IP Section 02.04)
The inspectors reviewed NCS program procedures and audits to verify compliance with 10 CFR 70 and applicable sections of the license application, including 3.6. Specifically, the inspectors interviewed licensee NCS staff and reviewed the following:
ISA audit by the licensee, which was documented in EHS-AUDIT-25-8, "ISA Compliance Audit Report," dated August 7, 2025 the most recent revision to licensee procedure RA-301, "Floor Storage of Special Nuclear Material," Rev. 29, dated July 24, 2025 COP-843002, "Control of Movable Non-Favorable Geometry Containers,"
Rev. 18 RA-302, "Criticality Postings," Rev. 18 Criticality Incident Response and Corrective Action (IP Section 02.05)
The inspectors reviewed the licensees criticality accident alarm system (CAAS) and corrective action program (CAP) to verify compliance with 10 CFR 70 and applicable sections of the license application, including 3.7, 3.8, and 6.1.8. Specifically, the inspectors interviewed licensee NCS staff and:
reviewed NCS-related CAP entries, including CAP entries that resulted from licensee FWAs, and associated documents walked down portions of the CAAS walked down the emergency operations center (EOC) and portions of the licensee's emergency response equipment interviewed the emergency preparedness manager about response to a criticality accident, including triage, and re-entry following a criticality accident FACILITY SUPPORT 88070 - Permanent Plant Modifications The inspectors conducted a review to verify the licensee had established and implemented a configuration management system to evaluate, implement, and track changes to the facility in
6 accordance with the applicable requirements in Title 10 of the U.S. Code of Federal Regulations (10 CFR) Section 70.72 and the license application, Chapter 3, Management Measures, and 3.1 Configuration Management. The inspectors review also verified that the licensee had established management measures for changes to the facility in accordance with 10 CFR 70, Subpart H and the license application, and that modifications involving new processes met the requirements in 10 CFR 70.64.
Sample Selection (IP Section 02.01)
The inspectors reviewed licensing documents, changes the licensee determined did not require pre-NRC approval under 10 CFR 70.72, and changes that affected the integrated safety analysis summary (ISA) to select changes/modifications to review. The inspectors selected the following plant modifications to assess whether the licensee conducted evaluations according to their established configuration management system, identified as Configuration Control Forms (CCFs):
CCF 22033, Installation of New Aqueous Waste Tanks CCF 22126, Upgrades to Pellet Line 5 Addback Feed System CCF 22184, Replacement of Piping Run Between Scrap Cage and Scrap Cage Gamma Monitor CCF 23020, Safety Strap Upgrade on Uranium Hexafluoride (UF6) Cylinder Wash CCF 23084, New High Efficiency Particulate Air (HEPA) Filter CCF 23164, Replacement of Fume Tank T-47 CCF 24003, Upgrades of Distributed Control System Software CCF 24012, Relocate and/or Decommission Sheds and Containers CCF 24182, Temporary Housing Installation for Incinerator Heat Exchanger Cooling Water Facility Change/Modification Process (IP Section 02.02)
The inspectors reviewed the selected modifications listed above to verify the licensee established a configuration management system in accordance with 10 CFR 70.72 and the conditions of the license. Specifically, the inspectors conducted the inspection activities listed below:
reviewed the following procedures to verify the configuration management system was documented in written procedures and the procedures addressed the aspects in 10 CFR 70.72(a) o FA-114, Independent Technical Reviews o
RA-104, Regulatory Review of Configuration Change Authorization o
RA-115, ISA Generation and Technical Reviews/License Amendment Requests o
RA-124, Process Hazard Analysis (PHA) o TA-500, Columbia Manufacturing Plant Configuration Control o
TA-500-10, Configuration Management Risk Assessment Board (RAB) Meeting interviewed licensee staff, performed walk-downs of the following CCFs, and reviewed the selected configuration management packages to verify the licensees evaluation of changes provided valid technical bases to determine
7 whether an amendment to the license was required based on the criteria in 10 CFR 70.72(c). Specifically, the following change packages were reviewed:
o CCF 22201 o
CCF 22033 o
CCF 22184 o
CCF 22126 reviewed facility documentation associated with the selected changes to verify the affected documents were updated in accordance with 10 CFR 70.72(e) or the timeframe outlined in the license reviewed configuration management system records to verify the licensee submitted a summary with facility changes and revised ISA Summary pages to the NRC in accordance with 10 CFR 70.72(d) attended RAB meeting where proposed facility changes were discussed and personnel from safety disciplines such as Nuclear Criticality Safety, Radiation Protection, and Industrial Safety were assigned responsibility to determine how the changes would affect their discipline and what actions would need to be taken prior to implementation Management Measures (IP Section 02.03)
For the selected modifications, the inspectors reviewed the management measures established for affected IROFS (or credited safety controls) to verify the management measures ensured the IROFS (or credited safety controls) were available and reliable to perform their intended function as required by 10 CFR 70.61 and the license. Specifically, the inspectors conducted the inspection activities listed below:
interviewed licensee staff and reviewed change management procedures to verify the licensee implemented the aspects described in configuration management system procedures and the license application interviewed licensee staff and reviewed affected procedures to verify the licensee followed the procedure control process in accordance with the license reviewed post-modification testing procedures to verify they ensured adequate implementation of the design and functionality of the following safety systems:
o CCF 22033
functional tests of WT-908 and WT-909 gamma monitor interlocks
in-service/closed loop test of vessels and associated piping systems o
CCF 22126
test report for the Advanced Doped Pellet Technology (ADOPT) Pellet Line 5 addback upgrades
pellet line 5 airflow balancing test sheets o
CCF 23164
Hydrostatic test report of tank T-47
Pre-startup safety review for installation of tank T-47 reviewed maintenance and surveillance records of selected modifications to verify the licensee established periodic maintenance and surveillance testing in accordance with the license o
verification of IROFS VENT-S2A2B-103 overflow capacity
8 o
verification of IROFS SOLX-101 and SOLX-102 vessel diameter and spacing between vessels o
analysis of IROFS SOLX-110 and SOLX-111 backflow prevention mechanisms in solvent extraction DI water supply o
analysis of ventilation performance for pellet line 5 addback upgrades o
independent technical reviews for CCFs 22126, 22184, 22033, 23164, and 23084 interviewed licensee staff and reviewed training records to verify the staff involved in facility changes were qualified in accordance with the license and plant procedures interviewed licensee staff and reviewed training records to verify the licensee conducted training on plant modifications in accordance with the license application and plant procedures reviewed condition reports to determine whether the licensee identified configuration management, post modification testing, and/or plant modification issues and corrected the condition in accordance with approved corrective action program procedures and the license.
reviewed recent audit of the configuration management system and interviewed licensee staff to verify the scope and frequency of audits were being conducted in accordance with the license application and facility procedures License Application Changes (IP Section 02.04)
For the selected modifications, the inspectors interviewed licensee staff and reviewed applicable sections of the license application to verify the licensee evaluated license application changes and conducted NRC pre-approval screenings in accordance with the license requirements. Specifically, the inspectors conducted the inspection activities listed below:
reviewed the licensees procedure used to determine whether NRC pre-approval of license application changes was required to verify the licensee correctly evaluated license application changes New Processes at Existing Facilities (IP Section 02.05)
The inspectors reviewed a configuration management package of a new facility processes to verify the licensee addressed the requirements of 10 CFR 70.64 and evaluated whether prior NRC approval was needed for the change in accordance with 10 CFR 70.72 and the license conditions. Specifically, the inspectors conducted the inspection activities listed below:
interviewed licensee staff, performed walk-downs, and reviewed the configuration management package for the following process to verify the licensee addressed the requirements in 10 CFR 70.64 and provided appropriate bases for not needing prior NRC approval o
ADOPT Powder Blending Operations reviewed training material and records for operators of the ADOPT process reviewed PHA for ADOPT Powder Handling reviewed updated ISA summary for ADOPT Powder Blending
9 Records Retention (IP Section 02.06)
The inspectors reviewed a sample of plant documents impacted by the selected modifications to verify the licensee maintained records of facility changes in accordance with the license requirements and 10 CFR 70.72. The sample of documents included:
operating procedures piping and instrumentation diagrams (P&ID) training records and materials for operators in areas impacted by modifications updated ISA Summary submitted January 30, 2025 INSPECTION RESULTS No issues were identified.
EXIT MEETINGS AND DEBRIEFS The inspectors verified no proprietary information was retained or documented in this report.
On September 25, 2025, the inspectors presented the integrated inspection results to Roy Stutts and other members of the licensee staff.
10 DOCUMENTS REVIEWED Inspection Procedure Type Designation Description or Title Revision or Date IR-2025-5649, IR-2025-4837, PIR-2025-691, IR-2025-4243, IR-2025-3210, PIR-2025-1541, PIR-2025-810, PIR-2025-25 NCS-related CAP entries Various Corrective Action Documents REPORTABILITY EVALUATION FORM Reportability Evaluation for CAP PIR-2025-810 Corrective Action Documents Resulting from Inspection PIR-2025-XXXXXX NRC Inspector Identified Observation Related to NCS Procedures OM81246 SI-SAFETY, V1006A AND B PASSIVE OVERFLOWVERIFICATION - 26 WEEK OM 02/06/2025 Dispatch 231631 SI-SAFETY, PERIODIC BOTTOM BLOCK HOOK INSPECTIONAND NDT TEST - 52 WEEK PM Completed 01/31/2024 Dispatch 242369 SI-SAFETY, LOAD TEST - 52 WEEK PM Completed 03/27/2024 Dispatch 242370 SI-SAFETY, BUILDING CRANE GIRDER RUNWAY AND MONORAILBEAM PERIODIC INSPECTION - 52 WEEK PM Completed 03/27/2024 Dispatch 302349 SI-SAFETY, PERIODIC BOTTOM BLOCK HOOK INSPECTIONAND NDT TEST - 52 WEEK PM Completed 01/28/2025 Dispatch 313566 SI-SAFETY, BUILDING CRANE GIRDER RUNWAY AND MONORAILBEAM PERIODIC INSPECTION - 52 WEEK PM Completed 03/25/2025 Dispatch 313567 SI-SAFETY, LOAD TEST - 52 WEEK PM Completed 03/25/2025 Dispatch 317466 SI-SAFETY, BRIDGE CRANE PERIODIC INSPECTION AND PM -13 WEEK PM Completed 04/16/2025 88015 Work Orders Dispatch 317502 SI-SAFETY, HOIST AND TROLLEY PERIODIC Completed
11 Inspection Procedure Type Designation Description or Title Revision or Date INSPECTION AND PM - 13 WEEK PM 04/16/2025 Dispatch 334018 SI-SAFETY, HOIST AND TROLLEY PERIODIC INSPECTION ANDPM - 13 WEEK PM Completed 07/17/2025 Dispatch 334019 SI-SAFETY, BRIDGE CRANE PERIODIC INSPECTION AND PM -13 WEEK PM Completed 07/18/2025 Corrective Action Documents IR 2024-8126, 2024-8124, 2024-8135, 2024-8129, 2024-8131, 2024-8134 Various corrective action reports related to configuration management program Various Corrective Action Documents Resulting from Inspection PIR-2025-XXXX Corrective Action Documents from NRC identified observations related to PMA 301F01I03 P&ID for Solvent Extraction/UNH Purification Aqueous Waste System Rev. 1 325F02PI02 P&ID for Pellet Line 5 Pellet Prep and Fabrication Rev. 4 Drawings 333F03PI01 P&ID for Scrap Recovery/Precipitation System Pumpout Columns V-1005A/V-1005B and Q-tank Streams Rev. 34 PSEDoc-0009221 Design Review Screening for CCF-D-22184 PSEDoc-0009291 ITR for CCF-D-22184 Rev. 1 PSEDoc-0009959 Adopt Powder Handling Final Process Hazards Analysis Report 10/11/2023 PSEDoc-0010036 ITR for CCF-D-22033 06/14/2023 PSEDoc-0010099 V-717 Overflow Validation with Addition of New V-1493E/F and P-1493C 06/01/2023 PSEDoc-0010280 Qualification Plan for ADOPT URRS Tank Addition 09/28/2023 PSEDoc-0010427 ITR for Replace T-47 Fume Tank 10/11/2023 PSEDoc-0010639 Piping System Only Hydrostatic Test Report V-1493E/F 12/18/2023 PSEDoc-0010814 In-Service/Closed Loop Test Report for V-756C/D, P-756B, V-1493E/F, and P-1493C 02/26/2024 PSEDoc-0010837 Confirmation of SOLX-101 and SOLX-102 for Tanks V-756C/D and V-1493E/F 03/07/2024 88070 Engineering Evaluations PSEDoc-0010862 Hydrotest Report T-47 03/15/2024
12 Inspection Procedure Type Designation Description or Title Revision or Date PSEDoc-0010971 ITR for CCF-D-22126 05/01/2024 PSEDoc-0011025 Pre Start-Up Safety Review T047 Fume Tank 04/22/2024 PSEDoc-0011113 ITR for CCF 23084 05/29/2024 PSEDoc-0011238 Adopt Powder Blending PHA Action Items 1, 11, 12, 13, 14, 16, 21, 23, 25 Closure Documentation 07/18/2024 PSEDoc-0011250 Adopt Powder Blending PHA Action Items 3, 4, 6, 10, 26 Closure Documentation 07/23/2024 PSEDoc-0011543 Test Report for ADOPT PLN 5 Addback Upgrades 10/28/2024 PSEDoc-0011883 Pellet Line #5 FN-1909 Airflow Balancing Test Sheets 04/09/2025 COP 820114 Automatic Feed Preparation System Rev. 88 COP 850060 Pellet Expansion Blending Operations Rev. 19 COP-827701 ECO Powder Preparation Equipment Rev. 32 FA-114 Independent Technical Reviews Rev. 11 RA-104 Regulatory Review of Configuration Change Authorization Rev. 36 RA-115 ISA Generation and Technical Reviews/License Amendment Requests Rev. 3 RA-124 Process Hazard Analysis Rev. 22 SYP-225 Chemical PPE Matrix Rev. 5 TA-500 Columbia Manufacturing Plant Configuration Control Rev. 44 Procedures TA-500-10 Configuration Management Risk Assessment Board Meeting Rev. 5 Self-Assessments EHS-AUDIT 24-8 Regulatory Component Audit for Configuration Management, Audits, and Records Management 08/02/2024 Work Orders Dispatch #233157 Functional Test of Gamma Monitor interlock for WT-908 and WT-909 01/30/2024