ML25324A299
| ML25324A299 | |
| Person / Time | |
|---|---|
| Site: | 07201004 |
| Issue date: | 12/04/2025 |
| From: | Gerond George NRC/NMSS/DFM/IOB |
| To: | Ocampos B Orano TN Americas, TN Americas LLC |
| References | |
| IR 2025202 | |
| Download: ML25324A299 (0) | |
Text
Brian Ocampos Quality Assurance Director TN Americas LLC 7160 Riverwood Drive, Suite 200 Columbia, MD 21046
SUBJECT:
ORANO TRANSNUCLEAR AMERICAS, LLC - U.S. NUCLEAR REGULATORY COMMISSION INSPECTION REPORT 72-1004/2025-202
Dear Brian Ocampos:
On August 28, 2025, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection at Orano TransNuclear Fabrication (TNF) facility in Kernersville, North Carolina. The inspectors discussed the results of this inspection with Brad Beard and other members of your staff. The results of this inspection are documented in the enclosed report.
No findings or violations of more than minor significance were identified during this inspection.
In accordance with 10 CFR 2.390 Public inspections, exemptions, requests for withholding, a copy of this letter, its enclosure, and your response (if any) will be made available electronically for public inspection in the NRC Public Document Room or from the NRCs Agencywide Documents Access and Management System (ADAMS). ADAMS is accessible from the NRC website at http://www.nrc.gov/reading-rm/adams.html.
Sincerely, Gerond A. George, Chief Inspection & Oversight Branch Division of Fuel Management Office of Nuclear Material Safety and Safeguards Docket No. 72-1004
Enclosure:
Inspection Report No. 72-1004/2025-202 December 4, 2025 Signed by George, Gerond on 12/04/25
Enclosure U.S. NUCLEAR REGULATORY COMMISSION Inspection Report Docket Number:
07201004 Report Number:
07201004/2025-202 Enterprise Identifier:
I-2025-202-0004 Certificate Holder:
ORANO TRANSNUCLEAR AMERICAS, LLC.
Facility:
ORANO TransNuclear Fabrication Kernersville facility Location:
Kernersville, NC Inspection Dates:
August 26, 2025 to August 28, 2025 Inspectors:
R. Patel, Transportation, and Storage Safety Inspector, Lead A. Djapari, Transportation, and Storage Safety Inspector E. Rosario, Transportation, and Storage Safety Inspector A. Rowe, Transportation, and Storage Safety Inspector Approved By:
Gerond A. George, Chief Inspection and Oversight Branch Division of Fuel Management
2
SUMMARY
The U.S. Nuclear Regulatory Commission (NRC) conducted a routine inspection at Orano TransNuclear Fabrication (TNF) facility in Kernersville, NC from August 26-August 28, 2025, to evaluate ongoing activities related to the storage of spent nuclear fuel in NRC-approved dry storage systems (DSSs). The purpose of this inspection was to verify and assess the adequacy of TNFs activities associated with the fabrication of Nuclear Horizontal Modular Storage (NUHOMS) DSS to determine if the activities were performed in accordance with the requirements of Title 10 of the Code of Federal Regulations (10 CFR) Part 72, Licensing Requirements for the Independent Storage of Spent Nuclear Fuel, High-level Radioactive Waste, and Reactor-Related Greater-than-Class C Waste, the Certificates of Compliance (CoCs) 1004 and 1042 for which TNF holds the design approval, and TNFs NRC-approved Quality Assurance Program (QAP). The inspectors observed fabrication activities, reviewed records, and interviewed personnel to assess whether the DSS is being fabricated and controlled in accordance with the commitments and requirements specified in the safety analysis report (SAR), the CoC and technical specifications, 10 CFR Part 72, and the NRC-approved QAP.
List of Findings and Violations No findings or violations of more than minor significance were identified.
Additional Tracking Items None.
3 INSPECTION SCOPES The inspectors conducted an inspection using applicable portions of inspection procedure (IP) 60852, ISFSI Component Fabrication by Outside Fabricators, which is a currently approved IP located on the NRCs public website at http://www.nrc.gov/reading-rm/doc-collections/insp-manual/inspection-procedure/index.html. The inspectors reviewed selected procedures and records, observed activities, and interviewed personnel to assess the CoC holder performance and compliance with the Commission rules and regulations, license conditions, quality procedures, and applicable standards. The inspection was declared complete when the objectives of the IP were met, consistent with IMC 2690, Inspection Program for Storage of Spent Reactor Fuel and Reactor-Related Greater-Than-Class C Waste at Independent Spent Fuel Storage Installations and for 10 CFR PART 71 Transportation Packagings.
IP-60852 - ISFSI Component Fabrication By Outside Fabricators Design Controls (IP Section 2.01)
The inspectors reviewed TNFs NUHOMS 61BTH DSS licensing drawings against the design and fabrication drawings (FDs) to verify the consistency of critical dimensions and material specification as well as testing and inspection requirements to determine whether they were consistent with the design and fabrication specifications.
Specifically, the inspectors focused on design commitments and requirements for important-to-safety (ITS) category A and B components of the NUHOMS system design from the safety analysis (SAR) to design and fabrication drawings.
The inspectors conducted interviews with design engineering personnel to review the design change process, including the initiation, analysis, verification, and approval of engineering change notices (ECNs) and drawing change notices (DCNs). The inspectors reviewed a sample of ECNs and DCNs and design documentation associated with the NUHOMS 61BTH DSS package, including justification for safety classification of components to verify the components were adequately classified.
The inspectors also reviewed TNFs design review process and associated documentation, including the sequence of internal design review meetings from design concept initiation to final design reviews to ensure conformance with quality procedures. Additionally, the inspectors reviewed the design controls that were in place for the transmittal and handling of design drawings received from ORANO TNF and how TNF transitioned from design to fabrication, as applicable. The inspectors also evaluated the process for distributing controlled drawings.
Nonconformance and Corrective Action Controls (IP Section 2.02)
The inspectors reviewed a sample of nonconformance records (NCRs) and corrective action reports (CARs) and interviewed personnel to verify that TNF effectively implemented nonconformance control program and corrective action program (CAP) in accordance with the requirements of 10 CFR Parts 21 and 72. The inspectors verified that TNF completed corrective actions for identified deficiencies and nonconformances in a technically sound and timely manner. The review included an evaluation of how TNFs nonconformance control program and CAP that addressed materials, parts, and components that do not conform to requirements and identified quality deficiencies since 2022. The inspectors also reviewed provisions for reporting
4 defects that could cause a substantial safety hazard within these programs. The inspectors reviewed a sample of TNF supplier finding reports (SFRs) written resulting from TNF audit and surveillance activities. The inspectors also discussed the NCRs, CARs, SFRs, with TNF personnel, as applicable. The inspectors also toured the shop floor and verified those components with an open NCR whether TNF tagged or segregated the item as required by QAP.
Trained and Certified Personnel Controls (IP Section 2.03)
The inspectors selected records and procedures and interviewed selected personnel and observed selected activities to verify that individuals performing activities affecting quality are properly trained and qualified. The inspectors verified that management and QA staff are cognizant and provide appropriate oversight. The inspectors reviewed procedures and documents regarding training, qualification, and certification of personnel involved in quality activities. The inspectors reviewed the qualifications and training for selected lead auditors to determine if they met the requirements stated in the QAP. The inspectors also reviewed the qualification records of engineering personnel responsible for performing design activities and approving design changes related to the NUHOMS 61BTH DSS. In addition, the inspectors reviewed training records for a random sample of personnel in quality-related positions to determine if they received the required indoctrination to and familiarization with the QAP. Specifically, the inspectors reviewed welder procedure qualifications records, welder 6-month performance records, nondestructive examination (NDE) personnel qualification records and annual acuity records to verify the records were current and in compliance with the applicable Codes and Standards and QAP.
Fabrication, Assembly and Test Controls (IP Section 2.04)
The inspectors reviewed TNFs FDs, shop travelers, and associated procedures. For welding activities, the inspectors reviewed weld procedure specifications and welder performance qualification records, along with records used as part of TNFs process for welding material control, such as the welding material request cards and welding operation records. The inspectors performed a walkdown of DSSs been fabricated to assess their material condition and quality controls. This included the NUHOMS 61BTH shell weld assembly DSS. Specifically, the inspectors observed NUHOMS 61BTH shell weld repair activities to verify welding, and NDE have been performed using qualified approved procedures by qualified personnel and calibrated measuring and test equipment (M&TE) in accordance with the applicable Code and conformance to the SAR. The inspectors reviewed documentation that included traveler sign-off steps, welding procedure specifications, procedure qualification records, welder procedure qualification, NDE procedures, NDE, and weld visual inspection reports, weld wire material test reports, NDE material certifications to verify conformance to the applicable Codes and Standards, TIPs, and SAR requirements.
The inspectors observed the following activities:
Dimensional inspection of the 9-Tube Bundle Lift Gas Tungsten Arc Welding of the DF 61BTH2 shell assembly Submerged Arc Welding of the 61BTH2 Shell Assembly
5 Dry Penetrant Test examination of the DSS Shell weld repair Visual inspection of the Shell tubes Radiograph Inspection of 61BTH shell assembly weld repair Ultrasonic Thickness Test of 61BTH shell assembly The inspectors also reviewed the control of M&TE program to evaluate how TNF identified, specified, and controlled tools, and equipment in accordance with applicable sections of their QAP, quality standard procedures, and regulatory requirements. The inspectors selected a sample of the M&TE used during the fabrication of the NUHOMS 61BTH DSS. The sample included a review of shop travelers that identified the use of specific M&TE. The inspectors selected a vernier caliper, thermometer, light meter, radiographic densitometer standard, densitometer, and a welding machine. The inspectors reviewed calibration records to verify calibration dates, testing standards, and traceability of the associated M&TE. The inspectors reviewed the calibration records to verify calibration dates, testing standards, and traceability of the associated M&TE.
Procurement Controls (IP Section 2.05)
The inspectors reviewed TNFs processes that address procurement, including traceability, and receipt inspection of material to verify that TNF properly implemented their QAP requirements. The inspectors reviewed selected drawings and records and interviewed selected personnel to verify that the procurement specifications for materials, fabrication, inspection, and services performed at TNF met design requirements and requirements contained in the SAR and CoC. The inspectors verified that TNF used a graded approach for identifying ITS components during the design process and applied this graded quality to components and material procurement documents for NUHOMS fabrication activities. The inspectors selected ITS components such as the shell assembly closure lid, and damaged fuel basket assembly to verify procurement controls. The inspectors reviewed the procurement documents specific to the fabrication of these components including purchase orders and receipt inspections.
Quality Assurance Program Controls (IP Section 2.06)
The inspectors reviewed TNFs QAP and various TNF implementing procedures (TIPs) to assess the effective implementation of their QAP. The inspectors conducted reviews of both quality manuals, policies, and procedures, to determine whether TNF adequately controlled and implemented activities under their NRC-approved QAP and quality activities subject to 10 CFR Part 72 regulations. The inspectors reviewed procedures to verify if TNF clearly defined and documented the quality program authorities and responsibilities and that the quality assurance organization functioned as independent group.
Part 21 Controls (IP Section 2.07)
The inspectors reviewed the 10 CFR Part 21 TIP to verify if provisions were in place for reporting defects that could cause a substantial safety hazard. The inspectors requested a list of 10 CFR Part 21 evaluations and notifications associated with the fabrication activities and interviewed personnel to verify if they were familiar with the
6 implementing procedure. The inspectors also verified if TNF complied with 10 CFR 21.6, Posting requirements.
Audit Controls (IP Section 2.08)
The inspectors reviewed the TNF audit program to determine if TNF scheduled, planned, and performed audits or surveillances of suppliers in accordance with their QAP, and selected a sample of audits and surveillances from the time of the last NRC inspection to the present. The inspectors also reviewed internal audits conducted between 2022 and 2025 to verify that all applicable QAP elements were audited annually and in accordance with the established audit schedules. In addition, the inspectors evaluated audits and surveillances that identified findings to determine if corrective actions were entered into the CAP as required and confirmed that closures of findings were verified during the same audit or in subsequent audits, as documented in follow-up reports.
INSPECTION RESULTS No violations of more than minor significance were identified.
EXIT MEETINGS AND DEBRIEFS The inspectors verified that no proprietary information was retained or documented in this report.
On August 28, 2025, the inspectors presented the NRC inspection results to Brad Beard, Chief Operations Officer, and other TNF staff.
7 DOCUMENTS REVIEWED Inspection Procedure Type Designation Description or Title Revision or Date CP-33 Densitometer - Recommended Calibration Interval: 90 days Rev 2 TNF-076 0.10-0.500 Inch Radius Gage 07/09/2025 TNF-519 Gage Block inspection Certificate - Inch blocks 08/14/2025 TNF-567 Calibration Failure Notice - White LED Light Meter 12/12/2024 TNF-577 Helium Leak External Standard Gas Pern 05/29/2025 TNF-665 Caliper Calibration 08/17/2025 Calibration Records TNF-998 Digital Depth Gage 06/03/2025 2021-115 TNF Welder, W-89, Welds Performed Without Qualification 05/12/2021 2022-249 Skipped OP Inspection Step 12/15/2022 2023-021 Nonconforming Parts Not Properly Controlled 02/14/2023 2023-046 Receipt Inspection Reports Not Linked to Correct Purchase Orders and Nonconcurrence Reports 03/23/2023 2023-114 Flaking of Coating During Inspection of TSP for WC-EOS-37PTH-002-B4L 08/14/2023 2024-113 Review of Condition Action Reports from IA-2024-01 11/19/2024 Corrective Action Documents 2025-017 Inspection of Basket Plate Surface Conditions Not Proceduralized: Informally Inspected and Dispositioned 02/27/2025 Corrective Action Documents Resulting from Inspection 2025-095 Welding Operator Performance Qualification Self-Stamp 08/28/2025 61BTH2-420 NUHOMS 61BTH Dry Storage Cask (DSC) Fuel Tube, Cutting, and Forming Rev 3 NUH61BTH-4003 NUHOMS 61BTH DSC Type 2 Transition Rails Rev 10 NUH61BTH-4006 NUHOMS 61BTH DSC Type 2 Top Grid Assembly alternate 3 and Alternate 4 Rev 11 Drawings NUH61BTH-5005 NUHOMS 61BTH DSC Type 3 Hold Down Ring Rev 1 CDGEP-2020-01 Commercial Grade Dedication Evaluation/Plan (CGDEP)
Stainless Steel Forging Rev 2 Commercial Grade Dedication CGDEP-2023-05 Testing Services Rev 0
8 Inspection Procedure Type Designation Description or Title Revision or Date CGDR-2020 56 Commercial Grade Dedication Report (CGDR) - Stainless Steel Forging 61BTH2 Rev 0 CGS-CGSR-2019-19-2-00 Commercial Grade Survey Report (CGSR) - Stainless Steel Forging Rev 0 DCR 1008758 EOS-37PTH DSC, Project No.: 10430.FD1 Prairie Island DFSS Rev 0 DCR 1009747 NUHOMS 61BTH, Project No.: NUH-61BTH Rev 0 DCR 1010366 NUHOMS 61BTH, Project No.: 10430.FD2 Monticello DFSS Rev 0 Engineering Changes DCR 1010405 NUHOMS 61BTH, Project No.: 10430.FD2 Monticello DFSS Rev 0 FPM 9.2-1 Welding Employee Stamp List 08/28/2025 08082-114 Welding Procedure Specification 08082-114 - GMAW Semiautomatic Rev 2 08084-101 Welding Procedure Specification 08084-101 - Joints (QW-402)
Rev 9 121217 Procedure Qualification Record 121217 for 08084-101, SAW Rev 3 FPM 9.2-8 Supervision of Welding Activity Training Rev 5 FPM 5.1-1 TN Fabrication Traveler Manufacturing Plan & Quality Record Rev 14 G-2498 Welder and Welding Operator Performance Qualification Test 05/15/2021 NCR 2023-013 Fabrication NCR 2023-013: Raw material listed on traveler had incorrect Receipt inspection Report listed on the bill of materials Rev 1 NCR 2023-144 Fabrication NCR 2023-144: sampled canisters dimensions nonconforming Rev 0 NCR 2025-031 Fabrication NCR 2025-031: Measurements below tolerance Rev 0 UNSAT FC 2025-046 Unsatisfactory Fabrication Condition 2025-046: Shell stamp engraving Rev 1 Miscellaneous W-89 Record of Welding Operator Performance Qualification 05/15/2021 NDE Reports 61BTH2-VTNG VT Acceptance Criteria for ASME Section III NG Rev 1
9 Inspection Procedure Type Designation Description or Title Revision or Date TIP 16.1 Corrective Action Rev 35 TIP 18.1 Internal Audits Rev 18 TIP 2.3 Qualification of Inspection and Test Personnel Rev 9 TIP 4.1 Procurement Document Control Rev 41 TIP 5.8 Fabrication Drawing Control Rev 2 Rev 16 TIP 7.3 TIP 7.5 Dedication of Commercial Grade Items Supplier Vendor Oversight Rev 13 TIP 7.6 Commercial Grade Survey Rev 9 FPM 2.3 Qualification & Certification of Nondestructive Examination Personnel Rev 4 NDE-FP Film Processing (Radiographic)
Rev 0 NDE-RT Radiographic Evaluation Report Rev 2 NDE-UTT Ultrasonic Thickness Examination Procedure Rev 8 NDE-VT Visual Examination Procedure Rev 5 Procedures QIP-UT-XM19 Ultrasonic Examination for Weld Repair Rev 0 2024-004 Supplier Finding Report No. 2024-004, 02/16/2024 2024-007 Supplier Finding Report No. 2024-007 04/03/2024 2024-010 Supplier Finding Report No. 2024-010 05/08/2024 2024-017 Supplier Finding Report No. 2024-017 10/21/2024 IA-2022-01 Internal Audit: Management Audit 11/22/2022 IA-2022-09 Internal Audit: TN Fabrication - Material Control and Fabrication 01/06/2023 IA-2023-09 Internal Audit: TN Fabrication - Material Control and Fabrication and Project/ Fabrication Engineering 10/16/2023 IA-2024-01 Internal Audit: Management Audit of QA 12/17/2024 SE-2024-052-00 Annual Supplier Evaluation - Weld Filler Material 04/23/2024 SE-2024-102-00 Annual Supplier Evaluation - Stainless Steel Forgings 09/14/2024 SE-2025-020-00 Annual Supplier Evaluation - Stainless Steel Forgings 02/12/2025 SE-2025-074-00 Annual Supplier Evaluation - Calibration Services 08/01/2025 SE-2025-075-00 Annual Supplier Evaluation - Materials Testing 07/22/2025 SE-2023-111-00 Supplier Evaluation No. 2023-111 09/22/2023 Self-Assessments SE-2024-091-00 Supplier Evaluation No. 2024-091 08/07/2024
10 Inspection Procedure Type Designation Description or Title Revision or Date 1010022 Receipt Inspection Report No. 1010022 - 61BTH2-4001-8, Bottom Forging, ASME SA-182 F304 Rev 0 1010024 Receipt Inspection Report No. 1010024 - 61BTH2-4001-8, Bottom Forging, ASME SA-182 F304 Rev 0 Rev 0 EOS37-1012-517 GPS-61BTH2-ALA Procurement Specification for EOS Steel Basket Plate Procurement Specification for R45 Ala Backplate Rev 3 P2022-0827 Purchase Order P2022-0827 - Helium Gas 08/25/2022 P2023-0954 Purchase Order P2023-0954 Arc3 Gases Helium 08/25/2023 P2023-1123 Calibration Services (TNF-567 - Calibration Failure Notice
- White LED Light Meter) 12/12/2024 P2024-0025 Calibration Services (TNF-1023 - Dead weight tester) 05/23/2024 P2024-0921 Purchase Order P2024-0921 Bottom Forging 09/09/2024 P2025-0389 Calibration Services (TNF-519 - Gage Block inspection Certificate - Inch blocks) 08/19/2025 P2025-0436 Calibration Services (TNF-577 - Helium Leak External Standard Gas Pern) 06/17/2025 P2025-0512 Purchase Order P2025-0512 05/09/2025 1007108 Receipt Inspection Report No. 1007108 - Helium Gas Rev 2 Shipping Records 1008041 Receipt Inspection Report No. 1008041 Rev 0