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2002 Davis-Besse Nuclear Power Station Corrosion Incident
On March 5, 2002, a significant safety issue was uncovered at the Davis-Besse Nuclear Power Plant in Ohio. A hole due to corrosion was found in the reactor vessel head during routine maintenance. This incident, while not causing a reactor accident, revealed a major risk of nuclear material release. It led to extensive legal, operational, and regulatory actions, including a record fine from the Nuclear Regulatory Commission (NRC) and heightened safety measures at the plant.

Background
The Davis-Besse Nuclear Power Station, with a generating capacity of 894 megawatts, is located on the shores of Lake Erie near Port Clinton, in Ottawa County, Ohio, northeast of Oak Harbor. Officially named the Davis–Besse Nuclear Generating Station by the U.S. Energy Information Administration, it houses a single pressurized water reactor and is operated by Energy Harbor. Since commencing commercial operations in 1977, Davis-Besse has achieved notable performance milestones. For instance, it achieved the number one spot in the United States for capacity factor in 1994 and garnered the highest possible rankings from the Institute of Nuclear Power Operations (INPO) as well as the Nuclear Regulatory Commission (NRC) in the period from approximately 1993 to 1995. Before the incident in 2002, the facility had consistently adhered to the standard nuclear safety regulations and protocols, upholding a solid record of compliance and operational safety.

Accident
On March 5, 2002, an unexpected discovery was made during a routine inspection at the Davis-Besse Nuclear Power Station. Inspectors found a significant void in the reactor vessel head, akin in size to a football. This was the result of Primary Water Stress Corrosion Cracking (PWSCC), leading to through-wall cracks in the control rod nozzles.

The discovered corrosion had resulted in an oblong cavity about 7 x 5 inches (18 x 13 cm) in size, alarmingly close to breaching the low alloy steel of the reactor vessel head, stopping merely short of the stainless steel cladding. The observed leak, which involved borated water seeping at a rate under 0.2 gallons per minute, was minor yet significantly surpassed the leakage rates commonly associated with Primary Water Stress Corrosion Cracking (PWSCC). This indicated an atypical and severe degradation of the reactor vessel's structural integrity.

This condition, while not causing an immediate operational incident, posed a substantial risk. It highlighted the possibility of a severe accident scenario, including the potential for a coolant accident or control rod ejection. The incident necessitated the production of a new reactor pressure vessel head and led to industry-wide scrutiny of existing inspection methods. In response, the Nuclear Regulatory Commission contemplated changes to the inservice inspection requirements to bolster nuclear safety.

Consequences
The severe corrosion found at the Davis-Besse plant led to immediate actions by FirstEnergy and oversight authorities. The plant was shut down for repairs and upgrades, including a complete replacement of the reactor vessel head and an enhanced focus on safety culture. FirstEnergy also faced financial repercussions: the Nuclear Regulatory Commission (NRC) levied a record $5 million fine for the violations leading to the corrosion, and the company settled with the Department of Justice for an additional $28 million.

The plant resumed operations in 2004, under the NRC's stringent supervision, which continued until 2009. This oversight involved independent reviews and comprehensive scrutiny of FirstEnergy's safety practices, particularly its implementation of a safety-conscious work environment. The intense regulatory focus aimed to ensure that the issues contributing to the incident were fully addressed.

By 2009, FirstEnergy had met the NRC's conditions for improved operational and safety standards, demonstrating a commitment to rectifying past organizational flaws. This marked a significant milestone in the plant’s history, signaling a commitment to maintaining rigorous safety standards.