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By Chris Reese

NEW YORK (Reuters) - What started earlier this year as a couple of rust spots on a Midwest reactor lid has mushroomed into a repair bill for the U.S. nuclear power industry that is likely to top $1 billion.

FirstEnergy Corp. said it was surprised back in February when it found cracks in the lid capping the reactor at its 925 megawatt Davis-Besse plant in Oak Harbor, Ohio.

More surprising was the discovery of a hole in the 6-inch thick steel lid, eaten by boric acid that had been leaking for years through tiny cracks around the nozzles that guide fuel rods into the vessel that contains the nuclear reaction.

Davis-Besse's pressurized water reactor uses the same basic design as 69 other U.S. nuclear reactors which together account for about 12 percent of the nation's power supply.

Following the startling discovery at Davis-Besse, the federal Nuclear Regulatory Commission ordered special inspections at all of the nation's pressurized water reactors to determine whether any other vessel heads need to be pulled and replaced --a huge, costly job.

A Reuters survey of nuclear plant operators showed work is planned or already under way to replace vessel heads on 17 reactors.

While not all companies were willing to discuss the cost of replacing reactor vessel heads, those that did estimated the job would cost on average $60 million per unit.

At that price, replacement costs for the 13 units including Davis-Besse would add up to roughly $1.02 billion, and more vessel heads may have to be swapped.



SOARING COSTS FROM DAVIS-BESSE

However, the replacement cost of the reactor head itself does not include the biggest expense -- down time.

A shut nuclear unit can cost its owners nearly $500,000 a day buying electricity it would have generated otherwise.

First Energy estimates the Davis-Besse outage is costing the company $10 million to $15 million a month in replacement power, soaring to $20 million a month in July and August when air conditioning pushes up electricity demand.

With 10 months of down time since February, the replacement power cost for Davis-Besse alone would average $140 million.

Because most utilities have regulated rates, they cannot automatically pass the repair and replacement power costs on to consumers without first winning regulatory approval.

"Basically our rates are capped in terms of what we can charge customers," FirstEnergy spokesman Richard Wilkins said.

The owners of the Three Mile Island nuclear plant in Pennsylvania have said they will replace the reactor lid in the autumn of 2003 because of the difficulty and high cost of removing insulation around the head before inspection.

The $100 million cost of replacing the head at Three Mile Island, in part, has prompted the plant's owner, AmerGen Energy Co., to consider selling the reactor.

The head replacement process at Davis-Besse was nearly complete as of early December.

Davis-Besse has been shut since February when the corrosion was discovered, but the actual vessel head replacement took about 45 to 60 days, Wilkins said. Davis-Besse is expected to resume power production in early 2003.



OVER TWO FEET OF CONCRETE

The replacement job is a formidable one.

An 18-by-18 foot hole has to be cut in the two-and-a-half foot thick concrete wall of the containment building, and the old vessel head -- an 85-ton metal dome about 17 feet in diameter and eight feet tall -- has to be eased outside.

The new vessel head is moved into the building and the hole in the containment building is closed and restored to its original technical specifications.

The old vessel head is decontaminated and wrapped in a protective shrink-wrap type material to be sent to a disposal facility in Utah to be permanently buried.

FirstEnergy, for its Davis-Besse facility, was able to purchase a replacement vessel head from another facility where construction had begun on a nuclear reactor but was never completed.

Copyright 2002, Reuters News Service





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