The Davis Besse corrosion was caused by a buildup of boric acid from reactor cooling water that had been leaking from nozzle cracks since the mid-1990s. The first signs of corrosion appeared four years ago when rust began clogging filters, investigators said.
Despite a 1988 NRC directive to keep reactor lids free of boron, the layers of the powdery deposits hardened so much atop the dome — where access is difficult because of space and radiation exposure — that workers couldn't pry it loose.
But the company's engineers did not link the rust to safety-related corrosion and were assured that the boron powder was harmless since they believed heat from the reactor would evaporate any moisture.
But it is now believed the water leaking from the nozzle cracks, rather than evaporating, settled beneath the hardened layers of boron, providing enough moisture to turn the powder back into corrosive boric acid.