Sargent & Lundy

Callaway Buried Essential Service Water Piping Replacement

Project marked first use of HDPE piping in a nuclear safety-related application in the United States

Portland, Missouri
Buried Essential Service Water (ESW) Piping Replacement Project
Client: AmerenUE

  • First-of-a-kind project successfully completed from inception to completion in less than two years including design, procurement, regulatory approval, installation and return to service
  • Life of the plant solution to MIC problems in the existing buried piping that was replaced and improved system hydraulic performance
  • Industry recognized innovative project that earned the NEI Top Industry Practice (TIP) award

The Callaway nuclear plant Essential Service Water (ESW) system was originally designed and constructed using carbon steel piping. In the early 2000s, numerous instances of pinhole leaks, pitting, and other localized degradation of the ESW system piping due to erosion, corrosion and microbiologically induced corrosion (MIC) were identified.
In early 2007, the Callaway plant initiated a project to replace the existing buried carbon steel ESW system piping.

It was decided that the replacement buried ESW piping would be made of High Density Polyethylene (HDPE) due to its resistance to erosion, corrosion, and microbiologically induced corrosion (MIC). While HDPE piping had been used in several nuclear plants (Callaway included), this project was the first use of HDPE piping in a nuclear safety-related application at a nuclear power plant in the United States.

Project Scope:

  • Engineering and design
  • Procurement and installation specifications
  • Regulatory approval assistance
  • Construction support

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Thomas Behringer

Senior Vice President




Tom brings 34 years of experience, working on new and operating nuclear power plants.