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Enbridge Pipelines Inc.Edmonton to Hardisty Pipeline ProjectChapter 7 Engineering

submerged arc welded (DSAW) welding for the spiral seam welding process.1The line pipe will be manufactured to CSA Z245.1 standards.2

Table 7-2 summarizes the preliminary design parameters and estimated3quantities of line pipe required for the Project. These parameters will be finalized4during detailed engineering and design.5

Table 7-2: Line Pipe Design Parameters6

A B C D E

1 Design ParameterLine PipeType 1 -General

Line PipeType 2 -General

Heavy WallPipe - Bores

and RoadCrossings

Heavy WallPipe

UncasedRailway

Crossings

2 OD (mm) 914.4 914.4 914.4 914.4

3 CSA Notch ToughnessCategory 11 1 1

4 Maximum OperatingPressure (MOP) (kPa) 9930 9930 9930 9930

5 Design Factor 0.8 0.8 0.8 0.8

6 CSA Location Factor 1.0 1.0 1.0 0.625

7 Minimum DesignTemperature (C) 00 0 0

8 Maximum DesignTemperature (C) 3838 38 38

9 Minimum Steel Grade(MPa) 483 483 483 483

10 Estimated Wall Thickness(mm) 11.8 12.2 15.9 20.6

11 Estimated Quantity (m) 127,278 50,178 4,875 240


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Quality Control1

Line pipe will be purchased from qualified pipe suppliers and trading houses.2Steel suppliers, mills and coating plants are pre-qualified using a formal3qualification process consistent with ISO standards prior to line pipe purchase.4Qualification encompasses comprehensive evaluation of steel and pipe5manufacturing facilities and requirements for the mill to produce and test line pipe6to Enbridge standards and specifications. Line pipe is engineered with stringent7chemistry tolerances, roundness and nominal wall thickness. A quality8management system is in place for each pipe order to ensure the pipe9manufacturer adheres to the purchase specifications and applicable codes and10standards. The quality management system ensures that each joint is traceable11to the steel supplier and pipe mill shift during production and that each batch of12pipe is mechanically tested to prove strength and toughness. Lastly, inspection13personnel are present in the pipe mill during all pipe production and coating .14

Welding15

Field girth welding of line pipe for the proposed pipeline will be by automatic gas16metal arc welding (GMAW). The tie-in welding for the proposed pipeline will17involve manual shielded metal arc welding (SMAW). All field girth welds will be18non-destructively inspected using ultrasonic or radiographic inspection methods.19 A joining program will be developed consistent with OPR-99 and welders will be20qualified in accordance with the requirements of CSA Z662-11.21

Protective Coating22

The primary external corrosion control for the proposed pipeline will be provided23by a fusion bonded epoxy (FBE) coating that will be applied at a pipe coating24plant. Heavy wall pipe for horizontal directional drilled (HDD) or bored sections25of the pipeline may also receive a dual powder coating that will provide an26additional abrasive resistant coating to protect the FBE coating. During27construction, rock shield, sand padding, wooden lagging or concrete coating will28be used where required to provide additional mechanical protection for the pipe29

coating. Field girth welds will be coated with a system compatible with the plant-30

applied FBE coating.31

The proposed Project will not transport hydrocarbons containing significant32corrosive or abrasive properties and therefore, an internal pipe coating will not be33required34


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The majority of the proposed pipeline ROW will be contiguous and adjacent to1an existing Enbridge ROW, the proposed pipeline will be made electrically2continuous with the existing pipelines by using continuity bonding. This electrical3continuity will provide common CP to all of the pipelines within the pipeline4corridor.5

Test stations and coupon test stations will be installed at appropriate intervals6along the proposed pipeline to confirm the effectiveness of the applied CP current7and to permit pipeline access for other corrosion control monitoring activities.8

Sectionalizing Valves9

Remotely-operated sectionalizing valves will be installed along the proposed10pipeline, in accordance with the requirements of CSA Z662-11, Clause 4.4.11Sectionalizing valve locations will generally coincide with the locations of the12exisiting valves along the existing Enbridge ROW. Other factors considered in13selecting sectionalizing valve locations include: public safety, environmentally14sensitive areas, and operations and maintenance requirements. Table 7-315

outlines the preliminary sectionalizing valve locations for the proposed pipeline. -16 The Pipeline Schematic in Appendix 7-1 can be referenced for more information17on the valve locations. These locations have been reviewed and confirmed by18Enbridges internal operations and risk management departments. The locations19of the sectionalizing valves along the pipeline will be finalized during detailed20engineering and design.21

All sectionalizing valves along the proposed pipeline will be single slab through22conduit full-port gate valves with remote operated actuators. Each sectionalizing23valve site will be equipped with remote communication capability.24

Typical sectionalizing valve drawings are located in Appendix 7-2.25

The design, manufacture and testing of all valves and fittings will be completed in26accordance with the requirements of our internal Enbridge standard, EES - 02327(2012) and CSA Z662-11. All valves and fittings will be compatible with the line28pipe to which they are connected.29

30

Table 7-3: Preliminary Sectionalizing Valve Locations31

A B C


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1

Depth of Cover2

The minimum installation depths of cover for the proposed pipeline will comply3with all applicable legislation and codes, as summarized in Table 7-4.4

Table 7-4: Minimum Depth of Cover5

A B

1 Location Minimum Depth of Cover in Soil m)

2 General 0.9

3 Paved Roads/AccessRoads1.2

4 Railways 2.0

5 Watercourses 1.2

Pipeline Crossings6

The proposed pipeline will cross existing highways, roads, railway lines, foreign7pipelines and utility lines. Table 7-5 lists the approximate number of known8crossings. All crossings will be designed and constructed to conform to current9

NEB regulatory requirements and applicable standards.10Table 7-5: Road, Railway and Other Crossings11

A B

1 Crossing Type Approximate Number

5 Upstream Iron Creek IsolationValve

SE 35-44-13 W4M 140.5

6 Downstream Iron CreekIsolation Valve

NE 17-44-12 W4 148.1


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5 Foreign Pipelines

Oil & Gas

268

6 Utility Lines

Gas Coop, Water, Power,F.O. Cabels

300

7 Total 752

The load imposed on the line pipe by road and rail traffic will be considered in the1design of these crossings. Generally, bored crossings will be used below paved2highways and railway lines to avoid traffic disruptions. However, in locations3where the pipeline crosses unpaved roads that carry very low traffic volumes,4consideration will be given to constructing the crossings using conventional open5cut procedures.6

Foreign pipeline and buried utility lines will be crossed using several techniques,7including boring and open cut.8

Watercourse Crossings9

The proposed pipeline crosses four named watercourses, two unnamed10tributaries to Iron Creek, one unnamed ditch and two unnamed fish bearing11wetlands. The primary watercourse crossings are outlined in Table 7-6.12Watercourse crossing locations are described in Section 5.1.3 of the ESA13(Volume II of this Application) and are shown in Appendix 6, Figure 2 of the ESA14(Volume IIA of this Application). A preliminary HDD feasibility report is provided15in Appendix 7-3.16

Table 7-6: Watercourse Crossings17

Site

No. Name

Legal Location,UTM Co-ordinates

(NAD 83, Zone 12)

Watercourse Class andRestricted Activity

Period

RecommendedPipeline Crossing

Method

RecommendedContingency

Pipeline Crossing

Method

RecommendedVehicle/ EquipmentCrossing Method

(Open Water)

RecommendedVehicle/

EquipmentCrossing

Method (Frozen) WC1 Goldbar

CreekSW 28-52-23 W4M

344933E,5932486N

Uncoded Mapped ClassD

No RAP

Isolate if waterpresent/open cut if dry

or frozen to bottom

n/a Clear span bridge Snow fill/icebridge

WC2 Mill Creek SE 35-51-23 W4M349087E,5924205N

Uncoded Mapped ClassD

No RAP

Trenchless Isolate if waterpresent/open cut if

dry or frozen tobottom

Clear span bridge Snow fill/icebridge

WC3 I i C k SW 33 50 22 W4M U d Cl D I l t if t / E i ti i / E i ti i /


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SiteNo. Name

Legal Location,UTM Co-ordinates(NAD 83, Zone 12)

Watercourse Class andRestricted Activity

Period

RecommendedPipeline Crossing

Method

RecommendedContingency

Pipeline CrossingMethod

RecommendedVehicle/ EquipmentCrossing Method

(Open Water)

RecommendedVehicle/

EquipmentCrossing

Method (Frozen)

WC6 Unnamedtributary toIron Creek

SE 19-44-12 W4M451297E,5850627N

Unmapped Class DNo RAP


or frozen to bottom

n/a Clear span bridge Snow fill/icebridge

WC7 Battle River NE 25-42-10 W4M479339E,5833485N

Mapped Class C April 16 to June 30

Trenchless Isolate if waterpresent/open cut iffrozen to bottom

Existing crossing/clear span bridge

Existing crossing/snow fill/ice

bridge/ clear spanbridge

FD1 Unnamedfish-bearing

wetland

SW 18-46-15 W4M421308E,5869022N

n/aNo RAP

(Class V Wetland)


or frozen to bottom

n/a Access from bothsides

Snow fill/icebridge

FD2 Unnamedfish-bearing

wetland

NW 3-43-10 W4M474739E,5836448N

n/aNo RAP

(Class IV Wetland)


or frozen to bottom

n/a Access from bothsides

Snow fill/icebridge


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Pressure Testing1

The proposed pipeline will be hydrostatically pressure tested in accordance with2the requirements of OPR-99 and,CSA Z662-11. The preliminary hydrostatic test3plan for the pipeline is attached in Appendix 7-4.4

Before pressure testing, each section of pipeline will be cleaned with pigs to5remove construction debris. This debris will be collected and disposed in6accordance with applicable regulatory requirements.7

During detailed engineering and design, a hydrostatic pressure test program and8hydrostatic test plan will be developed. Water will be used as the primary test9medium, however, depending on the time of year, heat may be required to10prevent freezing. Water for hydrostatic testing will be drawn from approved water11sources and, after use, will be disposed of in accordance with all applicable12regulatory requirements.13

Buoyancy Control14Buoyancy control may be installed along sections of the pipeline located under15watercourses and in areas where the water table is high. Screw anchors, pipe16weights, concrete coating or a combination thereof will be used to provide17buoyancy control, as necessary. The most suitable buoyancy control method will18depend on the site-specific conditions at each location and will be determined19during detailed engineering and design.20

7.1.3. Pigging Facilities Specifications21

Table 7-7 outlines the preliminary design parameters for the pig trap facilities.22The barrel OD, material grade and wall thickness for the various components of23the pig trap facilities will be finalized during detailed engineering and design.24

The pig traps will be designed to handle the latest models of in-line inspection25tools, as well as standard pigs for cleaning and pipeline integrity. The pig trap26end closures will be double yoke swing type, with a pressure interlock protective27system to safeguard against the door being opened when the trap is pressurized28(as specified in CSA Z662-11).29

The pipe and barrel section of the pig trap assemblies will be made of either low30carbon, high strength, low alloy steel or quenched and tempered carbon steel,31and will be produced as a seamless pipe or from formed pipe or rolled plate. The32final selection of materials will be made during detailed engineering and design33


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Table 7-7: Pig Trap Design Parameters1

A B C D E

1 Design Parameter Edmonton Terminal SendingTrap Hardisty Terminal Receiving Trap

2 Line Pipe Barrel Pipe Line Pipe Barrel Pipe

3 OD (mm)NPS 36(914.4mm)

NPS 42(1066.8mm)

NPS 36 (914.4mm) NPS 42 (1066.8mm)

4CSA Notch ToughnessCategory

Cat I Cat I Cat I Cat I

5 MOP (kPa)1440psig

(9930kPaa)

1440psig

(9930kPaa)

1440psig

(9930kPaa)

1440psig (9930kPaa)

6 Design Factor 0.6 0.6 0.6 0.6

7 CSA Location Factor 1.0 1.0 1.0 1.0

8Minimum DesignTemperature (C)

-43 C -43 C -43 C -43 C

9Maximum DesignTemperature (C)

38 C 38 C 38 C 38 C

10 Pressure Rating PN 100 PN 100 PN 100 PN 100

11Minimum Steel Grade(MPa)

483 483 483 483

12Minimum WallThickness (mm)

12.7mm 12.7mm 12.7mm 12.7mm


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1

7.1.4. Pump Facility Specifications2

Enbridge Project Development System Hydraulic Design completed the Hydraulic3design for the Project as part of the Canadian Mainline Expansion initiative. The4objective is to increase mainline capacity between Edmonton and Hardisty by5constructing a 914.4 mm (NPS 36) pipeline with an annual capacity of 127,1906m3/day (800,000 bbl/day).7

Facility Layout and Schematic8

Appendix 7-5 illustrates the preliminary layouts for the initiating mainline pump9station at Edmonton Terminal as well as the intermediate Kingman and Strome10Stations. The final layouts will be determined during detailed engineering and11design.12

The typical process flow diagram (PFD) for the mainline pump stations and pig13traps can be found in Appendix 7-6 .14

Pump Requirements15

The Edmonton, Strome and Kingman mainline pump stations will each be16equipped with the required electrical power to be obtained from the local17electrical utility provider. In addition to the information contained in Table 7-8,18each mainline pump station facility will have:19

An Electrical Building (EB):20o Low voltage control systems;21o uninterruptible power supply units; and22o 480 V MCC;23

An Electrical Services Building (ESB);24o Medium Voltage (4160 V) equipment for the pump motors;25o Miscellaneous equipment.26

The new booster pump at Edmonton Terminal will obtain power from an existing27

ESB.28Table 7-8 outlines the preliminary pump specifications (to be finalized during29detailed engineering and design).30

31


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Table 7-8: Pump Facility Requirements1

A B C D E

1 Station Annual FlowRate m 3/d)

MOP ofDischarge Pipe

kPa)

EstimatedPump

HorsepowerHP)

Estimated VFDHorsepower HP)

2 Edmonton TerminalBooster Pump 127,190 1900 2 x 1500 2 x 1500

3 Edmonton TerminalMainline Pump Station

127,190 9930 4 x 6060 4 x 7000

4 Strome Mainline PumpStation

127,190 9930 4 x 6060 4 x 7000

5 Kingman MainlinePump Station 127,190 9930 4 x 6060 4 x 7000


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The ESB and EB for each mainline station are prefabricated modular units with1

all electrical equipment installed prior to shipment.2

The electrical system will be designed to allow the 4160 V motor buses and the3480 V utility buses to remain isolated from one another so that they function as4independent systems.5

The UPS systems will be designed to maintain critical control and shutdown6equipment operability in the event that the primary electrical supply is interrupted7including alternate power to the Station Isolation Valves.8

Primarily for the purpose of noise control, all new mainline pump units will be9installed in buildings.10

The one new booster pump at Edmonton Terminal will be installed outdoors11adjacent to one identical existing booster pump within an existing manifold.12Electrical power will be supplied from an existing ESB for the manifold. The13existing terminal electrical system was designed to allow the 4160 V motor buses14and the 480 V utility buses to remain isolated from one another so that they will15function as independent systems. The existing UPS system was designed to16maintain critical control and shutdown equipment operability in the event that the17primary electrical supply is interuppted.18

Pressure Control19

The primary pressure control system uses VFDs. Each pump unit will have a20dedicated VFD unit for maximum efficiency to control flow rate, pressure and21

provide smooth start up. Each unit will be controlled from the Enbridge control22 center.23

Additionally, each mainline pump station has pressure transmitters that feed into24the Total Pipelines Control (TPC) system. The TPC protection system is a25monitoring system that uses the SCADA communication network to monitor the26pipeline conditions (pressure, flow, etc.). Based on the present or anticipated27pipeline pressure conditions, TPC can transmit shutdown commands and/or28setpoints to any or all mainline pump stations on a particular line.29

The new booster pump at Edmonton Terminal will have pressure transmitters that30feed into a system similar to that described for the mainline pumps mentioned31above already in operation for the existing terminal.32

Facility Pipe33


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All major equipment and piping will be above ground in a compact station design.1Corrosion control measures will include painting all above-ground equipment and2facilities. CP will be provided for underground steel components.3

Thermal relief valves will be provided to protect piping and equipment connected4to the pump facility. Thermal relief valve discharges will be drained to oil sumps,5which will also collect fluids from equipment drains. Recovered oil from the6sumps will be injected into the suction side of the pumps.7

Piping at the proposed new mainline pump stations and existing facilities will be8designed in accordance with the parameters summarized in Table 7-9.9

Table 7-9: Facility Pipe Design Parameters10

A B C D1 Design

ParameterMainline PumpStation Piping

Edmonton TerminalFacility

Hardisty TerminalFacility

2 MOP (kPa) 9,930 1,900 4,960 1,9003 Estimated Steel

GradeGR 414 GR 483 GR 241 GR 290 GR 359 GR 241

4 Class PN 100 PN 20 PN 50 PN 205

Design Factor0.6 0.6 0.6

6 Minimum DesignTemperature (C)

-43 C -43 C -43 C

7 Maximum DesignTemperature (C)

38 C 38 C 38 C

8 Outside Diameter(mm)

609.6 914.4 609.6 914.4 609.6 762 914.4

9 Estimated WallThickness (mm)

12.7 9.52 12.7 9.52

11

Sump Tank1213The Mainline Pump Station facilities will use an above ground sump tank design14(vented to atmosphere) as storage for drain piping and is located inside a pump15shelter building. The building area itself provides primary containment utilizing a16bermed concrete floor under all equipment.17


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The booster pump at Edmonton Terminal will be connected to an existing buried1

sump tank.2

Pressure Vessels3

The need for pressure vessels will be determined during detailed engineering4and design. Any requirement for registration will be satisfied and all designs for5pressure vessels will be registered in accordance with CSA B51-03.6

7.1.5. Pressure Regulating and Metering Specifications7

Pressure Regulating8

The primary pressure control system uses VFDs. Each pump unit will have a9dedicated VFD unit for maximum efficiency to control flow rate, pressure and10provide smooth start up. Each unit will be controlled from the Enbridge control11center.12

Additionally, each mainline pump station has pressure transmitters that feed into13

the Total Pipelines Control (TPC) system. The TPC protection system is a14monitoring system that uses the SCADA communication network to monitor the15pipeline conditions (pressure, flow, etc.). Based on the present or anticipated16pipeline pressure conditions, TPC can transmit shutdown commands and/or17setpoints to any or all mainline pump stations on a particular line.18

The new booster pump at Edmonton Terminal will have pressure transmitters that19feed into a system similar to that described for the mainline pumps mentioned20

above already in operation for the existing terminal.21

Pressure control and pressure relief will be installed at Hardisty Terminal to22protect existing PN 20 tank manifold facilities. A relief line is planned to be tied23into an existing relief system connected to existing tankage. Relief system24design and sizing will be finalized during the detail engineering stage of the25project and will follow Enbridge Engineering Standard D12-104 (Pressure Relief).26

Metering27

Each mainline pump station uses sonic flow meters with temperature, density and28viscosity rectification as part of the mainline leak detection system for Mass29Balance System (MBS).30


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There are no custody transfer meters as part of this pipeline application.1

7.2. Engineering Design Principles2

7.2.1. Compliance with Primary Codes and Standards3

The Project will be designed, constructed and operated in compliance with the4latest NEB regulatory requirements. The primary applicable regulation is the5

OPR-99, which incorporates , by reference , CSA Z662-11. (Annex K of CSA Z6626will be considered for alternative flaw acceptance criteria of the GMAW girth7welds) These standards, in turn, reference other standards and publications,8which will be followed as appropriate in the design and material selection for each9element of the Project.10

Localized conditions along the proposed pipeline ROW that are not specifically11addressed in CSA Z662-11 include: slope instability, buoyancy control, and12watercourse crossings.13

The Project is considered routine in terms of its geotechnical location, pipeline14design and construction and does not require the development of any designs,15specifications, programs, procedures, measures or plans for which no standard is16set out in OPR-9917

Appendix 7-7 contains a complete list of codes, standards, and specifications that18will be followed for the Project. 19

7.2.2. Company Standards, Procedures and Specifications20

The Project will also be designed and operated to meet the requirement of the21most recent versions of Enbridges engineering standards and guidelines, as22listed in Appendix 7-7, all of which comply with the OPR-99 and have been filed23with the NEB.24

Project Procurement will implement and coordinate quality processes and25

requirements with the Project Quality Manager. These work processes and26 requirements will address quality checks during the procurement cycle, including27third party inspection at vendor facilities. The processes and requirements will28include:29

use of Enbridge pre-qualified vendors;30


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Project Procurement will coordinate reviews of the inspection reports with the1

Project Quality Manager and respective discipline leads for acceptance and / or2 further action.3

Any materials and equipment received at site or at Enbridge staging facilities that4are assessed by Enbridge and its representatives as being non-conforming in5any technical aspect will be quarantined and managed in accordance with6Enbridge quality procedures.7

Enbridge Manuals8

Enbridge will employ existing O&MPs for the operation of the Project, which are9on file with the Board. These manuals will be revised to include any new10procedures as required by the Project. These O&MPs include:11

General reference procedures, including topics such as: regulatory12compliance, incident reporting, public awareness, record keeping and13training;14

Safety procedures, including topics such as: safe work practices, hazard15assessment, confined space entry, fire protection, lock-out/tag-out, and16personal protective equipment;17

Pipeline facility procedures, including: work planning and preparation,18environmental protection, ROW maintenance, foreign crossings, pipe19repair and testing, and tank maintenance;20

Welding procedures, including welder qualification requirements;21

Petroleum quality and measurement procedures to ensure product quality22and custody transfer measurement accuracy; and23

Emergency response procedures, including pre-emergency24preparedness, emergency response responsibilities and actions, product25containment, recovery and cleanup, local release control point mapping26and mitigation measures.27

28

Appendix 7-1Edmonton to Hardisty Pipeline Project

Enbridge Pipelines Inc.


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