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7. ENGINEERING
7.1. Engineering Design Details
7.1.1.
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7
F
H2 S
Density
3
(kg/m )
Viscosity @
Viscosity @
50F(cSt) 21.1C/70F (cSt)
Viscosity @
38C/100.4F
(cSt)
9
10
935
350
177.1
101
56.5
< 0.3
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Class Locations
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As the proposed pipeline will transport crude oil, it will be designed and operated
as a low vapour pressure (LVP) pipeline. In accordance with Table 4.2 of CSA
Z662-11, for the design of LVP pipelines with Class 1 and Class 2 location
designation and in non-sour service, a class location factor of 1.0 will be used for
general installation as well as bores and road crossings and 0.625 will be used
for uncased railway crossings.
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Line pipe for the proposed pipeline will be made of low carbon, high-strength, low
alloy estimated Grade 483 (X-70) steel and will be manufactured using double
Page 7-188
submerged arc welded (DSAW) welding for the spiral seam welding process.
The line pipe will be manufactured to CSA Z245.1 standards.
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A
Design Parameter
Line Pipe
Type 1 General
Line Pipe
Type 2 General
Heavy Wall
Pipe - Bores
and Road
Crossings
Heavy Wall
Pipe
Uncased
Railway
Crossings
OD (mm)
914.4
914.4
914.4
914.4
Maximum Operating
Pressure (MOP) (kPa)
9930
9930
9930
9930
Design Factor
0.8
0.8
0.8
0.8
1.0
1.0
1.0
0.625
Minimum Design
Temperature (C)
Maximum Design
Temperature (C)
38
38
38
483
483
483
483
10
11.8
12.2
15.9
20.6
11
127,278
50,178
4,875
240
0
38
Page 7-189
Quality Control
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Line pipe will be purchased from qualified pipe suppliers and trading houses.
Steel suppliers, mills and coating plants are pre-qualified using a formal
qualification process consistent with ISO standards prior to line pipe purchase.
Qualification encompasses comprehensive evaluation of steel and pipe
manufacturing facilities and requirements for the mill to produce and test line pipe
to Enbridge standards and specifications. Line pipe is engineered with stringent
chemistry tolerances, roundness and nominal wall thickness.
A quality
management system is in place for each pipe order to ensure the pipe
manufacturer adheres to the purchase specifications and applicable codes and
standards. The quality management system ensures that each joint is traceable
to the steel supplier and pipe mill shift during production and that each batch of
pipe is mechanically tested to prove strength and toughness. Lastly, inspection
personnel are present in the pipe mill during all pipe production and coating.
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Welding
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Field girth welding of line pipe for the proposed pipeline will be by automatic gas
metal arc welding (GMAW). The tie-in welding for the proposed pipeline will
involve manual shielded metal arc welding (SMAW). All field girth welds will be
non-destructively inspected using ultrasonic or radiographic inspection methods.
A joining program will be developed consistent with OPR-99 and welders will be
qualified in accordance with the requirements of CSA Z662-11.
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Protective Coating
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The primary external corrosion control for the proposed pipeline will be provided
by a fusion bonded epoxy (FBE) coating that will be applied at a pipe coating
plant. Heavy wall pipe for horizontal directional drilled (HDD) or bored sections
of the pipeline may also receive a dual powder coating that will provide an
additional abrasive resistant coating to protect the FBE coating. During
construction, rock shield, sand padding, wooden lagging or concrete coating will
be used where required to provide additional mechanical protection for the pipe
coating. Field girth welds will be coated with a system compatible with the plantapplied FBE coating.
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Cathodic Protection
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Page 7-190
The majority of the proposed pipeline ROW will be contiguous and adjacent to
an existing Enbridge ROW, the proposed pipeline will be made electrically
continuous with the existing pipelines by using continuity bonding. This electrical
continuity will provide common CP to all of the pipelines within the pipeline
corridor.
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Test stations and coupon test stations will be installed at appropriate intervals
along the proposed pipeline to confirm the effectiveness of the applied CP current
and to permit pipeline access for other corrosion control monitoring activities.
Sectionalizing Valves
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All sectionalizing valves along the proposed pipeline will be single slab through
conduit full-port gate valves with remote operated actuators. Each sectionalizing
valve site will be equipped with remote communication capability.
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The design, manufacture and testing of all valves and fittings will be completed in
accordance with the requirements of our internal Enbridge standard, EES - 023
(2012) and CSA Z662-11. All valves and fittings will be compatible with the line
pipe to which they are connected.
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Table 7-3: Preliminary Sectionalizing Valve Locations
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A
Description
Legal Description
SW 30-51-22 W4M
19.0
SW 14-48-19 W4M
71.3
Highway 26 Sectionalizing
Valve
SW 05-47-16 W4M
99.0
Page 7-191
SE 35-44-13 W4M
140.5
NE 17-44-12 W4
148.1
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Depth of Cover
The minimum installation depths of cover for the proposed pipeline will comply
with all applicable legislation and codes, as summarized in Table 7-4.
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Location
General
0.9
Paved Roads/Access
Roads
1.2
Railways
2.0
Watercourses
1.2
Pipeline Crossings
The proposed pipeline will cross existing highways, roads, railway lines, foreign
pipelines and utility lines. Table 7-5 lists the approximate number of known
crossings. All crossings will be designed and constructed to conform to current
NEB regulatory requirements and applicable standards.
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Crossing Type
Approximate Number
Major Highway
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Page 7-192
Gravel Road
161
Railway
Foreign Pipelines
268
Utility Lines
300
Total
752
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The load imposed on the line pipe by road and rail traffic will be considered in the
design of these crossings. Generally, bored crossings will be used below paved
highways and railway lines to avoid traffic disruptions. However, in locations
where the pipeline crosses unpaved roads that carry very low traffic volumes,
consideration will be given to constructing the crossings using conventional open
cut procedures.
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Foreign pipeline and buried utility lines will be crossed using several techniques,
including boring and open cut.
Watercourse Crossings
The proposed pipeline crosses four named watercourses, two unnamed
tributaries to Iron Creek, one unnamed ditch and two unnamed fish bearing
wetlands. The primary watercourse crossings are outlined in Table 7-6.
Watercourse crossing locations are described in Section 5.1.3 of the ESA
(Volume II of this Application) and are shown in Appendix 6, Figure 2 of the ESA
(Volume IIA of this Application). A preliminary HDD feasibility report is provided
in Appendix 7-3.
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Site
No.
WC1
Name
Goldbar
Creek
WC2
Mill Creek
WC3
Irvine Creek
WC4
Unnamed
ditch
WC5
Unnamed
tributary to
Iron Creek
Legal Location,
UTM Co-ordinates
(NAD 83, Zone 12)
SW 28-52-23 W4M
344933E,
5932486N
SE 35-51-23 W4M
349087E,
5924205N
Recommended
Pipeline Crossing
Method
Isolate if water
present/open cut if dry
or frozen to bottom
Trenchless
SW 33-50-22 W4M
356003E,
5914212N
NW 31-46-16 W4M
411778E,
5874974N
NW 26-44-13 W4M
447153E,
5853340N
Unmapped Class D
No RAP
Isolate if water
present/open cut if dry
or frozen to bottom
Isolate if water
present/open cut if dry
or frozen to bottom
Isolate if water
present/open cut if dry
or frozen to bottom
Unmapped Class D
No RAP
Mapped Class D
No RAP
Recommended
Contingency
Pipeline Crossing
Method
n/a
Recommended
Vehicle/ Equipment
Crossing Method
(Open Water)
Clear span bridge
Recommended
Vehicle/
Equipment
Crossing
Method (Frozen)
Snow fill/ice
bridge
Isolate if water
present/open cut if
dry or frozen to
bottom
n/a
Snow fill/ice
bridge
Existing crossing/
clear span bridge
n/a
Existing crossing/
snow fill/ice
bridge
Snow fill/ice
bridge
n/a
Snow fill/ice
bridge
Page 7-193
Site
No.
WC6
Name
Unnamed
tributary to
Iron Creek
Legal Location,
UTM Co-ordinates
(NAD 83, Zone 12)
SE 19-44-12 W4M
451297E,
5850627N
Recommended
Pipeline Crossing
Method
Isolate if water
present/open cut if dry
or frozen to bottom
Recommended
Contingency
Pipeline Crossing
Method
n/a
Recommended
Vehicle/ Equipment
Crossing Method
(Open Water)
Clear span bridge
Recommended
Vehicle/
Equipment
Crossing
Method (Frozen)
Snow fill/ice
bridge
WC7
Battle River
NE 25-42-10 W4M
479339E,
5833485N
Mapped Class C
April 16 to June 30
Trenchless
Isolate if water
present/open cut if
frozen to bottom
Existing crossing/
clear span bridge
FD1
Unnamed
fish-bearing
wetland
SW 18-46-15 W4M
421308E,
5869022N
n/a
No RAP
(Class V Wetland)
Isolate if water
present/open cut if dry
or frozen to bottom
n/a
Existing crossing/
snow fill/ice
bridge/ clear span
bridge
Snow fill/ice
bridge
FD2
Unnamed
fish-bearing
wetland
NW 3-43-10 W4M
474739E,
5836448N
n/a
No RAP
(Class IV Wetland)
Isolate if water
present/open cut if dry
or frozen to bottom
n/a
Snow fill/ice
bridge
Page 7-194
Pressure Testing
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Before pressure testing, each section of pipeline will be cleaned with pigs to
remove construction debris. This debris will be collected and disposed in
accordance with applicable regulatory requirements.
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During detailed engineering and design, a hydrostatic pressure test program and
hydrostatic test plan will be developed. Water will be used as the primary test
medium, however, depending on the time of year, heat may be required to
prevent freezing. Water for hydrostatic testing will be drawn from approved water
sources and, after use, will be disposed of in accordance with all applicable
regulatory requirements.
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Buoyancy Control
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Buoyancy control may be installed along sections of the pipeline located under
watercourses and in areas where the water table is high. Screw anchors, pipe
weights, concrete coating or a combination thereof will be used to provide
buoyancy control, as necessary. The most suitable buoyancy control method will
depend on the site-specific conditions at each location and will be determined
during detailed engineering and design.
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7.1.3.
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Table 7-7 outlines the preliminary design parameters for the pig trap facilities.
The barrel OD, material grade and wall thickness for the various components of
the pig trap facilities will be finalized during detailed engineering and design.
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The pig traps will be designed to handle the latest models of in-line inspection
tools, as well as standard pigs for cleaning and pipeline integrity. The pig trap
end closures will be double yoke swing type, with a pressure interlock protective
system to safeguard against the door being opened when the trap is pressurized
(as specified in CSA Z662-11).
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The pipe and barrel section of the pig trap assemblies will be made of either low
carbon, high strength, low alloy steel or quenched and tempered carbon steel,
and will be produced as a seamless pipe or from formed pipe or rolled plate. The
final selection of materials will be made during detailed engineering and design.
The pipe will be manufactured to CSA Z245.1 standards.
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Page 7-195
1
A
Design Parameter
Line Pipe
Barrel Pipe
Line Pipe
Barrel Pipe
OD (mm)
NPS 36
(914.4mm)
NPS 42
(1066.8mm)
NPS 36 (914.4mm)
NPS 42 (1066.8mm)
Cat I
Cat I
Cat I
Cat I
MOP (kPa)
1440psig
(9930kPaa)
1440psig
(9930kPaa)
1440psig
(9930kPaa)
1440psig (9930kPaa)
Design Factor
0.6
0.6
0.6
0.6
1.0
1.0
1.0
1.0
Minimum Design
Temperature (C)
-43C
-43C
-43C
-43C
Maximum Design
Temperature (C)
38C
38C
38C
38C
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Pressure Rating
PN 100
PN 100
PN 100
PN 100
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483
483
483
483
12
Minimum Wall
Thickness (mm)
12.7mm
12.7mm
12.7mm
12.7mm
Page 7-196
7.1.4.
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Appendix 7-5 illustrates the preliminary layouts for the initiating mainline pump
station at Edmonton Terminal as well as the intermediate Kingman and Strome
Stations. The final layouts will be determined during detailed engineering and
design.
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The typical process flow diagram (PFD) for the mainline pump stations and pig
traps can be found in Appendix 7-6.
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Pump Requirements
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The Edmonton, Strome and Kingman mainline pump stations will each be
equipped with the required electrical power to be obtained from the local
electrical utility provider. In addition to the information contained in Table 7-8,
each mainline pump station facility will have:
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The new booster pump at Edmonton Terminal will obtain power from an existing
ESB.
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Table 7-8 outlines the preliminary pump specifications (to be finalized during
detailed engineering and design).
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Page 7-197
Station
Annual Flow
3
Rate (m /d)
MOP of
Discharge Pipe
(kPa)
Estimated
Pump
Horsepower
(HP)
Estimated VFD
Horsepower (HP)
Edmonton Terminal
Booster Pump
127,190
1900
2 x 1500
2 x 1500
Edmonton Terminal
Mainline Pump Station
127,190
9930
4 x 6060
4 x 7000
127,190
9930
4 x 6060
4 x 7000
Kingman Mainline
Pump Station
127,190
9930
4 x 6060
4 x 7000
Page 7-198
The ESB and EB for each mainline station are prefabricated modular units with
all electrical equipment installed prior to shipment.
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5
The electrical system will be designed to allow the 4160 V motor buses and the
480 V utility buses to remain isolated from one another so that they function as
independent systems.
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7
8
The UPS systems will be designed to maintain critical control and shutdown
equipment operability in the event that the primary electrical supply is interrupted
including alternate power to the Station Isolation Valves.
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10
Primarily for the purpose of noise control, all new mainline pump units will be
installed in buildings.
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18
The one new booster pump at Edmonton Terminal will be installed outdoors
adjacent to one identical existing booster pump within an existing manifold.
Electrical power will be supplied from an existing ESB for the manifold. The
existing terminal electrical system was designed to allow the 4160 V motor buses
and the 480 V utility buses to remain isolated from one another so that they will
function as independent systems. The existing UPS system was designed to
maintain critical control and shutdown equipment operability in the event that the
primary electrical supply is interuppted.
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Pressure Control
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23
The primary pressure control system uses VFDs. Each pump unit will have a
dedicated VFD unit for maximum efficiency to control flow rate, pressure and
provide smooth start up. Each unit will be controlled from the Enbridge control
center.
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27
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Additionally, each mainline pump station has pressure transmitters that feed into
the Total Pipelines Control (TPC) system. The TPC protection system is a
monitoring system that uses the SCADA communication network to monitor the
pipeline conditions (pressure, flow, etc.). Based on the present or anticipated
pipeline pressure conditions, TPC can transmit shutdown commands and/or
setpoints to any or all mainline pump stations on a particular line.
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The new booster pump at Edmonton Terminal will have pressure transmitters that
feed into a system similar to that described for the mainline pumps mentioned
above already in operation for the existing terminal.
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Facility Pipe
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All piping will be made of low carbon, high strength, low alloy steel. Welding of
pipe joints will use SMAW welding. Welding specifications and procedures will
be developed and welders will be qualified in accordance with the requirements
of OPR-99 and CSA Z662-11.
Page 7-199
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3
All major equipment and piping will be above ground in a compact station design.
Corrosion control measures will include painting all above-ground equipment and
facilities. CP will be provided for underground steel components.
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5
6
7
Thermal relief valves will be provided to protect piping and equipment connected
to the pump facility. Thermal relief valve discharges will be drained to oil sumps,
which will also collect fluids from equipment drains. Recovered oil from the
sumps will be injected into the suction side of the pumps.
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Piping at the proposed new mainline pump stations and existing facilities will be
designed in accordance with the parameters summarized in Table 7-9.
Table 7-9: Facility Pipe Design Parameters
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Design
Parameter
Mainline Pump
Station Piping
Edmonton Terminal
Facility
Hardisty Terminal
Facility
2
3
MOP (kPa)
Estimated Steel
Grade
Class
4
5
6
7
8
9
Design Factor
Minimum Design
Temperature (C)
Maximum Design
Temperature (C)
Outside Diameter
(mm)
Estimated Wall
Thickness (mm)
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12
13
14
15
16
17
9,930
GR 414
1,900
GR 241
4,960
GR 290
PN 100
0.6
PN 20
0.6
PN 50
-43 C
-43 C
-43 C
38 C
38 C
38 C
609.6
12.7
GR 483
914.4
GR 359
1,900
GR 241
PN 20
0.6
609.6
914.4
609.6
9.52
12.7
9.52
762
914.4
Sump Tank
The Mainline Pump Station facilities will use an above ground sump tank design
(vented to atmosphere) as storage for drain piping and is located inside a pump
shelter building. The building area itself provides primary containment utilizing a
bermed concrete floor under all equipment.
Page 7-200
Pressure Vessels
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5
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The need for pressure vessels will be determined during detailed engineering
and design. Any requirement for registration will be satisfied and all designs for
pressure vessels will be registered in accordance with CSA B51-03.
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7.1.5.
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10
11
12
The primary pressure control system uses VFDs. Each pump unit will have a
dedicated VFD unit for maximum efficiency to control flow rate, pressure and
provide smooth start up. Each unit will be controlled from the Enbridge control
center.
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14
15
16
17
18
Additionally, each mainline pump station has pressure transmitters that feed into
the Total Pipelines Control (TPC) system. The TPC protection system is a
monitoring system that uses the SCADA communication network to monitor the
pipeline conditions (pressure, flow, etc.). Based on the present or anticipated
pipeline pressure conditions, TPC can transmit shutdown commands and/or
setpoints to any or all mainline pump stations on a particular line.
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21
The new booster pump at Edmonton Terminal will have pressure transmitters that
feed into a system similar to that described for the mainline pumps mentioned
above already in operation for the existing terminal.
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25
26
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Metering
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Each mainline pump station uses sonic flow meters with temperature, density and
viscosity rectification as part of the mainline leak detection system for Mass
Balance System (MBS).
Page 7-201
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7.2.
7.2.1.
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The Project will be designed, constructed and operated in compliance with the
latest NEB regulatory requirements. The primary applicable regulation is the
OPR-99, which incorporates, by reference, CSA Z662-11. (Annex K of CSA Z662
will be considered for alternative flaw acceptance criteria of the GMAW girth
welds) These standards, in turn, reference other standards and publications,
which will be followed as appropriate in the design and material selection for each
element of the Project.
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13
Localized conditions along the proposed pipeline ROW that are not specifically
addressed in CSA Z662-11 include: slope instability, buoyancy control, and
watercourse crossings.
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17
18
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Appendix 7-7 contains a complete list of codes, standards, and specifications that
will be followed for the Project.
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7.2.2.
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The Project will also be designed and operated to meet the requirement of the
most recent versions of Enbridges engineering standards and guidelines, as
listed in Appendix 7-7, all of which comply with the OPR-99 and have been filed
with the NEB.
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27
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32
33
34
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Page 7-202
Project Procurement will coordinate reviews of the inspection reports with the
Project Quality Manager and respective discipline leads for acceptance and / or
further action.
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5
6
7
Any materials and equipment received at site or at Enbridge staging facilities that
are assessed by Enbridge and its representatives as being non-conforming in
any technical aspect will be quarantined and managed in accordance with
Enbridge quality procedures.
Enbridge Manuals
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11
Enbridge will employ existing O&MPs for the operation of the Project, which are
on file with the Board. These manuals will be revised to include any new
procedures as required by the Project. These O&MPs include:
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15
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17
Safety procedures, including topics such as: safe work practices, hazard
assessment, confined space entry, fire protection, lock-out/tag-out, and
personal protective equipment;
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20
21
22
23
24
25
26
27
Emergency
response
procedures,
including
pre-emergency
preparedness, emergency response responsibilities and actions, product
containment, recovery and cleanup, local release control point mapping
and mitigation measures.
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Page 7-203
Appendix 7-1
Edmonton to Hardisty Pipeline Project
Enbridge Pipelines Inc.
Appendix 7-2