Hydrostatic Pressure Testing Plan

Transcription

1 ENBRIDGE PIPELINES INC. Reference No A02 Revision: 0 Date: 05-Nov-2008

2 TABLE OF CONTENTS 1. INTRODUCTION Purpose Project Description Terminology REGULATIONS, STANDARDS, SPECIFICATIONS AND OTHER APPLICABLE DOCUMENTS TESTING SCHEDULE SAFETY Public and Personnel Safety Protection of Property Protection of the Environment Notifications TEST WATER WITHDRAWAL AND DISPOSAL Water Withdrawal Water Disposal Landowner Permission STRENGTH AND LEAK TEST Pipeline Specifications Test Pressure and Duration TEST SECTION PREPARATION Burial Testing Hours Pipeline Test Heads Assemblies Cleaning Pig Run for New Pipelines Installation of Temperature Recorders TEST PROCEDURES Filling with Water Pressurizing the Test Section Temperature Stabilization Squeezing the Test Section Yield Plotting Temperature Reading Intervals during Hydrotesting Test Acceptance Criteria Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page ii

3 9. TEST SECTIONS Spread 9 Testing Sequence Spread 11 Testing Sequence Pre-tested Fabricated Assemblies One Hour Pre-tests Co-construction Testing Procedure COLD WEATHER TESTING General Requirements Testing With Heated Water Filling Dewatering TEST INSTRUMENTATION Test Instruments Calibration of Instruments Validation of Charts PIPELINE DEPRESSURIZING, DEWATERING AND DEHYDRATION Depressurizing of Test Section Dewatering Dehydration HYDROTEST DOCUMENTS List of Hydrotest Documents Submission of Test Documents LEAK DETECTION Leak Investigation and Repairs Methods of Leak Detection Leak Repair REFERENCES APPENDIX A: ACRONYMS AND ABBREVIATIONS APPENDIX B: LIST OF ATTACHMENTS Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page iii

4 LIST OF TABLES Table 1: Project Pipeline Specifications... 6 Table 2: Strength Test (Four-Hour Duration)... 7 Table 3: Leak Test (Duration Is Not Less Than Four Hours)... 7 Table 4: Above-Ground One-Hour Pre-test Pressures Table 5: Project Watercourse Crossings (for One-Hour Pre-tests) Table 6: Co-construction Watercourse Crossing Table (for Pre-test Check) Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page iv

5 1. INTRODUCTION 1.1 Purpose This (this plan), prepared by Enbridge Pipelines Inc. (Enbridge) for the National Energy Board (NEB) outlines pressure testing requirements (using water) for the light sour (LSr) pipeline portion of the Southern Lights Project (the project). 1.2 Project Description The project pipeline is a new 508 mm OD (NPS 20) pipeline with an average annual capacity of 29,500 m 3 /d (186,000 bbl/d) for LSr crude oil transportation. The Canadian portion of the export pipeline has two main components: Construction of a new 508 mm OD (NPS 20) LSr crude export pipeline from Cromer, Manitoba to the Canada-US border near Gretna, Manitoba, a distance of 288 km. Construction of three new pump stations at Cromer, Glenboro and Manitou (in Manitoba). The project pipeline consists of two construction spreads: 1. Spread 9 extends for km from Cromer Pump Station east to a location east of the Glenboro Black Marsh and will be constructed by a contractor. This spread has seven test sections. 2. Spread 11 is a km section extending east from the east end of Spread 9 to near the Canada- United States (US) border, just beyond Gretna, Manitoba and will be constructed by a second contractor. This spread has six test sections. Pipeline contractors (contractors) will be responsible for the hydrostatic testing (hydrotesting) of test sections of the project pipeline. 1.3 Terminology Appendix A lists acronyms and abbreviations used in this plan. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 1

6 2. REGULATIONS, STANDARDS, SPECIFICATIONS AND OTHER APPLICABLE DOCUMENTS This project complies with: Onshore Pipeline Regulations (OPR 99) under the National Energy Board Act Section 8 of Canadian Standards Association (CSA) Z662-07, which provides specifications for pipeline pressure testing Section 4.9 of Enbridge s engineering standard D , Pipe Design and Construction, Main Line, which deals with pipeline testing Manitoba Water Stewardship (MWS) requirements Canadian Association of Petroleum Producers (CAPP)/Canadian Energy Pipeline Association (CEPA) Hydrostatic Test Water Management Guidelines (September 1996) 3. TESTING SCHEDULE The project schedule proposes that the project pipeline be constructed in the fall of 2008 with the construction for each spread starting in mid-to-late August, Section 10 describes the cold weather hydrotesting procedure to be used if pipeline construction is delayed. 4. SAFETY 4.1 Public and Personnel Safety Enbridge will designate a testing inspector who will be on site to supervise safety and technical operations at all times during hydrotesting. Enbridge will also designate a testing engineer who will be on site to oversee each hydrotest. The contractor will: Comply with CSA Z662-07, Clause 8.17, Safety During Pressure Tests. Provide the testing inspector a detailed safety plan two weeks before start of the hydrotesting program. Take all necessary safety precautions during hydrotesting. Employ only qualified and experienced testing personnel. Remove all unauthorized personnel from the pipeline right-of-way (ROW) during hydrotesting. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 2

7 Install warning signs before the start of each hydrotest. Install fences to prevent the public from entering the ROW during hydrotesting, as necessary. Patrol and inspect the ROW to keep the public away from the ROW during hydrotesting. Inspect test section for leaks at pressures less than 100% of the specified minimum yield strength (SMYS). Treat all hoardings as confined spaces and adhere to all required safety measures. 4.2 Protection of Property This pipeline is located primarily in rural Manitoba, will be buried at a minimum depth of 0.9 m and will not require special precautions for protection of property. In sensitive areas where specialty crops are grown, the pipe will be buried under a minimum cover of 1.2 m. For pipe sections under highway and railway crossings, heavy wall pipe will be buried at a minimum depth of 1.5 m (under highways) and 2.0 m (under railways) to reduce stress levels caused by passing vehicles. 4.3 Protection of the Environment The pipeline terrain is characterized primarily by level or gentle sloping ground, except for a few areas in river and creek valleys. The contractor will: Obtain test water from water bodies that are approved by MWS. Use screens and reduce flow as required to preserve the ecology of the source water. Laboratory test the input source, discharge water and the soil at all potential disposal sites to ensure they meet MWS requirements. Report water releases as spills if they contravene MWS requirements, immediately upon discovery. 4.4 Notifications Enbridge will: Notify the NEB at least seven days before the start of a pipeline hydrotest to allow NEB staff to be present during the hydrotest. Notify all relevant groups. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 3

8 5. TEST WATER WITHDRAWAL AND DISPOSAL The contractor will take the following measures to comply with regulations set out by the Department of Fisheries and Oceans (DFO) Fisheries Act when water is withdrawn from streams, rivers or lakes: observe water withdrawal flow limits install fish guard screens on water intakes to comply with the DFO s Fresh Water End-of-Pipe Fish Screen Guideline (March 1995) not alter, disrupt or destroy fish habitat not deposit any deleterious substances in water frequented by fish 5.1 Water Withdrawal Enbridge has identified the Cromer station hydrotest water pond, Souris River and Lake Seven, located about 3 km north of the project pipeline near LSr KP , as potential water sources for hydrotesting. The water will be used for: hydrotesting Spread 9 and Spread 11 pre-testing of various water crossing pipe sections mixing with the drill mud while drilling (e.g., during a horizontal directional drill under Souris River) creating counter-buoyancy in the water crossing pipe sections Spread 9 The contractor will: Withdraw water from the existing hydrotest water pond at Cromer station. Transfer the water from test section to test section. Dispose of the water from test section 9-6 and test section 9-7 (the eastern-most sections) into a firewater pond (constructed by Enbridge) at Glenboro pump station or small amounts on the ground following proper disposal procedures Spread 11 The contractor will: Withdraw water from Lake Seven. The majority of Lake Seven is located at E/ W4. Lake Seven crosses at Mile 31N into NE W4. Use a fill line from Lake Seven to the test section break point (located at about KP ) between test section 11-1 and test section Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 4

9 Transfer the water from test section to test section. Dispose of the water from test section 11-6 into the new firewater pond (constructed by Enbridge) at Gretna station Souris River The contractor will withdraw water from Souris River for the following activities: pre-testing the 508 mm OD (NPS 20) LSr pipeline section crossing Souris River by HDD method pre-testing the 914 mm OD (NPS 36) Alberta Clipper Expansion Project (ABC Project) pipeline section crossing Souris River by HDD method mixing of the HDD drill mud creating counter-buoyancy in a pipe section if it is installed using the isolation method The contractor will also: Withdraw water from the Souris River for the activities listed above. Discharge the pre-test water on the ground or contain it in tanks to fill pipe sections to achieve counter-buoyancy. Water from the 508 mm OD (NPS 20) project pipeline section will be released to the Gretna pond. Dispose of the drill mud following the proper disposal procedure as outlined in the Environmental Protection Plan as filed with the NEB. All water withdrawal, treatment and disposal procedures will comply with MWS guidelines. 5.2 Water Disposal Regulatory authorities in Manitoba require water acquired from a watershed to be returned to the same watershed. Enbridge has built water storage ponds at Glenboro station and Gretna station for fire fighting purposes. Hydrotest water will be mechanically cleaned and stored in these ponds with no chemical additives. The water will be tested for contaminants, treated if necessary and filtered using temporary containment during dewatering after hydrotesting. No antifreeze chemicals, biocides, corrosion inhibitors, oxygen scavengers or leak detection tracers will be added to the hydrotest water. The only materials in the hydrotest water will be trace amounts of rust, welding residue and residue from pipe manufacturing. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 5

10 Hydrotest water will be sampled and tested at the following stages. 1. Baseline testing of source water as the hydrotest water is drawn from the source. 2. Intermediate sampling of the water during transfer into the last test section before it is released. 3. Release sampling to demonstrate the water meets release quality requirements. Quality requirements include ph, sodium adsorption ratio (SAR), electrical conductivity (EC) and total dissolved solids (TDS) measurements. 5.3 Landowner Permission If land is negatively affected by water disposal or temporary land (not within the existing ROW) is required to place the fill or dewatering lines, the contractor will: Obtain written permission from landowners and tenants. Send a copy of such authorization to the Enbridge construction manager before starting any testing. 6. STRENGTH AND LEAK TEST 6.1 Pipeline Specifications Table 1 outlines the project pipeline specifications. Table 1: Project Pipeline Specifications Property Value Pipeline size (NPS) 20 Pipeline outside diameter size(mm) 508 Pipeline class location 1 Line pipe wall thickness (mm) 6.35 Heavy wall pipe wall thickness (mm) 7.92 Railroad crossing pipe wall thickness (mm) Corrosion allowance (mm) 0.0 Line pipe material grade Grade 483/550 Line pipe material manufacturing process Electric resistance welded (ERW) Service Liquid, low vapour pressure (LVP), non-sour Maximum operating pressure (kpa)/(psi) 9,653/1,400 Design code CSA Z Pipeline type Buried Minimum cover (mainline) (m) 0.9 Minimum cover (road and railroad crossings) (m) 1.5 and 2.0 Coating system Fusion-bonded epoxy (FBE) dual powder system (DPS) Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 6

11 6.2 Test Pressure and Duration Hydrotesting is divided into two phases: 1. Strength Test phase. The strength test determines the strength of the steel. 2. Leak Test phase. The leak test, conducted after the strength test, verifies that the test section is leakfree. Table 2 and Table 3 show minimum and maximum hydrotest pressure limits, per CSA Z Table 2: Strength Test (Four Hour Duration) CSA Z Class Location Minimum Test Pressure Limit a Maximum Test Pressure Limit b x MOP 110% SMYS x MOP 110% SMYS x MOP 110% SMYS x MOP 110% SMYS Notes: a MOP=maximum operating pressure b SMYS=specified minimum yield strength Table 3: Leak Test (Duration Is Not Less Than Four Hours) CSA Z Class Location Minimum Test Pressure Limit a Maximum Test Pressure Limit b x MOP 100% SMYS x MOP 100% SMYS x MOP 100% SMYS x MOP 100% SMYS Notes: a MOP=maximum operating pressure b SMYS=specified minimum yield strength The strength test will start at a pressure between the minimum and maximum test pressure limits. During the yield plot (see Section 8.5), the maximum test pressure is also limited to the 0.2% water volume deviation on the pressure versus volume plot. Per Table 8.1 of CSA Z662-07, the maximum leak test pressure at the lowest point of elevation along the test section shall be the lesser of the qualification pressure and the pressure corresponding to 100% of the SMYS of the pipe. The qualification pressure will be the lowest pressure achieved during the strength test at the high point of the test section. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 7

12 The leak test will start after the depressurizing valve has been properly closed and checked for leaks. Attachment 1 (see Appendix B) contains profile, length, volume and test pressures for each test section and the specifications for each hydrotest. Enbridge will validate the calculations based on actual field information before starting any hydrotest. 7. TEST SECTION PREPARATION 7.1 Burial The contractor will install a minimum of 10 m of heavy wall pipe (with a wall thickness of 7.92 mm) between a test section and the test heads as a safety precaution to the personnel working around the test heads and to lower the stress level to 64% of the SMYS for exposed pipe ends during hydrotesting. The contractor will backfill the test section except the ends where sufficient pipe to tie in the test heads will be left exposed. 7.2 Testing Hours The contractor will: Ensure that pressurizing and yield plotting (see Section 8.5) are completed during daylight hours, unless otherwise directed by the testing inspector. Provide adequate lighting at both ends of the test section when warranted. 7.3 Pipeline Test Heads Assemblies Two types of test heads are required during pipeline construction: 1. Conventional high-pressure test heads that are installed on two ends of a test section to be used during hydrotesting. 2. Low-pressure test heads, also known as launchers and receivers, used for cleaning or caliper pigging. Enbridge will supply each contractor with a minimum of six NPS 20 conventional high-pressure test heads. The contractor will supply the launchers and receivers. 7.4 Cleaning Pig Run for New Pipelines After a new pipeline is constructed, the contractor will run a cleaning pig through appropriate pipe sections to remove internal debris. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 8

13 7.5 Installation of Temperature Recorders Temperature recorders are installed to record temperatures along a test section to help determine the correlation between the pressure and temperature of the test medium (e.g., water). The contractor will install at least two dual pen temperature recorders at either end of the test section. For test sections longer than 10 km, a third temperature recorder will be needed in the middle section. The contractor will also install one single pen recorder near the test head to record the fill water temperature. The temperature probe will be placed into a thermowell and threaded into the fill line. 8. TEST PROCEDURES 8.1 Filling with Water The contractor will: Install a pressure gauge on each test head before filling. Install all temperature recorders, including a thermowell in the fill line at the test head. Ensure that the fill water complies with the conditions and restrictions of water permits. Install a calibrated flow meter in the fill line to record the fill rate and volume entering test sections. Contain fuel and lubricant leaks from pumps. Install a squeegy pig to maintain an air-water interface. 8.2 Pressurizing the Test Section When filling is complete, and with the testing inspector on site, the contractor will gradually increase the test pressure to about 3,000 kpa and inspect the test heads for leaks. The test section will be stabilized for a minimum of two hours to reduce the pressure and temperature fluctuations inside the test section before using the squeeze pump. 8.3 Temperature Stabilization This stabilization period of the hydrotest water will be determined by using a temperature-time plot and may take longer than the estimated two hours. The medium will be stabilized when the plot becomes sufficiently asymptotic or when the temperature of the test medium is at or near the temperature of the ground along the test section. This can be determined from the temperature chart readings. 8.4 Squeezing the Test Section Enbridge must check and revise, if necessary, the test pressure calculations before squeezing starts. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 9

14 The contractor will: Connect the squeeze pump to the test section once the test section water has stabilized and the testing inspector and testing engineer are on site. Disconnect all fill line jumper connections between test sections before connecting the squeeze pump. Validate the accuracy of the stroke counter of the squeeze pump by measuring the volume of one piston displacement, multiplying it by the number of pistons on the pump, and verifying this volume by pumping water into a barrel of known volume. Check the accuracy of the flow meter by pumping water into a barrel of known volume. Ensure connectors between the squeeze pump and the test head are rated in excess of the maximum test pressure. Install a check valve in the squeeze line as near to the test head as practical. An ANSI Class 900 (PN 150) check valve is required for test pressures equal to or less than 15,500 kpa. An American National Standards Institute (ANSI) Class 1,500 (PN 250) is required if the test pressure exceeds 15,500 kpa. The purpose of the check valve is to prevent the squeeze line from whipping if the squeeze pump or piping between the pump and the test head fails. Stop the pump to investigate the problem if the squeeze line starts to hammer during pressurizing. Gradually pump additional volume of water into the test section to a pressure that is about 3,000 kpa less than the yield plot start pressure, stop the pump and investigate the following: o o Check test heads at both ends for leaks. If a leak is found, tighten the leak using extreme caution. Check the static pressure at both ends of the test section. The difference between the pressure head h calculated from the measured pressure at each end of the test section should equal the surveyed elevation difference between the two ends. If a discrepancy is found, the surveyors must do a high-low profile between the two ends of the test section before increasing the pressure. 8.5 Yield Plotting A yield plot has to be drawn during hydrotesting when the test pressure at any point on the test section produces a hoop stress exceeding 95% of the SMYS of the pipe (this exceeds the CSA Z requirement of 100% of the SMYS of the pipe). Yield plots are not required for test sections less than 1,000 m in length (e.g., the Souris River hydrotest under co-construction). In such a case, the pressure in the section shall be gradually brought up to the test pressure and stabilized. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 10

15 Yield plotting is divided into two phases: the slope establishment phase (see Section 8.5.1) and the yield plot phase (see Section 8.5.2) Slope Establishment Phase After the squeeze pump is stopped at about 3,000 kpa less than the yield plot start pressure and the test heads are checked for leaks, the pump is restarted with the intention that it will stop only after the yield plotting is complete. The contractor must make sure that there is enough water in the squeeze tank to complete the yield plot. Before the pump is started, the contractor and the testing inspector must make sure that all pressure gauges, pressure and temperature charts, flow meters, dead-weight and electronic pressure testers and the outside thermometer are working properly. In addition, all cables and liquid lines need to be in good working order. The contractor will start the pump and set it at a rate to increase the pressure inside the test section between 50 to 100 kpa per minute. This rate must be established quickly and maintained during the yield plot. The testing engineer will take readings of the volume of water required to raise the pressure inside the test section by 100 kpa until the yield plot start pressure is reached and the pump is stopped. These readings will establish the relationship or slope between the pressure and volume. Once these readings are plotted by the testing engineer on graph paper, the slope establishment phase ends Yield Plot Phase While the pump is stopped, the contractor will once again check the test heads at the two ends of the test section for leaks. The testing engineer will extend the pressure-volume graph to predetermine the total volume of water that will be needed to raise the pressure inside the test section from the yield plot start pressure up to the strength test commencement (aim) pressure. The testing engineer will also draw the 0.2% volume of the test section line parallel to the pressure-volume graph. When the testing engineer is ready and all instruments are re-checked to ensure proper functioning, the testing engineer will advise the contractor to start the pump at the same previous speed. As the pressure increases inside the test section, the testing engineer will plot the actual volume of water needed corresponding to the pressure rise on the graph and compare it with the predetermined expected volume. In earlier stages of squeezing, the actual volumes will be close to the expected volumes. However, as the pressure is increased the pipe will yield and expand and need more water for the same pressure rise. As long as the water volume stays within the 0.2% limit, the yield plotting will continue. Yield plotting will stop when the aim strength test pressure is reached or if the water volume reaches the Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 11

16 0.2% limit. If the plot reaches the 0.2% limit anywhere between the aim and minimum strength test pressure, then the pump may be stopped and the strength test may begin. If the 0.2% limit is reached before reaching the minimum strength test pressure, the pump will be stopped to investigate the cause, which may be either over-yielding of the pipe or a leak in the test section. Enbridge prefers to set the aim strength test pressures close to 110% of the SMYS and has set the aim strength test pressures between 109 and 110% of the SMYS. Enbridge has reviewed the materials test records (MTRs) of the manufactured pipe and concluded that the lowest yield strength of the pipe is 484 MPa (70,200 psi). Hence, the testing crew must ensure that the squeeze pump is stopped at the right time and the pressure does not exceed 110% of the SMYS to avoid over-yielding of the pipe Strength Test Once the aim strength test pressure is reached, the contractor will stop the pump, check all test heads and instrument valves, fittings, and assemblies for leaks, and allow the test section to stabilize for about an hour. If the pressure inside the test section drops, the contractor will increase the pressure to the aim test pressure. The contractor may have to continue this process several times to stabilize the test section and to make sure that there is no leak. Once satisfied, the contractor will disconnect the squeeze pump, install bull plugs and a blind flange, and lock in the test pressure. The testing engineer will then declare the test section to be on-test. The pressure could fluctuate after the test section has been put on-test. To avoid pressure fluctuations, the contractor needs to stabilize the test section with one or two pressure boosts before putting the test section on-test again Test Pressure Reading Intervals During Strength Test Once the aim strength test is reached, the testing inspector will take the pressure readings per the following intervals and note the time, pressure and ambient temperature on a Pressure Log Sheet: every 5 minutes for the first 30 minutes (this is to monitor the initial pressure drops and pressure boost as required) every 10 minutes for the next 30 minutes (at this point, the test section will likely be stabilized) every 30 minutes for the next 3 hours The intervals mentioned above are applicable to new pipeline facilities that are strength-tested for four hours Leak Test Table 9.1 in CSA Z stipulates that the maximum leak test pressure shall be the lesser of the qualification pressure and the pressure corresponding to 100% of the SMYS of the pipe. The qualification pressure will be the lowest pressure achieved during the strength test at the high point of the test section. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 12

17 In most cases, the test section will have to be dewatered and depressurized from the strength test pressure to the maximum leak test pressure. This pressure reduction may not be necessary if the pipe wall thickness and grade are such that the maximum strength test pressure is already below the pressure corresponding to 100% of the SMYS Test Pressure Reading Intervals During Leak Test Once the strength test is complete and the leak test has commenced, the test inspector will take the pressure readings per the following intervals and note the time, pressure and ambient temperature on a Pressure Log Sheet: every 5 minutes for the first 30 minutes (this is to monitor the initial pressure drops and pressure boost as required) every 10 minutes for the next 30 minutes (at this point, the test section will likely be stabilized) every 30 minutes for the next 3 hours The intervals mentioned above are applicable to new pipeline facilities that are leak-tested for a minimum of four hours. 8.6 Temperature Reading Intervals during Hydrotesting The contractor will check the temperature recorders at least every two hours during the test period. If a recorder has stopped, the contractor will restart the chart recording without spinning it and note the reason for the interruption on the chart. 8.7 Test Acceptance Criteria Acceptance of a hydrostatic test will be based on the stabilization of the pressure during the leak test phase because the strength test phase validates the strength of the material. For new pipeline facilities the test is acceptable when the leak test pressure readings during the last two hours are within 10 kpa of each other. The contractor will continue the leak test for longer than four hours until this is achieved. 9. TEST SECTIONS Enbridge selected seven test sections for Spread 9 and six test sections for Spread 11. Attachment 1 (see Appendix B) contains the approximate lengths and volumes of these 13 test sections, starting from the west and extending east. Start points, end points and lengths of these sections may change during construction as a result of contractor consultation. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 13

18 9.1 Spread 9 Testing Sequence The contractor will: 1. Fill section 9-1 and section 9-2 first from the water available in Cromer firewater pond. This will store additional make-up water in the test sections. 2. Set the test bus between section 9-1 and section Test section 9-1 from its east end. 4. Connect section 9-2 to section Dewater section 9-1 into section 9-2 and section Test section 9-2 from its west end. 7. Connect section 9-3 and section Dewater section 9-2 into section 9-3 and section Move the test bus between section 9-3 and section Test section 9-3 from its east end. 11. Connect section 9-4 and section Dewater section 9-3 into section 9-4 and section Test section 9-4 from its west end. 14. Connect section 9-5 and section 9-6. The east end of section 9-6 will be at Glenboro pump station, where Enbridge will construct a new firewater pond for test water retention. 15. Dewater section 9-4 into section 9-5 and section Move the test bus between section 9-5 and section Test section 9-5 from its east end. 18. Connect section 9-6 and section Dewater section 9-5 into section 9-6 and section Test section 9-6 from its west end. 21. Dewater section 9-6 into section 9-7 and the Glenboro firewater pond. 22. Move the test bus between section 9-6 and section Test section 9-7 from its east end. 24. Dewater section 9-7 into the Glenboro firewater pond (located at the west end of section 9-7). 9.2 Spread 11 Testing Sequence The contractor will: 1. Fill section 11-1 and section 11-2 with the water available in Lake Seven through a fill line. This will store additional make-up water in the test sections. 2. Set the test bus between section 11-1 and section Test section 11-1 from its east end. 4. Connect section 11-2 and section Dewater section 11-1 into section 11-2 and section Test section 11-2 from its west end. 7. Connect section 11-3 and section Dewater section 11-2 into section 11-3 and section Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 14

19 9. Move the test bus between section 11-3 and section Test section 11-3 from its east end. 11. Connect section 11-4 and section Dewater section 11-3 into section 11-4 and section Test section 11-4 from its west end. 14. Connect section 11-5 and section Dewater section 11-4 into section 11-5 and section Move the test bus between section 11-5 and section Test section 11-5 from its east end. 18. Dewater section 11-5 into section 11-6 and the Gretna firewater pond. 19. Test section 11-6 from its west end. 20. Dewater section 11-6 into the Gretna firewater pond. 9.3 Pre-tested Fabricated Assemblies All prefabricated assemblies (mainline block valves and loop end cross-over tie-ins) will be pre-tested at the fabricators. They will be tested to a minimum of 1.4 times their design pressure as outlined in Section 7 of Enbridge s Operating and Maintenance Procedures Book 3, which will meet or exceed the pipeline qualification pressure at each installation location. The assemblies will be cut into the pipeline without further pressure testing once the mainline test is complete. 9.4 One Hour Pre-tests As a precaution, it may be beneficial to pre-test a pipe section before installing it to cross high pressure gas pipelines, highways, major rivers and other locations. Such pre-tests are done above-ground for one hour. Enbridge will identify such crossing locations. The contractor may also conduct these pre-tests if crossings are not identified by Enbridge. At a minimum, the contractor will pre-test all watercourse crossing pipe sections that will eventually be coated with continuous concrete (i.e., gunnited). The minimum pre-test pressure will be the pressure that will generate a hoop stress corresponding to 80% of the SMYS of the crossing pipe or 125% of the crossing pipe section maximum operating pressure (MOP), whichever is less. The maximum pre-test pressure will be the pressure which will generate a hoop stress corresponding to 90% of the SMYS of the crossing pipe. Table 4 contains above-ground one-hour pre-test pressures. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 15

20 Table 4: Above-Ground One-Hour Pre-test Pressures Description Pressure (kpa) (psig) Pipe section MOP 9,653 1, % of MOP 12,066 1,750 Minimum test pressure, 80% SMYS (508 mm OD [NPS 20], 6.35 mm WT, Grade 483) 9,660 1,401 Maximum test pressure, 90% SMYS (508 mm OD [NPS 20], 6.35 mm WT, Grade 483) 10,868 1,576 Minimum test pressure, 80% SMYS (508 mm OD [NPS 20], 7.92 mm WT, Grade 483) 12,048 1,747 Maximum test pressure, 90% SMYS (508 mm OD [NPS 20], 7.92 mm WT, Grade 483) 13,554 1,966 Once in place, the contractor will re-test the crossing pipe as part of the pipeline hydrotest. The contractor will submit documentation to Enbridge for the one hour pre-tests, including the pressure log and charts marked with the date, location and name of the crossing, and a dimensioned sketch of the piping. Table 5 identifies the watercourse crossing pipe sections that are likely to be coated with continuous concrete and will undergo one hour above-ground pre-tests. Table 5: Project Watercourse Crossings (for One-Hour Pre-tests) ID EKP Legal Location Name Pipe WT (mm) Test Pressure Minimum (kpa) Maximum (kpa) SE W4 Unnamed creek ,660 10, SE W4 Souris River ,048 13, NW W4 Spring Brook ,660 10, SE W4 Oak Creek (1) ,660 10, SE W4 Oak Creek (2) ,660 10, SW W4 Oak Creek (3) ,660 10, NE W4 Cypress River (1) ,660 10, NE W4 Cypress River (2) ,660 10, SE W4 Thornhill Coulee ,660 10, SW W4 Deadhorse Creek ,660 10, NW W4 Hespeler Creek ,048 13, NW W4 Buffalo Creek ,660 10, N/ W4 Drainage channel ,660 10, NW W4 Unnamed Creek ,660 10,868 Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 16

21 9.5 Co-construction Testing Procedure Enbridge is also constructing a 914 mm OD (NPS 36) pipeline in the same ROW as the project pipeline as part of its ABC Project. The ABC project pipeline extends from the Enbridge s terminal facility at Hardisty, Alberta though the provinces of Saskatchewan and Manitoba to Superior, Wisconsin in the United States (US). This new pipeline will transport heavy crude oil with an initial average capacity of 71,500 m 3 /d (450,000 bbl/d), and an ultimate capacity of 127,000 m 3 /d (800,000 bbl/d) when future pump stations are operational. The majority of the Manitoba portion of the ABC Project pipeline will be constructed in summer of 2009 and will parallel the project pipeline, which will be operating by that time. In a number of places, portions of the ABC Project pipeline in Manitoba will be constructed with the project pipeline during fall of These portions are called the co-construction areas in this plan. There are about 29 km of co-construction areas that require both 914 mm OD (NPS 36) and 508 mm OD (NPS 20) pipe sections to be constructed at the same time Watercourse Crossing Pipe Pre-test The contractor will pre-test all co-construction watercourse crossing 914 mm OD (NPS 36) pipe sections that will eventually be coated with continuous concrete (i.e., gunnited). The minimum pre-test pressure will be the pressure that will generate a hoop stress corresponding to 80% of the SMYS of the crossing pipe or 125% of the MOP of the crossing pipe section, whichever is less. The maximum pre-test pressure will be the pressure that will generate a hoop stress corresponding to 90% of the SMYS of the crossing pipe. Table 6 shows above-ground one-hour pre-test pressures for 914 mm OD (NPS 36) x Grade 483 pipe sections. Table 6: Co-construction Watercourse Crossing Table (for One Hour Pre-test) ID EKP Legal Location Name Pipe WT (mm) MOP (kpa) Minimum Test Pressure (kpa) SE W4 Unnamed creek ,716 8,722 9, SE W4 Souris River ,217 10,271 15, NW W4 Spring Brook ,217 8,722 9, SE W4 Oak Creek (1) ,217 8,722 9, SE W4 Oak Creek (2) ,711 8,722 9, SW W4 Oak Creek (3) ,711 8,722 9, NE W4 Cypress River (1) ,711 8,722 9, NE W4 Cypress River (2) ,711 8,722 9, SE W4 Thornhill Coulee ,711 8,722 9,812 Maximum Test Pressure (kpa) Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 17

22 ID EKP Legal Location Name Pipe WT (mm) MOP (kpa) Minimum Test Pressure (kpa) SW W4 Deadhorse Creek ,716 8,722 9, NW W4 Hespeler Creek ,716 9,635 10, NW W4 Buffalo Creek ,716 8,722 9, N1/ W4 Drainage channel ,716 8,722 9, NW W4 Unnamed Creek ,716 8,722 9,812 Maximum Test Pressure (kpa) 10. COLD WEATHER TESTING 10.1 General Requirements As a general rule, the contractor may use the following test mediums during winter depending on the pipe size: unheated or heated water for pipe sizes greater than 610 mm OD (NPS 24) heated water for pipe sizes between mm OD (NPS 8) and 610 mm OD (NPS 24) water-methanol solution where permitted or heated water for pipe sizes between mm OD (NPS 4) to mm OD (NPS 6) Heated water will be used during winter testing of the 508 mm OD (NPS 20) project pipeline. The contractor will: Reduce the amount of frozen backfill by not leaving the ditch open for an extended period of time. Adequately shelter and heat any open ditch required for tie-ins, test heads and other piping. Heat sources must not be in direct contact with the pipe; the shelter must support the snow load and not be affected by high winds. All open ditches must be kept free of standing water at all times. Install a temperature recorder by means of a thermowell to monitor the temperature of water added to the test section. Monitor the temperature of the circulated heated water at the discharge end. Monitor pipe and ground temperatures at several points along the test section. Fill the test section continuously. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 18

23 10.2 Testing With Heated Water The contractor will: Supply heaters large enough (5,000 L/min) to inject warm water (10 to 35 C) in the test head. Fill instrumentation lines with antifreeze to purge air and water, preventing the line from freezing off. One indication that freezing has occurred is that pressure begins to fluctuate. If freezing has occurred, the lines must be cleared. Use calibrated digital test pressure gauges (with backups) instead of deadweight testers because gauges eliminate the use of hydraulic hoses stretched from test head to test trailer. Even with antifreeze-filled instrumentation lines, the water from the pipeline will bleed into the lines and, when cold enough, will freeze and cause instrumentation malfunctions. Ensure that valves on the test head remain in the open position. If the heat supply fails, water trapped between the closed valve and blind flange will freeze and burst the valve body Filling Heated water is circulated through the test section to prevent the water from freezing during testing and dewatering and to melt the frozen ground surrounding the pipe to create a heat sink. The contractor will: Withdraw water from the water source into the tanks, and heat and circulate the water in the tanks before injecting the water in the test section. This process will provide a contingency volume of water during line fill and allow removal of entrained air from the water suction source. Inject the heated water into one end of the test section and allow it to come out of the other end. Use a hot slug during initial line fill. This involves injecting the initial 20% of fill volume with 20 to 35 C water. This initial slug will heat pipe walls and the ground, reducing the heat loss of the remaining line fill volume being injected. Continue the circulation for a minimum of two hours while maintaining a minimum discharge temperature of 2 C. Record the following: o o o accumulated volume of circulation water inlet and outlet water temperatures on charts or manually every 30 minutes time, temperature and water volume when changes to the inlet temperature are made Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 19

24 o o o pipe and ground temperatures at several points along the test section release the circulated water onto the surrounding land previously identified as acceptable to appropriate companies, landowners and regulatory authorities, or into a water truck install an energy-absorbing diffuser on the discharge end to prevent erosion, bottom scour or damage to vegetation 10.4 Dewatering The contractor will: Have compressors in place to begin dewatering immediately after the hydrotest is complete to prevent freezing of test water, which could result in equipment failure, line rupture or both. Take special care to drain valve bodies. 11. TEST INSTRUMENTATION 11.1 Test Instruments The contractor will supply the following instruments for pressure testing: deadweight testers with weights measuring 5 kpa with a 0 to 18,000 kpa range electronic pressure gauges pressure chart recorders (0 to 18,000 kpa) to be installed close to the deadweight tester water flow meters to measure water fill rates and volumes temperature chart recorders (-30 to 60 C) accurate to 1 C single pen temperature chart recorders with a thermowell to measure fill water temperature (-20 to 50 C and accurate to 1 C) thermometers accurate to 1 C to measure fill water and ambient temperatures pressure gauges (0 to 18,000 kpa) pig locators 11.2 Calibration of Instruments The contractor will validate the operation of the instruments before each hydrotest in the presence of the testing inspector. For example, the temperature recorders will be verified at ambient temperature. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 20

25 All instruments will be properly calibrated before the start of the testing program and will come with valid calibration certificates issued within the past 30 days. The testing inspector will review each calibration certificate before the start of the testing program Validation of Charts At the end of a hydrotest and after a chart is removed, the testing inspector will clearly write the following information on the back of the chart and sign it. 1. Test number 2. Company tag number 3. Location of recorder (any reference point and chainage) 4. Time and date the chart was removed 5. Weather at time of removal 6. Explanation of any irregularities or interruptions on the chart 12. PIPELINE DEPRESSURIZING, DEWATERING AND DEHYDRATION 12.1 Depressurizing of Test Section The testing inspector, after accepting the test, will witness the depressurizing of the test section and ensure it is done with extreme caution and no vibration. The contractor will: Depressurize the test section using an Enbridge-approved bleed-off assembly. Open and close the assembly slowly to protect the assembly from shock loading, and under no circumstances fully open the valve to achieve depressurization. Connect the depressurizing piping into a tank or, if approved, point the depressurizing piping in a direction to prevent damage to the ROW or adjacent property. Transfer the water into the adjacent test section once the pressure is reduced Dewatering The contractor will (after depressurizing the test section): Dewater the test section either into the next test section or to the test water discharge point. Dispose the test water per the water permits and to locations described in this plan. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 21

26 Install energy-absorbing diffuser(s) at the discharge end of the dewatering line to prevent erosion, bottom scour and damage to vegetation. Propel, by means of air, a bi-directional pig or sphere inside the test section to remove water and, wherever possible, probe the pigs or the spheres to verify their proper positions before and after each run. Securely support and tie down the dewatering line at the discharge end to prevent whipping of the line. Not use mechanical connections on dewatering lines. Conduct additional dewatering runs after the main runs to remove any left over water. These dewatering runs would likely be discharged to a receiving tank because there would be a high concentration of air entrainment Dehydration Full pipeline dehydration is not required because the project pipeline will be used in oil service where rigorous dew point control is not required. 13. HYDROTEST DOCUMENTS Hydrotest documents will support Enbridge s submissions to appropriate regulatory authorities and provide a permanent record of the project pipeline system for future reference. The construction manager will: Collect and sign all test documents (see Section 13.1 for a list of hydrotest documents) and courier them to the project manager within three days of completing a hydrotest. Photocopy and file all test documents in the construction office as backups to the original documents. Explain anomalies in recorded data on the Pressure Log Sheet by describing conditions that existed during the test. Provide a proper comparison between the as-tested and as-installed lengths, and whether the as-built test head chainages are horizontal or contoured. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 22

27 13.1 List of Hydrotest Documents The following lists project hydrotest documents. 1. hydrostatic test calculations (calculated test pressures) 2. hydrostatic test schematic and profile drawings showing: o o o o a scaled elevation profile of the test section preliminary locations of the test section cut point elevations with their preliminary chainages the testing inspector will identify any changes and the testing engineer will recalculate the test pressures based on the revised information and issue a new Calculation Test Sheet. 3. a hydrostatic test field report 4. a yield plot log sheet 5. a yield plot graph (using graph paper) 6. a pressure log sheet 7. a pressure chart of an eight-hour test period 8. a graph of temperatures and pressure loss versus time 9. a fill water temperature chart 10. pipe and ground temperature charts 11. an as-tested line drawing of test 12. a red-marked hydrostatic testing schematic 13. certificates of calibration If a pipeline test is repeated, the documentation must include all pipes and ground temperature charts from the commencement of filling to the end of the successful test and all yield plot logs and graphs. Unsuccessful test logs do not need to be sent in unless a leak or break has occurred. One hour pre-test documents will include a pressure log marked with the date, location and name of the crossing or assembly, and a dimensioned sketch. Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 23

28 13.2 Submission of Test Documents The Enbridge project manager will submit hydrostatic test documentation as required by the appropriate regulations (e.g., leave-to-open [LTO] documents per NEB s Onshore Pipeline Regulations). 14. LEAK DETECTION 14.1 Leak Investigation and Repairs When it becomes apparent that there is a leak, the contractor will visually inspect the test section. If the visual inspection does not reveal the leak location, the contractor will then advise the Enbridge construction manager of further action. If the defect in the line is as result of poor field welding or mechanical damage, such as a dent or buckle, the defective area shall be removed and replaced with a pre-tested pipe pup. If the defect is in the longitudinal or spiral weld, the entire joint of pipe shall be replaced. Refer to Section 14.2 for details about methods of leak detection Methods of Leak Detection It may be difficult to locate leaks when there is no surface indication of their locations, and in wet areas where leaked water cannot be easily detected. An awareness of available leak detection methods will be helpful in choosing the appropriate method for each case. The following lists leak detection methods. Barrier Pigs method Correlated Acoustic Emission Detector method Dyes method External Acoustic Emission Detector method Gas Tracers method Ground-looking Radar method Ice Plugging method Interpolated Acoustic Emission Detector method Odorants method Radioactive Tracers Method Sectioning method Smart Pigs methods Visual Leak Detection method Ref. No.: A02 Date Issued: 05-Nov-2008 Rev.: 0 Page 24