Enbridge Northern Gateway Pipelines

3000, 425 1st Street SW, Calgary, AB, T2P 3L8 (T) 403.231.3900 (F) 403.718.3525

August 3, 2012 E-FILE Attention: Ms. Sheri Young, Secretary to the Joint Review Panel

Enbridge Northern Gateway Project National Energy Board 444 Seventh Avenue SW Calgary, AB T2P 0X8 Dear Ms. Young, Re: Northern Gateway Pipelines Application to the National Energy Board

Enbridge Northern Gateway Project OH-4-2011 NEB File No: OF-Fac-Oil-N304-2010-01 01 NGP Responses to JRP IR 3.1(f)

In our response to JRP IR 3.1(f) dated March 8, 2012, Northern Gateway committed to filing updates to Facility Construction Specifications FCS001, FCS002, FCS012, FCS013, FCS016 and FCS017 upon completion of their revisions. As such, Northern Gateway now encloses updates to FCS001, FCS002 and FCS017 for filing. Northern Gateway expects that updates to the remaining Specifications will be completed by the end of the month and they will be filed with the JRP shortly thereafter. These documents are being filed electronically with the Board and will be served upon all OH-4-2011 Parties. If the Board should require additional information, please contact the undersigned at (403) 718-3444. Yours truly,

Ken MacDonald Vice President, Law and Regulatory Northern Gateway Pipelines Limited Partnership Enclosures cc: CEAA Attention: Sarah Devin

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FACILITY CONSTRUCTION SPECIFICATION

COPYRIGHT © 2012 ENBRIDGE PIPELINES INC. ALL RIGHTS RESERVED

Facility Construction Specification (FCS) Canada

Site Preparation and Earthwork FCS001 – (2012)

Project No: [type project name here] Volume No: [type volume # here] Version: [type version # here] Issue Date: [type date issued here]

Copyright © 2004 Enbridge Technology Inc., All Rights Reserved

Revision: 2.0 Approval Date: July 30, 2012

Enbridge Pipelines Inc.

Enbridge Energy Partners L.P.

Attachment 1 to NGP Responses to JRP IR 3.1(f)

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SITE PREPARATION AND EARTHWORK FACILITY CONSTRUCTION SPECIFICATION FCS001 - 2012

REVISION 2.0, JULY 30, 2012 PAGE i COPYRIGHT © 2012 ENBRIDGE PIPELINES INC. ALL RIGHTS RESERVED

Management of Change

1 Revision Summary

Revision Description

2.0 Complete revision

Reviewed and updated to reflect current industry standards and Company’s best engineering design practices.

2 Applicability

Revision Description Effective Date

2.0 This revision is applicable to all projects that have not received AFE approval.

Projects with AFE approval shall continue to abide by the previous revision.

If Projects with AFE approval choose to adopt the latest revision of the standard, a Project Decision Record is required.

July 30, 2012

Please see Section 18 – Revision History for a list of significant changes.


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REVISION 2.0, JULY 30, 2012 PAGE ii COPYRIGHT © 2012 ENBRIDGE PIPELINES INC. ALL RIGHTS RESERVED

Table of Contents 1 General ..................................................................................................................... 1

2 References ............................................................................................................... 1

2.1 Company Standards .......................................................................................... 1

2.2 Industry Standards ............................................................................................ 1

2.3 Legislated Codes ............................................................................................... 2

2.4 Other ................................................................................................................... 2

2.5 Abbreviations ..................................................................................................... 2

3 Demolition and Removal ......................................................................................... 2

3.1 Demolition .......................................................................................................... 2

3.2 Removal .............................................................................................................. 2

4 Clearing and Grubbing ............................................................................................ 3

4.1 General Requirements ....................................................................................... 3

4.2 Definitions .......................................................................................................... 3

4.3 Close-cut Clearing ............................................................................................. 3

4.4 Tree Preservation ............................................................................................... 3

4.5 Salvaged Timber ................................................................................................ 3

4.6 Woody Debris Disposal ..................................................................................... 4

5 Stripping and Stockpiling Topsoil .......................................................................... 4

6 Open-cut Excavation ............................................................................................... 4

6.1 General Requirements ....................................................................................... 4

6.2 Protection of Existing Facilities ........................................................................ 4

6.3 Definitions .......................................................................................................... 5

6.4 Excavation Procedures ..................................................................................... 5

7 Foundation and Subgrade Preparation .................................................................. 7

8 Backfill and Fill Materials ........................................................................................ 8

8.1 Native Backfill and Fill ....................................................................................... 8

8.2 Granular Backfill and Fill ................................................................................... 8

8.3 Clay for Impervious Liner ................................................................................ 10

8.4 Fillcrete ............................................................................................................. 10

9 Placing Backfill or Fill ........................................................................................... 11

10 Embankments ........................................................................................................ 11

10.1 Foundation Preparation ................................................................................... 11

10.2 Fill Placement ................................................................................................... 12

10.3 Moisture Content Control ................................................................................ 12

10.4 Compaction ...................................................................................................... 12

10.5 Quality Control ................................................................................................. 13

10.6 Frequency of Tests .......................................................................................... 13


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REVISION 2.0, JULY 30, 2012 PAGE iii COPYRIGHT © 2012 ENBRIDGE PIPELINES INC. ALL RIGHTS RESERVED

10.7 Method of Testing ............................................................................................ 13

11 Compaction ............................................................................................................ 14

12 Grading and Tolerances ........................................................................................ 14

12.1 Rough Grading ................................................................................................. 14

12.2 Final Grading .................................................................................................... 14

12.3 Tank Foundation Grading ............................................................................... 15

13 Surfaces to Receive Topsoil ................................................................................. 15

14 Fertilizer and Seed Types ..................................................................................... 15

15 Excess Materials .................................................................................................... 16

16 Testing and Inspections ........................................................................................ 16

17 Cleanup and Restoration ...................................................................................... 16

18 Revision History .................................................................................................... 17

18.1 Revision 2.0, July 30, 2012 .............................................................................. 17


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REVISION 2.0, JULY 30, 2012 PAGE 1 COPYRIGHT © 2012 ENBRIDGE PIPELINES INC. ALL RIGHTS RESERVED

1 General

This facility construction specification (FCS) covers the requirements for site preparation and earthwork, including earthwork for structures, and embankments for tank foundations and containment dykes.

The terms "supply," "transport," and "place," as they relate to earthwork, are defined as follows:

a) Supply – All work necessary to load and transport materials for placement in earthwork, including mixing in the borrow area or stockpiles by excavation methods, selective excavation procedures, moisture conditioning, stockpiling, and anything else necessary to obtain material of specified quality.

b) Transport – All work necessary to transport materials from the borrow area, stockpile, or excavation areas to required locations in the earthwork.

c) Place – All work necessary to dump, spread, mix, scarify, and compact fills in their final locations in the earthwork, as well as all work necessary during placement to achieve the specified moisture content.

In this document, the term “Company” shall hereafter refer to Enbridge.

The term "Contractor" shall hereafter refer to any and all parties who have been contracted to perform work as outlined in this specification and per manufacturer recommendations.

2 References

Work defined in this section shall be governed by the applicable provisions of the current editions of the following standards and regulations.

2.1 Company Standards

D05-101 – Facility and Tank Containment Systems

FCS002 – Installation of Underground Piping and Electrical Services

2.2 Industry Standards

ASTM C127 Standard Test Method for Density, Relative Density (Specific Gravity), and Absorption of Coarse Aggregate

ASTM D422 Standard Test Method of Particle-Size Analysis of Soils

ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort

ASTM D1140 Standard Test Methods for Amount of Material in Soils Finer than the No. 200 (75-µm) Sieve

ASTM D1556 Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method

ASTM D1557 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 [2,700 kN-m/m3])


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ASTM D2167 Standard Test Method for Density of Weight of Soil in Place by the Rubber Balloon Method

ASTM D3017 Standard Test Method for Water Content of Soil and Rock in Place by Nuclear Methods (Shallow Depth)

ASTM D4318 Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity Index of Soils

ASTM D6938 Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by nuclear Methods (Shallow Depth)

2.3 Legislated Codes

Provincial Occupational Health and Safety regulations

2.4 Other

Enbridge Safety – Contractor Safety Manual (CSM)

Enbridge Environment, Lands and ROW – Environmental Guidelines for Construction

2.5 Abbreviations

ASTM American Society for Testing and Materials (former name, not currently used as an abbreviation)

CSA Canadian Standards Association

CSM Contractor Safety Manual

FCS Facility construction specification

3 Demolition and Removal

3.1 Demolition

All demolition shall be as shown in the drawings. The use of explosives is not permitted without prior approval from the Company. If requested by the Company, the Contractor shall submit for approval all required details of the proposed demolition procedures.

The Contractor shall take all necessary precautionary measures before, during, and after the demolition work to ensure that adjacent structures, facilities, and items to be salvaged are not damaged.

3.2 Removal

The Contractor shall dispose of demolished materials as directed by the Company representative. Disposal of contaminated soils and other contaminants shall be in a manner satisfactory to the Company and in accordance with the government regulations and laws. The Contractor cannot remove any materials from the site without prior approval from the Company. All designated items to be salvaged shall be cleaned and delivered by the Contractor to the designated receiving area within the site. All costs shall be borne by the Contractor.


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4 Clearing and Grubbing

4.1 General Requirements

The Contractor shall carry out all clearing and grubbing as shown in the drawings and as specified herein. Clearing and grubbing shall be limited to the designated areas and shall abide by all Company guidelines and regulations of the federal and provincial environmental authorities.

4.2 Definitions

The terms ”clearing” and ”grubbing” as referred to in this FCS are defined as follows:

a) Clearing is defined as the removal of all trees, brush, underbrush, vegetative growth, logs, deadwood, debris, rubbish, and other objectionable matter.

Clearing shall include removal and disposal of the aforementioned materials down to natural ground level, including trees that are to be close cut (clearing flush with natural ground level). For trees which subsequently are to be grubbed, the height of the remaining stump shall be in accordance with applicable provincial regulations.

b) Grubbing is defined as the excavation and removal of tree stumps and roots to the following depths below existing ground surface:

i. Areas beneath structures (including slabs), embankments other than described in 4.2. b) ii. below, roads, and asphalt paving shall be grubbed to a minimum of 60 mm below existing ground level, and all roots larger than 10 mm shall be removed.

ii. Areas other than specified in 4.2. b) i. above or that fall under close-cut clearing shall be grubbed to a minimum of 150 mm below existing ground level. This requirement includes permanently non-load-bearing embankments or portions of embankments which are beyond the theoretical 45° load-bearing influence lines.

4.3 Close-cut Clearing

Close-cut clearing is defined as clearing flush with the natural ground level. Close-cut clearing shall be carried out for all areas beyond the top of excavation slopes to the clearing limit.

4.4 Tree Preservation

Trees beyond the clearing limits shall be preserved. In addition, any trees within the clearing limits designated to be saved shall be preserved. The Contractor shall take all precautionary measures such as maintaining the root system within the tree drip line, cutting off unsound branches, and applying tree wound dressing.

4.5 Salvaged Timber

All timber must be salvaged in accordance with the timber management regulations of the province in which the work is performed and as specified herein. All such timber becomes the property of the Contractor who must then remove it from the site.


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4.6 Woody Debris Disposal

Except for salvaged timber, woody debris material shall be stockpiled in an approved disposal area. However, unless permission is granted in writing by the Company, this material shall not be burned. The Contractor shall remove from the site all other material resulting from the clearing and grubbing operations.

5 Stripping and Stockpiling Topsoil

All organic material and topsoil shall be stripped from construction areas designated in the drawings. The stripping shall not be started until clearing and grubbing of the area has been completed. Topsoil shall not be stripped while in a wet or frozen condition or in a manner which adversely affects the soil structure. Topsoil shall be removed to its entire depth. Mixing of topsoil with subsoil shall be avoided. All topsoil shall be stockpiled onsite in the designated areas shown in the drawings or as directed by the Company representative, and secured against undue wind and water erosion. The maximum height of the stockpile shall not exceed 3000 mm.

6 Open-cut Excavation


The Contractor shall carry out all open-cut excavation as shown in the drawings and specified herein, and shall carry out all activities in accordance with the Company's Contractor Safety Manual (CSM). Particular attention shall be paid to the limitations and safety regulations of the Company as it relates to the operation. The Contractor shall monitor the slopes during the construction. If trenching is required, refer to FCS002.

6.2 Protection of Existing Facilities

Prior to any excavation, the Contractor shall take all precautionary steps and measures necessary to protect existing buried and above-ground facilities.

6.2.1 Protection of Existing Buried Facilities

Where size, depth, and locations of existing facilities are indicated in the drawings, this information is for guidance only. Completeness and accuracy are not guaranteed. The Contractor shall make confirmatory test excavations by water washing or hand excavation. The Contractor shall maintain and protect all buried facilities encountered or which are in the proximity of the excavation.

6.2.2 Protection of Existing Above-Ground Facilities

The Contractor shall conduct, jointly with the Company representative, a condition survey of existing above-ground facilities which may be affected by the work. The Contractor shall protect all such facilities from damage while the work is in progress. The Contractor shall monitor the existing facilities during the construction.


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6.3 Definitions

6.3.1 Rock Excavation

Rock excavation is defined as follows:

a) Excavation of material from solid masses of igneous, sedimentary, or metamorphic rock which, prior to its removal, was integral with its parent mass

b) Excavation of boulders or rock fragments having individual volume in excess of one cubic metre, which by actual demonstration cannot, to the Company's satisfaction, be reasonably loosened or ripped by a single-tooth, hydraulically operated ripper mounted on a Caterpillar Crawler Tractor D8-G Dozer or equivalent equipment.

6.3.2 Common Excavation

Common excavation is defined as follows:

a) Excavation of all materials that do not fall within the definition of rock excavation, including dense tills, hardpan, frozen materials, and partially cemented materials which can be ripped and excavated with heavy construction equipment

b) Trimming, levelling, removal of rocks and boulders, and ripping of excavated surfaces in borrow areas and disposal areas for restoration purposes as may be specified in the contract documents

6.4 Excavation Procedures

6.4.1 Dewatering

The Contractor shall keep excavations free of water while work is in progress, and shall protect open excavations against flooding and damage due to surface run-off and/or groundwater, by surface grading, ditching, wellpoints, and/or pumping. Flow in natural watercourses shall not be obstructed.

Any water resulting from draining the excavation shall be disposed of in a manner not detrimental to public and private property, or any portion of work completed or under construction. Dewatering methods shall be in accordance with the Company’s Environmental Protection Guidelines as well as all legal requirements.

The Contractor shall submit details of proposed dewatering methods to the Company for review and approval.


Banks or backslopes shall be cut at a safe angle of repose or sufficiently shored to protect any work within the excavated area as specified in the drawings unless approved otherwise by the Company.


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The Contractor shall take all necessary measures to prevent the mixing of excavated materials with the existing surface material. Excavated material which is selected to be used for backfill or fill shall be stockpiled adjacent to the work site as directed by the Company representative, and such material shall be kept free of all trash, organic, or objectionable material. All backfill or fill materials shall require the approval of the Company. Frozen material for backfill or fill is not acceptable. Unless specified otherwise, excavated material for backfill or fill shall be so handled, conserved, stored, and placed as to have the material placed back in the excavation or in embankments. Materials from excavation not suitable for backfill or fill shall be hauled off the job site by the Contractor.


In general, the Contractor shall use methods, techniques, and procedures to produce smooth and sound peripheral surfaces of all completed excavations to minimize overbreak and to avoid damage to adjacent structures. All rock excavation shall be completed before any structural element is installed in the vicinity of the rock excavation. Loose rock and rock fragments shall be scaled immediately from excavation walls and areas adjacent to the excavation.

Rock excavation with the use of explosives is not permitted on the site without prior approval from the Company. If blasting is permitted, the Contractor shall submit a blasting program for review. The proposal shall be prepared by a blasting consultant or a licensed explosives expert as deemed necessary by the Company. In general, the proposal shall include the following:

a) Types and quantities of explosives to be used

b) Loading charts and drill hole patterns

c) Type of caps

d) Blasting techniques

e) Blast protection measures for items such as fly rock, vibration, dust and noise control

f) Details on protective measures, time of blasting, and other pertinent details

Prior to blasting, the Contractor shall carry out a survey jointly with the Company representative to determine the condition of existing structures and facilities in the vicinity of the proposed blasting. Seismographic monitoring, if deemed necessary by the Company, shall be carried out to monitor the effects of the blasting.

The criteria pertaining to allowable vibrations in general, allowable vibrations and distances for new concrete/grout, and allowable vibrations and distances for adjacent structures shall be as determined by the blasting consultant or licensed explosives expert, and shall be approved by the Company. Irrespective of the criteria determined, all costs for repairing damages resulting from the blasting operations shall be borne by the Contractor. The Contractor shall submit complete and accurate records of all drilling and blasting.


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6.4.4 Overexcavation

Unauthorized excavations below design elevations shall be corrected by refilling to the proper elevation as follows:

a) For areas under footings/foundations and other load bearing surfaces, refill with concrete of the same strength specified for the footing/foundation.

b) For fill under other areas, refill with approved material compacted in accordance with the requirements of Section 11.

The cost of these corrective measures shall be borne by the Contractor.

6.4.5 Shoring, Sheeting, and Bracing

When necessary, the Contractor shall support the walls of an excavation by shoring, sheeting, and bracing. In some instances, the support work may require cofferdamming and/or underpinning.

Design of temporary support shall be the Contractor's responsibility and must meet the following requirements:

a) Compliance with Provincial Occupational Health and Safety regulations and the Company safety manual

b) Engaging of services of a qualified professional engineer who is registered in the province or territory in which the work is to be carried out, to design and inspect shoring, bracing, cofferdams, and underpinning required for the work

c) At least two weeks prior to starting the work, submission of design and supporting data to the Company

d) Design and supporting data submitted bearing the stamp and signature of a qualified professional engineer registered in the province or territory in which the work is to be carried out

Unless directed otherwise by the Company, the Contractor shall remove all shoring, sheeting, and bracing from the excavation during backfilling operations, by following these steps:

a) Do not remove bracing until backfilling has reached the level of the bracing.

b) Pull sheeting in maximum 200 mm increments until it is clear of installations, simultaneously placing and compacting backfill to fill voids left by pulling the sheeting.

c) Pull sheeting thereafter in 500 mm increments.

d) Where sheeting is permitted to be left in place, it shall be done so as directed by the Company.

7 Foundation and Subgrade Preparation

The Contractor shall remove loose material and debris from excavations for foundations and hand trim. Where material at the bottom of the excavation is disturbed, foundation soil shall be scarified to the undisturbed depth and re-compacted to density at least equal to undisturbed soil. Rock seams beneath foundation areas shall be cleared out and filled with concrete mortar or grout as approved by the Company.


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For excavated or stripped areas, which will subsequently receive backfill or fill, the subgrade shall be prepared to the satisfaction of the Company. All loose material, debris, roots, and all objectionable materials shall be removed and the entire area proof rolled where required by the Company representative.

Proof rolling is a method of detecting soft areas in a subgrade, which will ultimately provide support for fills, pavements, floors, and foundations. It is to be performed with the use of a minimum 14 tonne pneumatic tired roller (note that a D9 Cat bulldozer only has a mass of about 36,000 kg). The procedure requires two complete passes with the roller in one direction followed by a second series of two passes at right angles to the first series. The Company representative may authorize use of other acceptable proof-rolling equipment.

Where proof rolling reveals areas of defective (softened, rutted, or displaced) subgrade, the Contractor shall remove subgrade material to the depth and extent directed by the Company representative, backfill excavated subgrade with approved common material, and compact it to a density at least equivalent to that of the adjacent non-defective subgrade.

8 Backfill and Fill Materials

All backfill or fill materials shall be approved by the Company.

8.1 Native Backfill and Fill

Native backfill or fill materials shall be inorganic soil obtained either from excavations onsite and/or from borrow sites as approved by the soil consultant.

Native backfill or fill shall be well graded, containing no rocks larger than 100 mm at its greatest dimension, free from loam, roots, frozen lumps, organic matter, or other material which is unsuitable in the opinion of the soil consultant.

Where excavated native material is unsuitable for re-use, it shall be stockpiled onsite in the designated area shown in the drawings or as directed by the Company representative.

The Contractor shall give the Company five business days' notice to ensure that all borrow material meets the specifications, before removing material from any borrow source.

8.2 Granular Backfill and Fill

All granular backfill or fill materials shall be obtained from an offsite source, subject to the approval of the Company. The Contractor shall submit the gradation and information regarding the backfill material to the Company two weeks prior to backfilling.

Granular backfill or fill shall be hard, durable particles free from clay lumps, silt, cementitious materials, and organic material, and in accordance with the following classifications in and gradations as determined by ASTM D422:


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Table 8.1 – Granular Backfill and Fill Classifications

Type Standard Sieve Size

(mm) Percent Passing by

Weight (%)

Sand

10 100 5 95 – 100

2.40 80 – 100 1.00 50 – 85 0.600 25 – 60 0.300 10 – 30 0.150 2 – 10

Crushed Gravel

25 100 16 75 – 100 9.5 45 – 75

4.75 32 – 62 1.00 17 – 43 0.300 8 – 24 0.075 2 – 6

Pit Run Gravel

100 100 75 80 – 100 25 60 –80 5 25 – 45 1 16 – 25

0.600 8 – 18 0.150 4 – 10 0.075 2 – 6


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Washed gravel for pipe bedding and for perforated polyethylene subdrain pipe shall be as follows:

a) Clean, angular, crushed-run natural stone, free from shale, roots, and organic material, and conforming to the following gradation:

Table 8.2 – Washed Gravel Gradation

Type Standard Sieve Size

(mm) Percent Passing by

Weight (%)

Washed Gravel

50.0 100 19.0 80 – 95 4.75 50 – 70 2.00 40 – 55 0.425 10 – 20 0.075 0 – 5

All the sieve analysis and gradations for material types listed should be reviewed by a qualified professional geotechnical engineer.

8.3 Clay for Impervious Liner

Where clay soil is to be used for the impervious liner, it shall be a cohesive, fine-grained soil of low to intermediate plasticity, free from loam, roots, organic matter, frozen lumps, or other unsuitable material.

Unless specified otherwise, the clay shall satisfy the following specifications:

a) At least 30% of the soil particles in the material must pass the 0.075 mm (#200) sieve (ASTM D422).

b) The material must have a liquid limit of 30 or greater (ASTM D4318).

c) The material must have a plasticity index of 15 or greater (ASTM D4318).

Clay fill shall be obtained from borrow areas offsite. The Contractor shall make arrangements with the land proprietor to obtain the required borrow material. The Contractor may use any source, provided the material satisfies the requirements herein specified and the Contractor obtains prior approval from the Company. The clay soil must be compacted to achieve the required hydraulic conductivity as specified in D05-101.

8.4 Fillcrete

If specified in the drawings or approved by the engineer of record, Fillcrete can be used as an alternative to backfill material. Fillcrete shall have a minimum 28-day compressive strength of 1.0 MPa.


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9 Placing Backfill or Fill

The Contractor shall place backfill or fill after subgrade has been inspected and approved by the Company.

The material shall be placed only on clean unfrozen surfaces, properly shaped and compacted, and free from snow or ice.

Unless otherwise directed in the drawings, fill and embankment materials shall be placed to full width in uniform layers not exceeding 200 mm uncompacted thickness. Each layer shall be shaped to a smooth contour and compacted to the specified density before the succeeding layer is placed.

The Contractor shall remove and replace any portion of a layer in which material has become segregated during spreading.

When backfilling around structures/foundations or on both sides of wall-like elements such as grade beams, the backfill shall be brought up evenly around the structure/foundation or simultaneously on each side of the wall-like element such that no more than a 300 mm difference in level exists at any time.

The Contractor shall not backfill around cast-in-place concrete structures until the concrete has attained a compressive strength as follows:

a) At least 20 MPa

b) More than 70% of its specified 28-day compressive strength, whichever is greater

The Contractor shall remove all form materials and trash from the excavation before placing any backfill. The Contractor shall obtain the Company’s approval that the concrete work has attained the required strength prior to backfilling.

The Contractor shall not operate earth-moving equipment within one metre of walls of concrete structures for the purpose of depositing or compacting of backfill material.

10 Embankments

This section covers the construction of earth embankments for tank foundations and dykes.

10.1 Foundation Preparation

The Contractor shall strip and excavate the areas beneath tank foundations and dykes to the elevations and configuration shown in the drawings and in accordance with the requirements specified in this FCS. After excavation to the depths shown, the foundations shall be proof rolled as specified in Section 7. Any unsuitable foundation material forming soft or weak zones shall be removed and replaced with approved material.

Foundation surfaces shall be compacted to 100% of maximum standard Proctor dry density.


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10.2 Fill Placement

In addition to the requirements of Section 9 of this FCS, the following shall apply:

a) Fills shall be placed to the lines and grades shown in the drawings.

b) Native fill shall be placed in continuous horizontal layers of uniform thickness. The uncompacted lifts of the common fill material shall not exceed 200 mm.

c) The clay and gravel forming the impervious liner and slope protection, respectively, of the dyke shall be placed in lifts parallel to the slope of the dyke. Maximum uncompacted lift thickness shall be 200 mm.

d) Unless otherwise specified elsewhere in this FCS or shown in the drawings, clay, if used for impervious liner, shall be as specified in Section 8.3 of this FCS. Dyke slope protection shall be 25 mm minus crushed gravel.

e) Tank foundation material shall be placed in horizontal lifts. Maximum uncompacted lift thickness shall be 200 mm. Unless otherwise indicated in the drawings, the top of the tank foundation shall be sloped toward the centre of the tank at a 1% slope.

f) No fill material shall contain ice, snow, or frozen earth. Fill operations shall be suspended when either fill to be placed is frozen, and whenever, in the opinion of the Company representative, climatic conditions are unsatisfactory for placing of fill to conform to this FCS.

g) After heavy rains, equipment shall not be operated on the fill until the fill has dried sufficiently to prevent occurrence of excessive rutting (see Section 10.3).

h) Any portion of the fill which has suffered a reduction in density due to the action of rain shall be re-compacted or removed before the placing of succeeding layers.

i) Immediately prior to the suspension of fill operations, the entire top surface of the embankment shall be rolled with a smooth cylindrical roller so as to leave the area in smooth even conditions for drainage. The Contractor shall provide suitable equipment onsite at all times for this purpose.

10.3 Moisture Content Control

The moisture content shall be as uniform as practicable throughout any one layer. The moisture content shall be such as to provide for proper compaction of the material, and shall be determined by the Contractor to suit the gradation of the material being placed.

The moisture content in the fill shall not vary 2% above or below optimum moisture content as determined from ASTM D698.

Material that is too wet for proper compaction shall be spread and permitted to dry, assisted if necessary by discing, mixing with other materials, or other suitable methods, until the moisture content is reduced to within the specified limits.

When the moisture content of the material is below the specified lower limit, the Contractor shall add water to the material or mix it with material of higher moisture content.

10.4 Compaction

Compaction shall be in accordance with Section 11 of this FCS. Each layer in the tank foundation shall be compacted to 100% maximum dry density, and each layer in the tank containment berms shall be compacted to 95% of corrected maximum dry density.


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10.5 Quality Control

Each classification of fill shall meet the following requirements for density and moisture content:

a) Average of results of any 10 consecutive density tests shall be equal to or greater than specified density.

b) Results of not more than 2 in any 10 consecutive density tests may be less than specified density.

c) Average of results of any 10 consecutive moisture content tests shall lie within specified moisture content limits.

d) Results of not more than 2 in any 10 consecutive moisture content tests may lie outside specified moisture content limits.

e) Average of results of any 10 consecutive gradation tests shall lie within specified gradation.

f) Results of not more than 2 in any 10 consecutive gradation tests may lie outside specified gradation.

g) Gradation and plasticity of all representative clay samples shall be as specified.

h) In case of fill which does not reach the required density, additional measures which may be required to increase density include:

i. Compacting with additional passes of rollers

ii. Adding ballast to rollers to the maximum capacity specified by the roller manufacturer

iii. Adjusting moisture content of fill prior to re-compacting

iv. Reducing the thickness of the layer prior to re-compacting

10.6 Frequency of Tests

At least one field density test and one moisture content determination shall be made for each 100 m3 or portion thereof of each classification of compacted fill placed during one shift.

At least one particle size analysis and one plasticity index determination shall be made for each 500 m3, except that at least one additional particle size analysis shall be made for each significant change in material being used.

10.7 Method of Testing

The maximum density of each classification of fill shall be determined in accordance with ASTM D698.

The density of fill shall be taken to be adjusted bulk density of fraction of fill passing the 19 mm sieve.

Bulk density shall be determined in the field in accordance with ASTM D1556. Dimensions of the apparatus modified shall suit soil tests as specified in ASTM D2167, ASTM D6938, or ASTM D3017. Whichever test method is most suitable in the opinion of the testing agency shall be used to obtain representative density of the fill tested.

Adjusted bulk density of the fraction of fill passing the 19 mm sieve shall be determined from the bulk density by laboratory tests, using procedures which are most appropriate in the opinion of the testing agency.


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Particle size analysis shall be performed in accordance with ASTM D422 or ASTM D1140, whichever is appropriate, modified as required to suit soil tested.

Liquid and plastic Limit tests shall be performed in accordance with ASTM D4318.

11 Compaction

Compaction equipment must be capable of obtaining required densities in materials on the project and shall be subject to the approval of the Company. Unless otherwise specified by the Company or shown in the drawings, minimum compaction on backfill or fill materials shall be as follows. In addition, the minimum compaction shall be based on corrected maximum dry density (per ASTM D698) for materials involving oversize correction, or maximum dry density (per ASTM D698) for materials not involving oversize correction:

Soil foundations including fill to correct over-excavation 100% Under floor slabs, slabs-on-grade; pavements and traffic; or load-bearing areas 98%

All other areas unless specified otherwise 95%

The Contractor shall shape and roll the backfill or fill to achieve a smooth, even, and uniformly compacted layer before adding the next layer of material.

Water shall be applied as necessary during compaction to obtain the specified density.

If material is excessively moist, it shall be aerated by scarifying with suitable equipment until the moisture content is corrected.

In areas not accessible to rolling equipment, the Contractor shall compact to the specified density with mechanical tampers approved by the Company representative.

The Contractor shall not operate heavy rollers to compact backfill within one metre of concrete walls. Compaction of this latter zone shall be with hand-operated tampers or similar equipment, which will not risk any damage to the structure.

12 Grading and Tolerances

12.1 Rough Grading

Rough grading shall be carried out in a manner to allow for the specified depths of succeeding layers of fill, maintaining positive drainage away from buildings, and ensuring the designed slopes of drainage ditches. Unless noted otherwise, the rough graded surface shall be carried out according to the details shown in the drawings within a tolerance of 50 mm of specified elevations

12.2 Final Grading

Final grading shall consist of placing and compacting the layers of fill materials to within the following tolerances:

a) Layers above the rough grade level, except the finish layer, to a tolerance of 25 mm of specified elevations

b) A finish layer tolerance of 10 mm of specified elevations.


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c) For tolerances pertaining to tank foundations, see Section 12.3.

12.3 Tank Foundation Grading

The following tolerances shall apply for the final surface of tank foundations, unless stricter tolerances are given in the drawings. It is essential that foundations true to a plane be provided for the tank erection. The foundation shall have adequate bearing to maintain the trueness of the foundation.

Where foundations nominally true to a horizontal plane are specified, tolerance shall be as follows:

a) Where concrete ringwalls are provided under the shell, the top of the ringwall shall be level within ±3mm in any 9 m of the circumference and within ±6 mm in the total circumference measured from the average elevation.

b) Where concrete ringwalls are not provided, the foundation under the shell shall be level within ±3 mm in any 3 m of circumference and within ±12 mm in the total circumference measured from the average elevation.

Where sloping foundations are specified, elevation differences about the circumference shall be calculated from the specified high point. Actual elevation differences about the circumference shall be determined from the actual elevation of the specified high point. The actual elevation differences shall not deviate from the calculated differences by more than the following tolerances:

a) Where concrete ringwalls are provided, ±3 mm in any 9 m of circumference and ±6 mm in the total circumference

b) Where concrete ringwalls are not provided, ±3 mm in any 3 m of circumference and ± 12 mm in the total circumference.

13 Surfaces to Receive Topsoil

Topsoil must be replaced on only those areas designated in the drawings and only in areas where vegetation growth is encouraged. Surfaces to receive topsoil finishing shall be graded to eliminate uneven areas and low spots to ensure positive drainage. All contaminated soil, debris, and deleterious material shall be removed. The entire area shall be cultivated to a minimum depth of 50 mm. After the surface has been approved by the Company representative, the Contractor shall retrieve topsoil from the approved stockpile and spread it in uniform layers. The finished topsoil surface shall be within a vertical tolerance of 25 mm.

14 Fertilizer and Seed Types

The Company must be advised on fertilizer and seed types, and application rates and means of incorporation into the soil.

Grass seed, fertilizer mulch, and other materials are to be delivered in standard containers clearly marked with contents, weight, analysis, and name of supplier or manufacturer. Seeding operations shall be performed only during favourable weather conditions in accordance with good horticultural practice. Grass seed shall be Certified Canada No. 1 seed, free of disease, weed seeds, or other foreign material.

For fertilizer rates and seed mix, refer to the Company's Environmental Guidelines for Construction (Environment, Lands and ROW).


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15 Excess Materials

All excess materials resulting from the work shall be stockpiled onsite. Stockpile locations will be identified by the Company representative.

16 Testing and Inspections

The Contractor shall engage an independent CSA certified testing agency to perform tests of materials and compaction in the earthworks.

The Contractor shall pay all costs for testing and inspection by the testing agency.

17 Cleanup and Restoration

Upon completion of work, the Contractor shall remove all debris and surplus materials brought onsite, repair defects, clean, and reinstate the site to the satisfaction of the Company.


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18 Revision History

18.1 Revision 2.0, July 30, 2012

2 References

Added ASTM D1557 as an applicable governing standard.

3.2, 6.2.2, 6.3.1, 6.4.1, 6.4.2, 6.4.3, 6.4.5, 7, 8, 8.1.1, 8.1.2, 8.1.3, 9, 10.2, 11, 13, 15, 17

Removed all instances of the term “Inspector” and replaced with identifiable terms such as “Company Representative” and “Soil Consultant.”

4.2. Definitions

a) Replaced “1000 mm” maximum stump height with “applicable provincial regulation.”

5 Stripping and Stockpiling Topsoil

Added that topsoil shall be stockpiled onsite “in the designated areas shown on the drawings or as directed by the Company Representative.”


Added “Prior to Excavation, the Contractor shall obtain the work permit from the Company.”

Added “The contractor shall monitor the sloped during the construction.”

6.2.2 Protection of Existing Above-Ground Facilities

Added “The contractor shall monitor the existing facilities during the construction.”


Removed “Excavation and shoring shall be kept as close as possible to the structure foundation.”

Added that banks or backslopes shall be cut at a safe angle of repose or sufficiently shored to protect any work within the excavated area “as specified on the drawings unless approved otherwise by the Company.”

Added that materials from excavation not suitable “or required” for backfill shall be hauled off the job site “as directed by the Company representative.”


Added that criteria … shall be as determined by the blasting consultant or licensed explosives expert “and approved by the Company.”

7 Foundation and Subgrade Preparation

Removed that the Contractor shall hand trim, “make firm” and remove loose material…

Added that where material at the bottom of the excavation is disturbed, foundation soil shall be “scarified to the undisturbed depth and” recompacted…


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8.1 Native Backfill and Fill

Added that native material unsuitable for re-use shall be stockpiled onsite “in the designated areas shown on the drawings or as directed by the Company Representative.”

Replaced five days with “five business days.”

8.2 Granular Backfill and Fill

Added “The contractor shall submit the gradation and information regarding the backfill material two weeks prior to backfilling to the Company.”

Replaced “polyethylene underdrain pipe” with “polyethylene sub-drain pipe.”

8.3 Clay and Impervious Liner

Inserted “Unless otherwise specified” before “the clay shall satisfy the following specifications.”

Added “The clay soil must be compacted to achieve the required hydraulic conductivity as specified in D05-101.”

8.4 Fillcrete

Added new section “8.4 Fillcrete” which reads “If specified on the drawings or approved by the engineer, Fillcrete can be used as an alternative to backfill material. Fillcrete shall have a minimum 28 day compressive strength of 1.0 MPA.”

9 Placing Backfill or Fill

Removed “The Inspector may authorize thicker layers if specified compactions can be achieved.”

Replaced “(a) at least 20 Mpa, or (b) its specidied 28 day strength” with “(a) at least 20 Mpa, or (b) More than 70% of its specified 28 day compressive strength whichever is greater.”

Rephrased second last sentence to read “The Contractor shall obtain the Company’s approval that the concrete work attained the required strength prior to backfilling.”

10,10.1, 10.2

Replaced “firewall” with “dyke”

10.1 Foundation Preparation

Replaced “acceptable material” with “approved material”

10.2 Fill Placement

d) Replaced “25mm maximum crushed granular” with “25 mm minus crushed gravel.”

d) Removed “sand and gravel and material for tank foundation shall be 10mm maximum sand.”

e) Removed “continuous with the lifts of native sand” as a requirement for tank foundation material placement.

e) Modified last sentence to read “Unless otherwise indicated on the drawings, the top of tank foundation shall be sloped toward the centre of the tank at a 1% slope.”


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12.1 Rough Grading

Modified the last sentence to read “Unless noted otherwise, the rough graded surface shall be carried out to the details shown on the Drawings within a tolerance of 50mm of specified elevations.”

12.2 Final Grading

a) Replaced “tolerance of 25mm of theoretical grades and 75 mm of theoretical lines” with “tolerance of 25mm of specified elevations.”

b) Replaced “Finish layer tolerance of 10mm of theoretical grade and 40 mm of theoretical lines” with “Finish layer tolerance of 10mm of specified elevations.”

12.3 Tank Foundation Grading

Added “It is essential that foundations true to a plane be provided for the tank erection. The foundation should have adequate bearing to maintain the trueness of the foundation.”

a) Removed “To achieve the tolerances specified above, it is essential that foundations true to a plane be provided for the tank erection. The foundation should have adequate bearing to maintain the trueness of the foundation.”

13, 14

Replaced suggested seed mix and suggested fertilizer rates with a reference to Enbridge Environmental Guidelines for Construction, which contains the information.


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Installation of Underground Piping and Electrical Services FCS002 – (2012)







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INSTALLATION OF UNDERGROUND PIPING AND ELECTRICAL SERVICES FACILITY CONSTRUCTION SPECIFICATION FCS002 - 2012



1 Revision Summary




2 Applicability





July 30, 2012



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Table of Contents 1 Scope ........................................................................................................................ 1

2 References ............................................................................................................... 1


2.2 Regulatory Standards ........................................................................................ 1


2.4 Abbreviations ..................................................................................................... 1

3 Trenching ................................................................................................................. 2

3.1 General ............................................................................................................... 2

3.2 Trench Excavation ............................................................................................. 2

4 Preparation of Trench Bottom ................................................................................ 3

5 Installation of Piping and Electrical Services ........................................................ 4

5.1 Piping Installation .............................................................................................. 4

5.2 Installation of Electrical Services ..................................................................... 4

6 Bedding for Pipes and Electrical Services ............................................................ 4

6.1 Pipe Bedding ...................................................................................................... 4

6.2 Bedding for Electrical Services ........................................................................ 5

7 Crossings ................................................................................................................. 5

8 Tolerances ............................................................................................................... 5

9 Cleanup and Restoration ........................................................................................ 5

10 Revision History ...................................................................................................... 6

10.1 Revision 2.0, July 30, 2012 ................................................................................ 6


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1 Scope

This facility construction specification (FCS) covers the civil-related requirements for the installation of underground piping and underground electrical cables.

In this document, the term “Company” shall hereafter refer to Enbridge.

The term "Contractor" shall hereafter refer to any and all parties who have been contracted to perform work as outlined in this specification and per manufacturer recommendations.

2 References

The following references shall serve as resources for this specification, and the most recent edition shall apply, unless otherwise specified.


FCS001 Site Preparation and Earthwork

FCS010 Electrical – Power, Lighting, Heating, Alarm, and Control

2.2 Regulatory Standards

Provincial Occupational Health and Safety regulations


ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12 400 ft-lbf/ft3 (600 kN-m/m3))

ASTM D4253 Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table

ASTM D4254 Standard Test Methods for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density

CAN/CSA S6 Canadian Highway Bridge Design Code

CSA C22.1 Canadian Electrical Code, Part I Safety Standard for Electrical Installations

CSA C22.3 No. 7-10 Underground Systems

2.4 Abbreviations

ASTM American Society for Testing and Materials

CSA Canadian Standards Association



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3 Trenching

3.1 General

The Contractor shall perform all required trench excavation for the installation of underground piping and electrical cables. In general, this work includes the following activities:

a) Removal of existing surface materials and facilities

b) Excavation from the trench of all materials regardless of kind so that underground piping and electrical services can be placed to alignment and grade as shown in the drawings or as directed by the Company representative

c) Support of the adjoining ground or structures

d) Stockpiling and disposal of excess excavated material

e) Control of surface and subsurface water in trenches

f) Temporary railings, coverings, and enclosures for excavations

g) Removal and replacement of unsuitable material

3.2 Trench Excavation

Unless shown otherwise in the drawings or directed by the Company for multiple pipe installations in a common trench, the following clearances shall apply:

Table 3.1 – Clearances for Multiple Pipe Installations

Outside Diameter of Large Pipe Clearance Between Pipes

Up to and including 500 mm 500 mm Over 500 mm to 900 mm 750 mm

Over 900 mm 900 mm

The width of the trench shall be as narrow as permissible while still providing adequate access to seal joints and to compact the backfill under and around the pipe.

The Contractor shall ensure accurate depth of trench to maintain design grade of pipe or electrical service and proper thickness of bedding. Recesses shall be provided as required at pipe joints to ensure full bearing along the barrel of the pipe. Tunneling shall not be allowed unless specifically approved in writing by the Company.

Unless it contravenes the Provincial Occupational Health and Safety regulations and recommendations of the soil report, trench walls shall be vertical to a height of 300 mm above the top of the pipe. Back slopes above this level shall be as shown in the drawings and in accordance with safety regulations. Trenches deeper than 1200 mm shall require cut back or temporary shoring; otherwise, the full depth of the trench shall be excavated to the appropriate angle of repose for the disturbed soil. Excavations deeper than 1200 mm shall be designed by the engineer based on the soil type.

Where piping is to be installed in an embankment, the trench shall be excavated only after completing the embankment to at least a level of 300 mm above the top of the pipe.


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The length of open trench shall be only as far in advance of pipe laying as safety, traffic conditions, and site operations permit, and as approved by the Company.

Excavated material is used to backfill the trench and may be windrowed alongside the trench at a minimum distance, as specified by the Occupational Health and Safety regulations in authorized working areas, in a manner that shall not endanger the work, hinder local traffic, block surface drainage, or obstruct access to other utilities. Where excavated material cannot be piled along the trench in compliance with the above restrictions, it shall be stockpiled at a location approved by the Company representative for return to the trench as backfill.

4 Preparation of Trench Bottom

The Contractor shall remove all rock, boulders and large stones, debris, snow, ice, and frozen soil or hard clay lumps from the trench. The Contractor shall then compact loosened soil at the trench bottom due to excavation activities to a density at least equal to undisturbed soil.

If rock, stones, boulders, or other hard materials are in the bottom of the trench and, in the opinion of the Company representative, will damage the cables, pipe or pipe coating, and are impractical to remove, the bottom of the trench shall be padded with appropriate bedding materials in accordance with FCS001. The bedding material shall be placed to such a depth that, after lowering in the pipe, a minimum 150 mm clearance exists around all protruding objects, while the minimum specified cover or elevation is maintained. The Contractor shall notify the Company when soil at the proposed elevation of trench bottom appears unsuitable for installing piping or electrical services. When the trench bottom is deemed by the Company representative to be unsuitable for providing an adequate support for the pipe or electrical service, the Contractor shall replace the unsuitable material with approved granular material compacted to 98% of Maximum Dry Density in accordance with ASTM D698.

Where the bottom of the trench is unstable and overexcavation is judged by the Company to be uneconomical, the Contractor shall construct special supports of timber, concrete, or other material, as designed and ordered by the Company. Temporary support timbers shall be removed before backfilling unless otherwise directed by the Company. All backfilled timber shall be pressure treated or treated to the satisfaction of the Company.

The finished trench bottom should be contoured as near as practicable to the radius of the pipe. If approved by the Company, a layer of loose earth, free from any damaging materials, may be left in the bottom of the trench for bedding the pipe. Wherever practicable, in the opinion of the Company representative, this bedding material may be sorted from the available trench spoil pile.

All work shall be performed in a dry trench. Removal of water from trenches, regardless of origin, shall be the Contractor's responsibility.

If the trench bottom softens due to the presence of water in the trench and construction activities, this unstable material shall be replaced by granular material compacted to 98% of Maximum Dry Density per ASTM D698, as directed by the Company representative. The costs related to this replacement shall be borne by the Contractor.


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5 Installation of Piping and Electrical Services

5.1 Piping Installation

The Contractor shall install all underground piping to the grades, lines, and elevations shown in the drawings.

Special care shall be taken not to damage coated pipe or fittings during handling.

When stringing pipe alongside a trench, pipe shall be supported on well-padded timber or sand-filled sacks supported by skids in such a way as to prevent damage to the exterior surface of the pipe. Sacks filled with straw shall not be used as padding.

Pipe and fittings shall be carefully lowered into the trench by derricks, nylon slings, ropes, or other approved tools or equipment in a manner that prevents damage to the pipe and injury to workers.

All work shall be carried out in a dry trench. Precautions shall be taken to ensure that underground pipe is not displaced through soil displacement or flotation due to water in the trench. Displaced pipe shall be removed from the trench and re-laid after the trench is dewatered and reshaped as necessary.

5.2 Installation of Electrical Services

The Contractor shall install all underground cables to the lines, grades, and elevations shown in the drawings. Refer to FCS010.

The Contractor shall exercise all precautionary measures to prevent damage to cables during handling and installation.

For cable that runs parallel to main pipelines, a clearance of 3 m shall be maintained between the cable and the pipeline.

Cables shall cross at right angles to and below mainline piping and shall be spaced at 300 mm minimum.

Cables shall not be installed across any backfill areas until backfill is compacted to 98% Maximum Dry Density per ASTM D698 for the full width of the trench.

6 Bedding for Pipes and Electrical Services

Trenches shall be backfilled immediately after pipes and electrical services are installed and inspected. Bedding shall not be started until backfilling material is approved by the Company representative.

6.1 Pipe Bedding

Unless otherwise shown in the drawings, all piping shall be bedded in sand conforming to the requirements detailed in FCS001. The Company may approve the use of alternative backfill if bedding sand is not available.

Sand shall also be used to backfill the pipe zone, which is defined as that portion of the trench 150 mm below the pipe and up to a level 300 mm above the top of the pipe. Fill material for backfill above the 300 mm layer above the top of the pipe shall meet the requirements of FCS001


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Sand shall be used for the full width of the trench for the pipe bedding and the pipe zone. Bedding sand shall be placed and compacted to give full uniform support of the pipe barrel. Bedding sand shall be brought up evenly on both sides of the pipe and be compacted to 95% Maximum Dry Density per ASTM D698 in maximum lifts of 150 mm by mechanical tampers. The method and equipment used for compaction shall be approved by the Company representative. If a trench width is excessive, the width of pipe bedding may be limited to 300 mm on each side of the pipe. In this case, approved compacted common backfill shall be used to fill the gap between the width of the bedding and both trench walls and shall be placed simultaneously with the bedding layers.

6.2 Bedding for Electrical Services

Unless otherwise shown in the drawings or approved by the Company, all underground cables shall be bedded in sand conforming to the requirements detailed in FCS001.

7 Crossings

This section specifies the civil requirements for pipelines and electrical services that run beneath roads, railway tracks, and second-party easements or right-of-ways.

The trench shall be backfilled in layers not exceeding 150 mm and compacted to 98% of Maximum Standard Proctor Density, in accordance with ASTM D698. For roads surfaced with gravel, the top 300 mm of the backfill shall be of the same material as the base and surface courses of the existing road.

8 Tolerances

Unless specified otherwise in the drawings, the following tolerances apply:

a) Underground piping shall be within 75 mm of the specified line and within 50 mm of the specified grade, with no sags or high spots.

b) Stub-up and stub-up risers shall be within 25 mm, in any direction, of the location shown in the drawings.

c) The top of native backfill in trenches shall be within 50 mm of design level, where additional upper layers of fill are to be provided.

d) The top of the final backfill surface shall be flush with the adjacent ground surface as it existed prior to excavation.

9 Cleanup and Restoration

Upon completion of work, the Contractor shall remove all surplus materials and debris, trim slopes, repair defects, and clean and reinstate the site to the satisfaction of the Company.


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10 Revision History

10.1 Revision 2.0, July 30, 2012

3.2 Trench Excavation

Replaced “600 mm to 900 mm” with “Over 500 mm to 900 mm.”

Inserted “The width of the trench shall be as narrow as permissible for adequate access to seal joints and to compact the backfill around the pipe.”

Added that unless it contravenes the Provincial Occupation Health and Safety Regulations, “and recommendations of the soil report,” trench walls shall…

Inserted “Trenches deeper than 1200mm will require cut back or temporary shoring or the full depth of the trench may need to be excavated to the appropriate angle of repose for the disturbed soil. The excavations deeper than 1200mm shall be designated by the engineer on the basis of the soil type.”

Added the requirement “at a minimum distance specified by the Occupation Health and Safety Regulations” regarding the windrowing of trench backfill material.

4 Preparation of Trench Bottom

Replaced “to a density equivalent to the acceptable in situ soil density” with “to a density at least equal to undisturbed soil”

Replaced “this unsuitable material” with “the unsuitable material”

Replaced “granular material” with “approved granular material”

Removed the requirement “as directed by the Inspector” regarding the replacement of unsuitable material with approved granular material.

5.1 Piping Installation

Removed the requirement “or as directed by the Inspector” regarding the installation of underground piping to the grades, lines and elevations shown on the Drawings.

5.2 Installation of Electrical Services

Removed the requirement “as directed by the Inspector” regarding the installation of underground cables to the grades, lines and elevations shown on the Drawings.

6 Bedding for Pipes and electrical Services

Inserted “Trenches shall be backfilled immediately after pipes and electrical services are installed and inspected. Bedding shall not be started it is approved by the Company representative.”


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6.1 Pipe Bedding

Inserted “The Company may approve the use of alternative backfill, if bedding sand is not available.”

Inserted “Fill material for the backfill above the 300 mm layer above the top of the pipe shall meet the requirements of FCS001- Site Preparation and Earthwork.”

Inserted “The method and equipment used for compaction shall be approved by the Company representative.”

Replaced “approval compacted common backfill” with “approved compacted common backfill”

Removed “In the event that bedding sand is not available, the Inspector may authorize the use of native backfill.”

7 Crossings

Inserted “The trench shall be backfilled in layers not exceeding 150 mm and compacted to 98 % of Maximum Standard Proctor Density, in accordance with ASTM D698. For roads surfaced with gravel, the top 300 mm (12 in.) of the backfill shall be of the same material as the base and surface courses of the existing road.”

8 Tolerances

Removed “where directed by the Inspector” as a potential situation where the tolerances may not apply.


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Field Coatings for Below Grade FCS017 – (2012)







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FIELD COATINGS FOR BELOW GRADE FACILITY CONSTRUCTION SPECIFICATION FCS017 - 2012



1 Revision Summary




2 Applicability





July 30, 2012



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Table of Contents 1 Scope ........................................................................................................................ 1

2 References ............................................................................................................... 1

2.1 General ............................................................................................................... 1

2.2 Order of Precedence .......................................................................................... 2

2.3 Related Technical Specifications and Standards ............................................ 2



2.6 Abbreviations ..................................................................................................... 3

2.7 Definitions .......................................................................................................... 4

3 General Requirements ............................................................................................ 5

3.1 General ............................................................................................................... 5

3.2 Spray Coating .................................................................................................... 7

4 Coating Materials and Equipment .......................................................................... 7

4.1 General ............................................................................................................... 7

5 Surface Preparation............................................................................................... 10

5.1 General ............................................................................................................. 10

5.2 Surface Preparation Requirements for Liquid Coatings ............................... 12

5.3 Surface Preparation Requirements for Heat Shrink Sleeve Coatings .......... 12

6 Coating Application ............................................................................................... 13

6.1 General ............................................................................................................. 13

6.2 Application of Liquid Coatings ....................................................................... 14

6.3 Application of Heat Shrink Sleeve Coatings .................................................. 16

7 Holiday Detection .................................................................................................. 17

8 Repairs ................................................................................................................... 18

8.1 General ............................................................................................................. 18

8.2 Repairs on Liquid Coatings ............................................................................. 19

8.3 Repairs on Heat Shrink Sleeves ..................................................................... 19

8.4 Repairs on FBE Coatings ................................................................................ 20

9 Quality Control, Inspection and Testing, and Acceptance ................................. 21

9.1 General ............................................................................................................. 21

9.2 Quality Control of Liquid Coatings ................................................................. 22

9.3 Quality Control of Heat Shrink Sleeve Coatings ............................................ 23

10 QC Records ............................................................................................................ 23

10.1 General ............................................................................................................. 23

10.2 Applicator Forms ............................................................................................. 23

10.3 Applicator Turnover Documentation Package ............................................... 24


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REVISION 2.0, JULY 30, 2012 PAGE iii COPYRIGHT © 2012 ENBRIDGE PIPELINES INC. ALL RIGHTS RESERVED

11 Quality Control Testing Procedures ..................................................................... 25

11.1 Testing for Salt Contamination of the Steel Surface for All Coatings .......... 25

11.2 Test: Abrasive Blasting Air Blotter Test ......................................................... 26

11.3 Test: Adhesion Test Using V-Notch Cross Cut Procedure for Liquid Coatings ....................................................................................................................... 27

11.4 Test: Shore D Hardness Test for Liquid Coatings ......................................... 29

11.5 Test: Peel Tests for Heat Shrink Sleeve Coating ........................................... 29

12 Revision History .................................................................................................... 30

12.1 Revision 2.0, July 30, 2012 .............................................................................. 30


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1 Scope

This facility construction specification (FCS) describes the minimum requirements for the application and repair of field joint coatings inside a facility. The coating systems contained in this specification are as follows:

a) Two-part liquid coatings applied by hand and spray techniques

b) Heat shrink sleeves

c) Overcoating of pipe for Horizontal Directional Drills (HDD) and bore-type installations

In this document, the term “Company” shall hereafter refer to Enbridge and its representatives.

The term “Purchaser” shall hereafter refer to the Company’s procurement or purchasing department.

The term "Manufacturer" shall hereafter refer to the company responsible for the formulation and characteristics of the coatings applied to girth welds, repairs, and field-applied overcoating listed in this specification (liquid coating and heat shrink sleeves).

The Applicator/Contractor (hereafter referred to as the Applicator) shall be responsible for implementing this specification in accordance with all the codes and standards contained in this specification. The Applicator shall be solely responsible for ensuring that the work is performed in strict compliance with environmental, health, and safety laws. The Applicator shall be approved through the Company quality process and appear on the Approved Applicator List.

2 References

The most recent edition of the following references shall apply, unless otherwise specified.

2.1 General

2.1.1

It is the Applicator’s responsibility to become familiar with the latest editions of the acts, regulations, laws, codes, and standards that are necessary for the performance of the work. These shall include but not be limited to the following:

a) CSA Z662 – Oil and Gas Pipeline Systems

b) Where regulated by federal standards, the National Energy Board (NEB) Onshore Pipeline Regulations

c) Alberta Pipeline Act and Pipeline Regulation

2.1.2

Where CSA Z662 is referenced, hereafter it shall mean CSA Z662 – Oil and Gas Pipeline Systems, all associated requirements of the Alberta Pipeline Act and Pipeline Regulation, and the National Energy Board Act, as applicable. If there is a conflict between the acts, regulations, laws, codes, and standards, the most stringent requirement shall be met by the Applicator without additional cost to the Company.


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2.1.3

The Applicator shall comply with the requirements of all applicable acts, regulations, laws, codes, and standards in performance of the work.

2.2 Order of Precedence

2.2.1

The order of precedence relating to the goods or services covered under this specification shall be as follows:

a) Referenced legislative requirements

b) Contract or purchase order documents, including the latest product datasheets

c) This specification

d) Referenced project, customer, and customer representative specifications

2.2.2

Under all circumstances, minimum legislative requirements shall be met. Project, customer, or customer representative specifications shall only serve to clarify or provide additions to the legislative requirements.

2.2.3

If a conflict, contradiction, or ambiguity is identified within the stated requirements, the Purchaser shall be contacted for written clarification before proceeding with manufacture or provision of services.

2.3 Related Technical Specifications and Standards

The following technical specifications and standards shall be read in conjunction with this specification. The most recent version of these specifications and standards shall be used. The requirements of these documents shall become part of this specification by reference herein:


C-110 Coating of Buried Steel with Plural-Component Spray Applied Coatings

C-210 Coating of Buried Steel with Rollable or Brushable Coatings

C-510 Heat Shrink Sleeve for Pipe Joint Protection

C-520 Heat Shrink Sleeve Application Over Two-Layer Polyethylene Systems

FCS012 Facility Piping Construction

FCS013 Piping Classes


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ASTM D4285 Standard Test Method for Indicating Oil or Water in Compressed Air

ASTM D2240 Standard Test Method for Rubber Property – Durometer HardnessCSA Z245.20 Series-10 Plant-applied External Coatings for Steel Pipe

CSA Z245.21 Series-10 Plant-applied External Polyethylene Coating for Steel Pipe

CSA Z662 Oil and Gas Pipeline Systems

ISO 8502-5 Preparation of Steel Substrates Before Application of Paints and Related Products -- Tests for the Assessment of Surface Cleanliness -- Part 5: Measurement of Chloride on Steel Surfaces Prepared for Painting (Ion Detection Tube Method)

ISO 8502-6 Preparation of Steel Substrates before Application of Paints and Related Products -- Tests for the Assessment of Surface Cleanliness – Part 6: Extraction of Soluble Contaminants for Analysis – The Bresle Method

ISO 8502-9 Preparation of Steel Substrates Before Application of Paints and Related Products – Tests for the Assessment of Surface Cleanliness – Part 9: Field Method for the Conductometric Determination of Water-Soluble Salts

NACE RP0287 Field Measurement of Surface Profile of Abrasive Blast-Cleaned Steel Surfaces a Using a Replica Tape.

NACE SP0274 High-Voltage Electrical Inspection of Pipeline Coatings

NACE SP0188 Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

SSPC-SP 1 Solvent Cleaning

SSPC-SP 10/NACE NO. 2 Near-White Metal Blast Cleaning

SSPC-VIS 1 Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

SSPC GUIDE 15 Field Methods for Retrieval and Analysis of Soluble Salts on Steel and Other Nonporous Substrates

SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages

2.6 Abbreviations

2LPE Two-layered polyethylene coating system

3LPE Three-layered polyethylene coating system

API American Petroleum Institute

ASTM American Society for Testing and Materials International (former name, not currently used as an abbreviation)


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CPCS Canadian pipeline construction specifications

DFT Dry film thickness

EC Engineering communication

EPP Environmental Protection Plan

FBE Fusion bond epoxy


HDD Horizontal directional drills

ITP Inspection and test plan

MSDS Material safety datasheet

NACE National Association of Corrosion Engineers

NDE Non-destructive examination

NIST National Institute of Standards and Technology

NPS Nominal pipe size

PQT Procedure qualification trials

QA Quality assurance

QC Quality control

ROW Right-of-way

SSPC The Society for Protective Coatings

WFT Wet film thickness

2.7 Definitions

Brush grade Coating designed for application using a paint brush or roller.

Four quadrant testing Testing at four quadrants requires measurements to be spaced along and around the girth weld (i.e., 12, 3, 6, and 9 o’clock or 1, 4, 7, and 10 o’clock).

Hard dry When the applied coating does not indent when pressed with a thumbnail with moderate pressure.

Inspection and test plan A table listing all inspections and tests that shall be conducted

(ITP) during the project, including references, frequency, and acceptance criteria.

Legislative requirements All applicable treaties, acts, statutory instruments, regulations, codes of practice, permits that are in effect or as amended from time to time at the field installation locations of the project.

Polyethylene System A2 Coating that consists of an adhesive and a polyethylene outer sheath.


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Polyethylene System B2 Coating that consists of a powdered epoxy primer, a powdered copolymer adhesive, and a powdered polyethylene outer layer.

Shall Signifies a required task or action is mandatory.

Spray grade Grade of coating material suitable for application by using airless plural component equipment.

Work Coating activities as described in the contract or project scope.

3 General Requirements

3.1 General

The Applicator shall adhere to the following general requirements.

3.1.1

The Applicator shall have a documented quality program in place and a controlled copy of the quality program manual shall be available to the Company at the place of work. The Company may audit the Applicator’s implementation of this quality program.

3.1.2

The Applicator shall submit an ITP to the Company for acceptance a minimum of three weeks prior to commencing the work.

3.1.3

The Applicator shall keep a copy of the technical datasheet and MSDS for each regulated product brought onto the worksite.

3.1.4

Prior to any construction, a procedure qualification trial shall be conducted. The Applicator shall successfully demonstrate the application of coating on at least three welds to the Company inspector. The demonstration shall be coordinated by the Applicator and the Company inspector. A minimum of 72 hours' notice shall be given to the Company inspector prior to the commencement of the demonstration. The Company shall provide the pipe material.

3.1.5

All QC measurements shall be carried out and recorded by the Applicator on forms submitted with the ITP. Before coating application activities commence, the Company shall review the QC forms submitted to ensure all measurements required by this specification are described.

3.1.6

The Company inspector shall have the right to witness the Applicator's equipment, work, and records at any time.


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3.1.7

The Applicator shall furnish and maintain in good working order all materials, consumables, labour, equipment, tools, spare parts, lighting, inspection, weatherproof enclosures, instruments, transport, safety equipment, protective clothing, and supervision, which are incidental to and necessary for the application and inspection of the external coating, in accordance with this specification and the Manufacturer’s recommendations.

3.1.8

All QC measurements and inspections shall be carried out and recorded by the Applicator. These shall be reviewed daily by the Company for acceptance.

3.1.9

The Applicator shall provide all necessary equipment and expertise to conduct testing for QA/QC, as prescribed in this specification and the accepted ITP. All QC inspection tools used to perform the work shall have current calibration records. Copies are to be submitted to the Company inspector prior to the commencement of work, and originals must be included in the Applicator turnover package at the end of the project. The calibrations shall be performed before production coating activities and shall be re-calibrated by a third party every 12 months minimum. The Applicator shall provide at least one employee that is NACE certified CIP Level I or equivalent for coating QC inspections. That employee or those employees shall be familiar with the application procedures and inspection techniques for pipeline coatings covered by this specification. All test materials shall have expiration dates on packages and shall be used at least three months prior to expiration date.

3.1.10

The Company inspector shall conduct destructive testing to verify application conformance (Shore D, V notch, or peel adhesion tests). Repairs to the coating at these test locations shall be at no incremental cost to the Company.

3.1.11

For all applications (piping, tie-ins, repairs, and overcoating), the Applicator shall use coating personnel and equipment that have been prequalified by the Manufacturer. A copy of the written approval for qualification must be forwarded to the Company inspector prior to the commencement of work. Only those Applicators who hold current approval by the Manufacturer shall apply coatings covered by this specification. The Applicator shall ensure that employees are qualified by the Manufacturer before commencement of work. Requalification of personnel shall be once every calendar year and whenever there has been a product change by the Manufacturer.

3.1.12

Coating application shall not take place during inclement weather including, but not limited to, snow, rain, and excessive windy conditions or where the Company inspector deems that coating integrity may be affected. The Company inspector may allow coating operations to proceed where the Applicator provides suitable weather protection in the form of a portable structure or other suitable cover.


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3.1.13

Contact thermometers shall be used to monitor steel temperatures. Infrared non-contact thermometers and temperature-indicating sticks (e.g., Tempilstik) are not acceptable for use.

3.1.14

The Applicator shall not be relieved from providing complete and satisfactory coating of the surfaces identified by the Company due to any omissions of this specification.

3.1.15

All coating products shall be heated and stored according to Manufacturer recommendations.

3.2 Spray Coating

3.2.1

The Applicator shall have all of its equipment certified by the Manufacturer.

3.2.2

Spray applications with spray-grade coating shall be conducted in an enclosure during all applications.

3.2.3

Mechanized coating equipment shall be properly maintained, stored, and protected from weather to reduce the possibility of equipment breakdowns.

3.2.4

The Applicator shall attempt to contain overspray. If overspray occurs and causes damage to property, the Applicator shall be solely responsible.

4 Coating Materials and Equipment

4.1 General

Only Company-approved coatings shall be used, as described in the following tables. Substitutions shall not be permitted.


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Table 4.1 Approved Liquid Coatings for Girth Welds

Approved Manufacturer and Coatings

Approved Application Method

Maximum Operating Temperature

Canusa-CPS HBE 95 Epoxy Spray Applied and Rollable – Brushable 95°C

Specialty Polymer Coatings Inc. SP-2888 R.G. Epoxy /

Urethane

Spray Applied and Rollable – Brushable 80°C

Specialty Polymer Coatings Inc. SP-3888 Epoxy


Specialty Polymer Coatings Inc. SP-6888 Epoxy


Specialty Polymer Coatings Inc. SP-8888 Novalac Epoxy


3M Scotchkote 327 Epoxy Spray Applied and Rollable – Brushable 80°C

Denso Protal 7250 Spray Applied 80°C Denso Protal 7200 Rollable – Brushable 80°C

Table 4.2 – Approved Liquid Coatings for Overcoat of Single Layer FBE Coating for Bores/HDDs

Scenario Approved Coating System

Liquid coatings for overcoat of single layer plant-applied fusion bond epoxy (FBE) coating

Any of the liquid coatings listed in Table 4.1 3M Scotchkote 352 Urethane (spray applied)

Table 4.3 – Approved Liquid Coatings for Girth Welds on Bores/HDDs

Scenario Approved Coating System

Liquid coatings for girth welds (application to bare metal) on slip bores and HD bores with

no design curvature

SPC SP 2888 RG Epoxy Urethane (spray or rollable – brushable

3M Scotchkote 327 Epoxy (spray or rollable – brushable )

Liquid coatings for girth welds (application to bare metal) on HDDs and HD bores with

design curvature

3M Scotchkote 327 Epoxy (spray or rollable – brushable )


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Table 4.4 – Approved Shrink Sleeve Coatings for Girth Welds on Bore/HDD

Plant-Applied Coatings Shrink Sleeve Manufacturer Approved Coatings

Polyethylene System A2 Canusa TBK-O Polyethylene System B2 Canusa TBK-80

Polyethylene System B2 Raychem HTLP 80-B with either Dirax or HTLP 80-B leading edge

sleeve

Table 4.5 – Approved Heat Shrink Sleeve Coatings for Girth Welds

Coating System

Maximum Operating

Temperature

Plant-Applied Coating System

Approved Manufacture &

Coating System

Area of Application

Two-Layer Heat Shrink Sleeve

50°C Polyethylene System A2

Canusa KTON Wrapid

Piping

50°C Polyethylene System A2

Canusa CRPN Patch

Repairs*

Three-Layer Heat Shrink

Sleeve

80°C Polyethylene System B2

Canusa GTS-80-L

Piping


Raychem HTLP 80-B

Piping


Raychem PERP 80 Patch

Repairs*

* Patch repair size limitations are specified in Section 8.3 of this specification.

4.1.1

The Applicator shall ensure the coating material to be applied meets the following requirements:

a) An approved material as defined in this specification

b) Identified with the following information:

i. Manufacturer’s name

ii. Product description

iii. Batch number

iv. Date of manufacture

v. Expiration date

vi. Location of manufacture

vii. Manufacturing identification number

c) Handled and stored in accordance with the Manufacturer’s recommendations at all times

d) Within the shelf life specified by the Manufacturer


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5 Surface Preparation

5.1 General

Surface preparation shall adhere to the following general requirements:

5.1.1

Surfaces to be blast cleaned shall be free of oil, grease, slivers, mud, soils, rough welds, burrs, weld spatter, etc. Prior to blast cleaning, the Applicator shall carefully examine the bare pipe for oil and grease and inform the Company inspector of which areas require attention. Any oil, grease, magnetic particle inspection products, or ultrasonic couplant shall be removed in accordance with SSPC-SP 1 using cleaning agents approved by the Manufacturer. Clean water shall then be used as a rinse. After cleaning, direct hand contact or any other type of contamination of the prepared steel surface shall be avoided at all times.

5.1.2

Before NDE, rough welds, weld splatter, and other sharp projections shall be ground smooth by the Applicator or as designated by the Company inspector.

5.1.3

All coating compressor units shall have adequate separators, filters, and drains to ensure contaminants such as oil and water are not deposited onto the steel surface. Accumulations of oil and water shall be removed by regular purging as part of daily maintenance of the abrasive blasting units. A blotter test shall be performed before project startup on all abrasive-blasting units for piping and tie-in coating to verify the cleanliness of the compressed air used for abrasive blasting. Abrasive blast air blotter tests shall be conducted at minimum once per week and whenever a mechanical breakdown occurs on the abrasive-blast units. Any abrasive-blasting unit that displays oil or water residue transfer shall be removed from service until the unit can display a clean test result. Refer to Section 11.2 for the abrasive blast air blotter test procedure.

5.1.4

All equipment, valves, and Company property shall be protected from abrasive-blasting activities prior to abrasive blasting startup.

5.1.5

Prior to abrasive blasting, the steel shall be dry and warmed to a temperature of at least 3ºC above the dew point. A digital psychrometer/dew point meter shall be used to monitor environmental conditions. The required pipe temperature and the environmental conditions shall be determined at the start of daily coating activities and at least once every four hours, or when weather conditions change.


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5.1.6

Cold blasting of the steel surface is acceptable when induction coil heating is used as a girth weld preheat method. The Applicator shall monitor the dew point and pipe surface temperature to ensure the steel remains at 3°C above the dew point and the steel surface cleanliness is maintained.

5.1.7

The abrasive blast media shall be Enviro-Grit glass abrasive or equivalent. Equivalent products shall be submitted to the Company for approval a minimum of two weeks prior to project start.

5.1.8

The air pressure at the end of the nozzle during abrasive blast operations shall be a minimum of 90 psi (620 kPa) according to recommended Manufacturer practices.

5.1.9

The girth weld shall be abrasive blasted in accordance with the SSPC-SP-10 near-white blast requirement, and the Applicator shall ensure this surface finish is attained by comparing it with the appropriate SSPC-VIS 1 photographs.

5.1.10

For piping girth welds, profile measurements shall be taken, at a minimum, at the start of each work day and after every hour of continuous blasting. Measurements shall be taken at a minimum of three different locations on the girth weld. The weld number shall be identified on each profile measurement taken and be recorded on the Applicator QC forms.

5.1.11

For tie-in girth welds, profile measurements shall be taken, at a minimum, at the start of each day and on every second girth weld thereafter. Measurements shall be taken at a minimum of three different locations on the girth weld. The weld number shall be identified on each profile measurement taken and recorded on the Applicator QC forms.

5.1.12

Residual blast products and dust shall be removed from the entire circumference of blasted surfaces using a clean dry bristle brush, vacuum, or clean dry compressed air. All spent abrasive material shall be contained and disposed of with minimal amounts remaining on site after project completion.

5.1.13

Metal areas that develop flash rust due to exposure to rain, moisture, or humidity shall be sweep blasted to return them to their original clean-blasted condition. The surface to be blasted shall be coated immediately after cleaning. A sweep blast shall be carried out when a blasted surface is left overnight.


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5.1.14

Tests shall be conducted by the Applicator to verify that the abrasive-blasted surface does not contain detrimental levels of non-visible soluble salt contamination. The Applicator shall conduct one soluble salt test on a production weld at a frequency of not less than once per week. If salt contamination levels are identified, the maximum allowable contamination level shall be less than 10 ppm.

5.1.15

Welds that are above the acceptable salt contamination limits shall be cleaned using a fresh water rinse to remove chlorides. If salt contamination is identified over the acceptable limit, the Applicator shall test every subsequent joint until acceptable soluble salt levels are identified, at no incremental cost to the Company.

5.2 Surface Preparation Requirements for Liquid Coatings

Surface preparation for liquid coatings shall adhere to the following requirements:

5.2.1

The abrasively cleaned surface shall have an angular anchor pattern profile averaging 0.075 mm (3.0 mils) to 0.10 mm (4.0 mils). Individual measurements shall not be less than 0.065 mm (2.5 mils). Profile measurements shall be taken with replica tape and spring micrometer in accordance with NACE RP0287.

5.2.2

Existing coating shall be feathered 50 mm to 75 mm (2 in. to 3 in.) when coating girth welds. The feathering shall remove the gloss and provide a roughened surface suitable for overcoating.

5.3 Surface Preparation Requirements for Heat Shrink Sleeve Coatings

Surface preparation for heat shrink sleeve coatings shall adhere to the following requirements:

5.3.1

The abrasively cleaned surface shall have an angular anchor pattern averaging 0.050 mm (2.0 mils) to 0.10 mm (4.0 mils). Individual measurements shall not be less than 0.0375 mm (1.5 mils). Profile measurements shall be taken with replica tape and spring micrometer in accordance with NACE RP0287.


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5.3.2

The plant-applied polyethylene coating shall be bevelled to 30° and feathered to remove the sharp transition from plant-applied coating to the steel. Bevelling and feathering shall remove plant-applied coating that has curled up and/or disbonded from the substrate. Following bevelling and feathering, the plant-applied coating adjacent to the cutback area shall be lightly abraded to a distance of at least 50 mm (2 in.) beyond each end of the sleeve width to provide a roughened surface suitable for overcoating. For directional drill/slip bore piping, the plant-applied coating adjacent to the cutback area shall be lightly abraded a minimum of 75 mm (3 in.). Scratch marks shall be visible around the entire pipe diameter following such light abrasion.

6 Coating Application

6.1 General

Coating application shall adhere to the following general requirements:

6.1.1

Surfaces to be coated shall be prepared, and shall be free of moisture, oil, grease, dust, and any other contaminants prior to the application of the coating.

6.1.2

The pipe surface temperature, at every point where coating will be applied, shall be a minimum of 10°C (50°F) and a minimum of 3C° (5°F) above the dew point temperature. Maximum steel temperature is 100°C (212°F) or as directed by the Manufacturer for liquid coating application, including sleeve primers. This pipe surface temperature and environmental conditions shall be determined at the start of daily coating activities and at least once every four hours, and more frequently in variable weather.

6.1.3

The surface temperature of the substrate must be maintained in the range recommended by the Manufacturer from abrasive blasting through coating cure. If that range is unavailable from ambient conditions, preheating shall be used. Preheating may also be used to accelerate cure in case of time or weather constraints.

6.1.4

If preheating is required prior to the coating application, the preheating method shall be completed according to the guidelines in Table 6.1.

6.1.5

Pre-heating shall not damage the existing coating.


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6.1.6

After the coating has cured, the Applicator shall measure the DFT of each girth weld coating at four quadrants according to the guidelines in Table 9.1.

6.1.7

For shrink sleeve application on Polyethylene Coating System B2, after the primer is applied, the Applicator shall measure the DFT or WFT of the primer at four quadrants according to the guidelines in Table 9.1. Full coverage of the steel by the epoxy shall be visually confirmed.

6.1.8

Holiday detection, backfilling, or handling shall not be conducted until the Manufacturer's recommendations for the acceptable time, temperature, or degree of cure is achieved for these activities. Shore D measurements on preheated girth welds applied with liquid coatings shall be conducted when the exterior coating surface temperature reaches 20°C ±5°C.

6.1.9

No quenching or forced curing of the coating with direct open flame shall be permitted.

Table 6.1 – Acceptance Preheat Methods for Girth Weld Coatings

Girth Weld Coatings Application Area Pre-heat Method

Liquid Coatings Piping and Sections Induction Coil Liquid Coating Tie-ins Induction Coil or Propane Heat Shrink Sleeve Piping and Sections Induction Coil Heat Shrink Sleeve Tie-ins Induction Coils or Propane FBE Powder Mainline and Sections Induction Coil FBE Powder Tie-in Induction Coil

6.2 Application of Liquid Coatings

Application of liquid coatings shall adhere to the following requirements:

6.2.1

Preheating shall not raise the temperature of the pipe above 120°C (240°F).

6.2.2

If the pipe surface temperature is below 10°C, the pipe shall be preheated. Preheating shall raise the surface temperature so that coating application takes place when the pipe surface is at or above the minimum temperature as specified by the Manufacturer. Direct flame may not be applied to the pipe after blast cleaning. If heating is required after blast cleaning to maintain the surface above 10°C (50 °F), induction coils or indirect heat may be used.


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6.2.3

Heating may be used to accelerate cure with induction coils or indirect heat.

6.2.4

The coating shall be applied in accordance with the Manufacturer recommendations with respect to the following:

a) Acceptable application equipment

b) Mixing

c) Storage and shelf life of coating material

d) Preheating coating material

e) Cleaning of tools and equipment

f) Spraying technique

g) Pot life

6.2.5

The relative humidity and the steel surface preheat temperature shall not be higher than the Manufacturer's recommended maximum.

6.2.6

The coating shall be applied immediately after correct steel temperature is achieved.

6.2.7

No solvents or accelerants are to be added to the liquid coatings.

6.2.8

The coating shall overlap existing coating by a minimum distance of 75 mm (3 in.). All abrasion marks on adjacent coating shall be covered.

6.2.9

Application shall be performed in a manner that prevents sags and runs, provides adequate cover in angles and crevices, and provides a smooth uniform coat. All WFT marks shall be smoothed and blended into adjacent coating.

6.2.10

The minimum thickness of cured coating shall be 0.64 mm (25 mils).


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6.2.11

If several coats are required to achieve the specified coating thickness, the Manufacturer’s recoat schedule shall be followed, with conditions of temperature and humidity taken into account. If the Manufacturer recommended maximum recoat time is exceeded, each coat shall be abraded prior to applying an additional coat.

6.2.12

When coating girth welds intended for bores or HDD service, the DFT of the liquid coating applied shall be a minimum of 1 mm (40 mils).

6.2.13

When overcoating single-layer FBE-coated pipe in the field, a minimum of 1 mm (40 mils) of liquid coating shall be applied to the sweep-blasted FBE coating. The blasting shall remove all gloss and provide a suitable anchor profile for the coating application. Any of the coating products listed in Table 4.2 shall be used.

6.2.14

The coating is considered cured when it has achieved an 80 Shore D hardness value or better.

6.3 Application of Heat Shrink Sleeve Coatings

Application of heat shrink sleeve coatings shall adhere to the following guidelines:

6.3.1

The requirements for storage, preheating, wrapping, and shrinking of shrink sleeve products shall be in accordance with the Manufacturer requirements

6.3.2

Immediately prior to application, the preheat temperature of the overlap areas and the girth weld area shall be verified for compliance. Verification shall be measured at 12, 3, 6, and 9 o’clock positions during all shrink sleeve installation steps.

6.3.3

The shrink sleeve overlap or closure shall not be placed over the pipe spiral or longitudinal seam.

6.3.4

The sleeve shall be applied over the joint area with a minimum overlap of 75 mm (3 in.) onto the external polyethylene coating. The Applicator shall apply sufficient heat to the sleeve to allow the mastic to flow outward extending beyond the edges and seam area of the sleeve. All sleeves shall be fully rolled to ensure no air entrapment.


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6.3.5

The overlap of the shrink sleeve onto the existing plant-applied coating shall be at least 75 mm.

6.3.6

The minimum overlap of the shrink sleeve onto existing plant-applied coating for directional drill/slip bore piping shall be 100 mm (4 in.).

6.3.7

When coating girth welds for directional drill or slip bore piping, the leading edge of the shrink sleeve shall be overcoated with a directional drill or slip bore sleeve according to the Manufacturer procedure.

7 Holiday Detection

Holiday detection shall adhere to the following general requirements:

7.1.1

The Applicator shall test each girth weld applied for coating integrity using a holiday detector.

7.1.2

The coating shall be checked with a holiday detector set to at least 125 volts/mil within the ranges specified in Table 7.1. The Company inspector shall verify the thickness at random locations.

7.1.3

Holiday detection shall be carried out using a properly sized spring electrode. A search electrode made of conducting rubber or brass may also be used. The correct size of the spring shall have 0.75 mm lateral distance between spring coils at the area where the electrode contacts the coated surface. The search electrodes shall be clean and free of coating residue.

7.1.4

Operation of the holiday detector shall be controlled to ensure the travel rate does not exceed 300 mm per second and to ensure the equipment does not remain stationary on the coating while the power is on.

7.1.5

To minimize possible coating damage due to repeated holiday testing, the Applicator shall limit the number of passes over a coated area with the holiday detector.

7.1.6

Care shall be taken not to damage adjacent coating with a lower DFT.


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7.1.7

All holidays shall be plainly marked immediately after detection and shall be repaired in accordance with this specification at the expense of the Applicator.

7.1.8

The holiday detection voltage shall be initially verified at the beginning of each work day and periodically through the day. Verification frequency shall be ≤4 hours.

7.1.9

Final holiday testing during the lowering-in process (piping and girth welds) shall be at the minimum DFT voltage of the piping coating according to the guidelines in Table 7.1.

7.1.10

Girth weld coating tie-in crews shall conduct the final holiday detection of the coated tie-in weld and piping in all bell holes. The piping that is exposed and is safely accessible shall be holiday detected on either side of the tie-in girth weld.

Table 7.1 – Required Holiday Detection Voltage Ranges

Coating System Holiday Detection Voltage Range

Fusion Bond Epoxy (Piping) 1500 – 1800 2 Layer External Polyethylene (Piping) 5000 – 8000 3 Layer External Polyethylene (Piping) 3500 – 8000 Liquid Coating Systems (Girth Welds) 3125 – 5000 Liquid Coating Systems (Bore/HDD G/W) 5000 – 7500 2 Layer Heat Shrink Sleeves (Girth Welds) 5000 – 9000 3 Layer Heat Shrink Sleeves (Girth Welds) 5000 – 9000

8 Repairs

8.1 General

Repairs shall adhere to the following general requirements:

8.1.1

Residues, markers, grease, or other material must be removed from the coating surface prior to abrasion.

8.1.2

The adjacent parent coating shall be roughened to at least 25 mm (1 in.) around the defect, and the edges shall be feathered.


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8.1.3

After abrading, all dust shall be removed from the prepared areas using compressed air, a clean, dry bristle brush, or a clean dry cloth.

8.1.4

Holiday detection of the repair areas shall be done at the same voltage as used for the original coating.

8.2 Repairs on Liquid Coatings

Repairs on liquid coatings shall adhere to the following general requirements:

8.2.1

Defects in liquid coatings shall be repaired with liquid coating materials as specified in Table 4.1. In general, the material used for repairs shall be the same material as the parent coating being repaired. Where applicable, a brush-grade material may be used to repair a spray-grade parent coating. Repair materials shall completely cover abraded areas.

8.2.2

Repair areas up to 60 cm² (9.3 in.²) in size shall be prepared by abrasive blasting or by using 80 to 120 grit sandpaper, extending onto adjacent coating at least 4 cm (1.5 in.).

8.2.3

Repair areas exceeding 60 cm² (9.3 in.²) shall be prepared by abrasive blast cleaning, extending onto adjacent coating at least 4 cm (1.5 in.).

8.2.4

Low DFT areas shall be repaired according to 6.2.11.

8.3 Repairs on Heat Shrink Sleeves

Repairs on heat shrink sleeves shall adhere to the following requirements:

8.3.1

If any burning, cracking, wrinkling, or other damage to the heat shrink sleeve occurs during installation, the sleeve shall be removed and replaced according to the Manufacturer's procedure.

8.3.2

If any burning, loss of adhesion, or cracking of the epoxy primer occurs during installation, the primer shall be removed and replaced according to the Manufacturer's procedure.


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8.3.3

Holidays or damaged areas revealing bare steel and/or adhesive that are less than 50 mm in diameter shall be repaired with the Manufacturer's repair patch or half a shrink sleeve. Approved repair materials are shown in Table 4.5. Holidays greater than 50 mm (2 in.) in diameter, and any lineal 300 mm (12 in.) of pipe containing more than five pinholes or damaged areas, shall be repaired with a full shrink sleeve.

8.3.4

When making coating repairs, the preheat temperature shall be according to the Manufacturer's procedure.

8.4 Repairs on FBE Coatings

Repairs on FBE coatings shall adhere to the following requirements:

8.4.1

Mechanical damage to FBE shall be repaired with a suitable liquid coating selected from the materials listed in Table 4.1. Repair material shall completely cover abraded areas.

8.4.2

Patch sticks may be used only immediately prior to lowering-in on pipelines that shall operate at ≤50°C (122°F) and use is limited to areas 5 mm and smaller. The patch sticks shall be from the same Manufacturer as the parent FBE. The patch stick Manufacturer application procedure shall be followed and limited to the repair area as listed in Section 8.4.3.

8.4.3

For repairs up to 5 mm in diameter, the damaged area and 12 mm adjacent coating shall be prepared using 80 to 120 grit sandpaper.

8.4.4

Repair areas up to 60 cm² (9.3 in.²) in size shall be prepared by abrasive blasting or using 80 to 120 grit sandpaper. Adjacent FBE shall be feathered 4 cm to 8 cm (1.5 in. to 3 in.).

8.4.5

Repair area girth welds exceeding 60 cm² (9.3 in.²) shall be stripped and recoated. Adjacent FBE shall be feathered 4 cm to 8 cm.

8.4.6

Repair areas on mill-coated pipe exceeding 60 cm² (9.3 in.²) shall be prepared by abrasive blasting and then coated with products listed in Table 4.1. Adjacent FBE shall be feathered 4 cm to 8 cm (1.5 in. to 3 in.).


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Table 8.1 – Piping Coating Repairs

Piping Coating Repair Procedure to be Used

Fusion Bond Epoxy Section 8.4 Dual Powder FBE Abrasion Resistant Coating Section 8.2 Polyethylene System A2 Section 8.3 Polyethylene System B2 Section 8.3

9 Quality Control, Inspection and Testing, and Acceptance

9.1 General

Quality control, inspection and testing, and acceptance shall adhere to the following requirements:

9.1.1

The Applicator is responsible for the quality of the work performed.

9.1.2

The Applicator’s QC personnel shall be on site during all aspects of the preparation, coating, and cure of applied coatings.

9.1.3

To monitor the Applicator’s performance relative to QC, the Company may designate an inspector. The Applicator’s records shall be available for review by the Company’s inspector at all times, and copies shall be submitted to the Company at the end of the project as part of the Applicator’s turnover documentation package.

9.1.4

All QC measurements specified in Table 9.1 must be recorded for every girth weld coated.

9.1.5

The DFT shall be measured with a DFT gauge (magnetic pull-off or fixed probed gauges). The gauge shall be verified for calibration at least once per day to a NIST Certified Coating Thickness Standard, or gauge Manufacturer supplied shims, that measure within 20% of the minimum required DFT. Where a coating fails to conform to the specified requirements, additional sampling shall be performed to ascertain the extent of failed coating. All affected coating determined to have failed the testing shall be repaired. Rejected coated girth welds shall be stripped and recoated at the expense of the Applicator.


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Table 9.1 – Required Applicator QC Documentation of Coatings

Coatings Test Type Test Reference Frequency

All Coatings Project Specific ITP As per specification 1 per project All Coatings Environmental

Conditions As per specification Start of work day and

every 4 hours All Coatings Visual Inspection of

Girth Weld for Contaminants

As per specification Every weld

All Coatings Abrasive Blast Air Blotter Test

As per specification At project startup and as per 5.1.3

All Coatings Visual Exam of Cleaned Girth Weld

SSPC-VIS 1 Every Weld

All Coatings Abrasive Blast Profile Measurements

NACE RP0287 At start of work day and as per Sections 5.1.8 and 5.1.9

All Coatings Salt Contamination of the Steel Surface

SSPC GUIDE 15 Minimum 1 weld per week

All Coatings Monitor Weld Preheat As per specification Every weld Liquid Coatings Dry Film Thickness As per specification Every weld 3 Layer Heat Shrink Sleeves Primer

Wet Film Thickness or Dry Film Thickness on Liquid Primer as required by Manufacturer

As per specification Every 25th weld

All Coatings Visual Inspection of Application

As per specification Every weld

All Coatings Holiday Detection NACE RP0274 Every weld Liquid Coatings Cure Test using

Shore D Hardness As per specification 4 welds per day

9.2 Quality Control of Liquid Coatings

9.2.1

The coating shall be inspected for, and be free of, the following conditions:

a) Pinholes

b) Missed or skipped areas

c) Roughness

d) Blistering, cracking, delamination

9.2.2

Runs and sags shall be kept to a minimum.


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9.2.3

The Applicator’s QC personnel shall visually inspect the full circumference of the applied coating for evidence of low film thickness areas. Particular attention to the weld area for low DFT readings shall be conducted as part of the inspection. The coating thickness may be measured during coating application using a WFT gauge. If the girth weld is preheated, obtained readings will provide only an estimate of applied coating. All marks made by the WFT gauge shall be brushed out.

9.3 Quality Control of Heat Shrink Sleeve Coatings

9.3.1

Each girth weld area shall be visually inspected at four quadrants circumferentially.

9.3.2

The completed sleeve shall be free of air pockets, wrinkles, lifted edges, burns, and other defects that may affect sleeve performance. Upon completion of the application, slight adhesive flow shall be evident at edges around the full circumference and along the seam of the closure.

10 QC Records

10.1 General

The Applicator shall keep detailed records of daily operations, quality control test results, and environmental conditions. This information shall be supplied to the Company immediately after completion of the project. However, the Company shall have access to review of these records at any time.

10.2 Applicator Forms

The Applicator’s forms shall record at least the following items:

a) Surface preparation:

i. Project name

ii. Pipe diameter size

iii. Date and time

iv. Adjacent pipe coating Manufacturer and type

v. Pipe temperature (ºC/ºF)

vi. Ambient temperature (ºC/ºF)

vii. Dew point temperature (ºC/ºF)

viii. Relative humidity (%)

ix. Visual inspection for contamination results

x. Solvent type (if required)

xi. Type of abrasive (Manufacturer and size)


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xii. Surface cleanliness achieved (SSPC SP-10/NACE NO. 2)

xiii. Surface profile depth and replica tape

xiv. Soluble salt testing results and type of test conduct

xv. Abrasive blasting air blotter test results

b) Coating application details:

i. Date and time

ii. Full name and batch number of materials

iii. Expiry date of materials

iv. Storage temperature of materials

v. Method of preheating

vi. Pipe temperature (ºC) at the time of application

c) Inspection

i. Date and time

ii. Coating thickness (DFT/WFT and location of readings)

iii. Holiday detection voltage setting and type of search electrode

iv. Number of holidays

v. Holiday repair method and coatings used

vi. Shore D testing result

vii. Visual appearance

10.3 Applicator Turnover Documentation Package

The Applicator shall provide a complete turnover documentation package at the end of the project. The following documentation shall be compiled and filed in binders in the following order:

a) All referenced standards and specifications as required for the project

b) The approved ITP

c) Coating Manufacturer technical datasheets and MSDS

d) Copies of all coating personnel qualification records from the coating Manufacturer

e) Applicator QC personnel certification documentation

f) Copies of all calibration records (holiday detectors, volt meters and inspection tools, etc.)

g) Applicator’s coating surface preparation, application, and inspection forms


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11 Quality Control Testing Procedures

11.1 Testing for Salt Contamination of the Steel Surface for All Coatings

11.1.1 Test: Option 1 – Field detection of chloride ion by Kitagawa tube

1. Use a ruler and marker to outline a representative surface area of 15 cm by 15 cm.

2. Using distilled or de-ionized water and a graduated cylinder, pour a measured volume of 22.5 ml of pure water into beaker A. (Note: The sample area and volume give a 1:10 ratio of volume to area.)

3. Repeat Step 2 with Beaker B.

4. Using a pair of tweezers or plastic gloves, dampen a cotton ball in the water in Beaker A, and thoroughly swab the area measured in Step 1. After swabbing, swirl the cotton ball in the water, and then squeeze it against the inside of Beaker A to extract most of the water from the cotton ball.

5. Repeat this swabbing, swirling, and squeezing operation four times with fresh cotton balls, and then leave the cotton balls in the water in Beaker A.

6. Use a fresh cotton ball to dry the measured test area and place it in Beaker A.

7. Stir the water and cotton balls for two minutes to achieve thorough mixing.

8. Record the final volume. (If low, bring up to 22.5 ml with distilled water).

9. Remove contaminated plastic gloves or tweezers. Using a new pair of tweezers or plastic gloves, proceed with Step 10.

10. Place a number of fresh cotton balls identical to those used in Steps 4 through 7 above into Beaker B. Let it sit covered, for at least three minutes. This step will provide the control sample.

This method uses a vacuum-sealed ampoule containing a wick treated with a known amount of silver chromate solution (red/brown). On contact with chloride ions this converts to silver chloride (white), sweeping up the wick excess chromate ion. Water from the sample goes up the wick by capillary action. When the wick is fully occupied by sample fluid, it accepts no more samples. Gradations on the side of the tube provide estimated levels of chloride ion directly in ppm. The determination range of the method is from 5 to 200 ppm. This method is described in ISO 8502-5. The precision depends on the chloride level. In the range of 5 to 20 ppm, precision is ±2ppm. In the range of 20 to 60 ppm, precision is estimated at ±5ppm. At higher levels, precision is estimated at ±10 ppm.


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11.1.2 Test: Option 2 – Elcometer 134 Chlor*Test Salt Detection Kit

Remove the cap from the CHLOR*EXTRACT solution bottle, and pour the entire contents into the test sleeve. If applying to a horizontal surface, clip the sleeve to prevent loss of solution and remove excess air. Peel off the blue pressure-sensitive backing from the test sleeve; remove the air from the test sleeve by squeezing it between fingers and thumb. When evacuating air, take care not to spill CHLOR*EXTRACT from the sleeve. Firmly apply the test sleeve to the test surface. Lift and hold the free end of the test sleeve upright to allow the extract solution to come into contact with the test surface. Use your other hand to massage the solution through the test sleeve against the surface for two minutes. When the massage is complete, remove the test sleeve.

For vertical or overhead surfaces, the solution flows down to the closed end of the test sleeve. For horizontal surfaces, press and slide your finger across the sleeve to move the solution to the closed end of the sleeve prior to removal. Use the clip to help retain the solution during sleeve removal. Using caution and avoiding touching the ends of the titration tube, snap off both ends with the metal snapper provided, and insert the titration tube into the test sleeve with small numbers and the arrow at bottom. Insert the sleeve with the extract solution and the titration tube into the hole previously made in the box lid.

Wait approximately 1½ minutes or until the solution has wicked to the top of the titration tube. The cotton at the top of the titration tube changes colour to amber when fully saturated. Immediately remove and read the number on the titration tube at the interface of the colour change.

Pink is normal, white is the chloride level.

This number is calibrated in micrograms per centimetre squared (µg/cm2) and parts per million (ppm); for this test, the ratio is 1:1.

When chloride levels exceed surface cleanliness specification requirements, the surface should be washed to remove the salt.

11.1.3 Test: Option 3 – Bresle Salt Test Kit for Steel Surfaces

Attach the Bresle patch to the surface. Inject the distilled water with a syringe into the Bresle patch and then extract it. Repeat through 10 cycles of injecting and extracting the liquid in the Bresle patch. Measure this liquid with the conductivity meter which measures the quantity of salts in both µg/cm² (ppm) and mg/m². This type of testing complies with ISO 8502-6, which relates to the extraction of soluble contaminants using the Bresle patch method, and ISO 8502-9, which relates to the conductometric determination of soluble salts.

11.2 Test: Abrasive Blasting Air Blotter Test

Clean, dry compressed air shall be used for nozzle blasting. Moisture separators, oil separators, traps, or other equipment may be necessary to achieve this requirement.

To ensure these requirements are met, a blotter test shall be performed on all abrasive blasting equipment.


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11.2.1 Option 1

1. Duct tape four to six white coffee filters to a wooden construction skid.

2. Turn off the abrasive blast media metering valve at the blast pot.

3. Run the abrasive blast air to purge any existing abrasive residue in the hose and whip. Run the air until no abrasives remain.

4. Leaving the skid on the ground with the coffee filter facing upward, the blast technician shall stand directly above the taped coffee filters and have the end of his blast nozzle at a standoff distance of 610 mm from the coffee filter.

5. The blast technician shall blast the air at the coffee filter for a minimum of 60 seconds.

6. The coffee filters shall be examined for transfer of contaminants.

7. No transfer of oil, grease, or water shall be acceptable.

11.2.2 Option 2

1. Turn off the abrasive blast media metering valve at the blast pot.

2. Run the abrasive blast air to purge any existing abrasive residue in the hose and whip. Run the air until no abrasives remain.

3. Duct tape a clean absorbing white cotton rag at the end and around the blast nozzle.

4. The blast technician shall run the air through the cloth for a minimum of 60 seconds.

5. The white rag shall then be taken off the nozzle and examined for transfer of contaminants.

No transfer of oil, grease, or water is acceptable.

11.3 Test: Adhesion Test Using V-Notch Cross Cut Procedure for Liquid Coatings

The coating inspector shall conduct this test on the girth weld location.

The adhesion test shall be run when the coating is completely cured as determined by the Company inspector and the Applicator’s QC personnel.

11.3.1 Test Samples

Conduct a "V-notch cross cut" test using the following procedure. The adhesion test shall be run when the exterior surface of the coated area is at 20°C ± 5°C. The test area shall consist of any coated area on the component or test sample that is free from all defects and within this specification’s minimum dry film thickness requirement.

a) Using a utility knife as stated below, make 25 mm (approximately) long scribes through to the metal surface to form a V with an angle of approximately 30° as shown in the sketch below. Insert the point of the utility knife horizontally (i.e., the flat of the blade) under the coating at the point of intersection of the cuts such that the blade point is at the metal surface. Use a levering action to force the flat point of the blade up from the metal surface describing a single vertical (i.e., at 90° to the surface) motion in an attempt to pry the coating off.


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b) Continue to force the coating from the steel substrate using the point of the utility knife until

resistance is met. Take care to protect the eyes and hands when carrying out this operation.

c) The metal blade shall have dimensions as shown in the following sketch and an exposed cutting edge of 25mm ± 6 mm.

25 mm ±6 mm

19 ±3mm tall 56 ±6 mm

RATING 1 to 5:

Rating 1: No removal of coating other than that caused by insertion of the flat point of the knife blade at the intersection point (nominally less than 1 mm)

Rating 2: No more than 2 mm of adhesion loss from the metal surface Rating 3: No more than 3 mm of adhesion loss of coating from the metal surface Rating 4: No more than 4 mm of adhesion loss from the metal surface and displays

resistance Rating 5: More than 4 mm of adhesion loss of coating from the metal surface and displays

no resistance


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The rating of the coating is determined by the adhesion failure. Limited cohesive failure within the coating shall be considered a pass, if there is satisfactory adhesion. Ratings 1 to 4 are considered acceptable, and Rating 5 is deemed a failure.

Cohesive failure caused by excessive interface or cross-section porosity leaving a noticeable honeycomb structure on the pipe surface shall constitute a failure.

11.3.2 Cause for Rejection

If the test fails to conform to the specified requirements, an additional test shall be performed to ascertain the extent of failed coating. If the second test fails, the girth weld shall be stripped and recoated. To ensure compliance, the Company inspector shall test the previously coated girth weld. All affected coating determined to have failed the testing shall be rejected. Rejected coated girth welds shall be stripped and recoated.

11.4 Test: Shore D Hardness Test for Liquid Coatings

11.4.1

The coating thickness must be 0.75 mm (30 mils) minimum at the spot where the hardness reading is measured. Shore D gauges can give false readings if pushed too fast or too slow. Hold the gauge in a vertical position and press the foot of the gauge firmly against the coating. Consistency is important. Conduct the test three times.

11.5 Test: Peel Tests for Heat Shrink Sleeve Coating

11.5.1

Two-layer peel tests shall be conducted during girth weld coating operations after the shrink sleeve has cooled according to the Manufacturer's procedure.

11.5.2

Three-layer peel tests shall be conducted during girth weld coating operations after the epoxy primer has cured according to the Manufacturer's procedure.

11.5.3

The test frequency shall be one test per 50 sleeves installed, or at the discretion of the Company inspector. Two strips shall be cut through the sleeve to the steel substrate. One strip shall be on the girth weld and the second strip on the overlap area. The strips shall be approximately 25 mm wide and 150 mm long, and at the 3 o’clock orientation on the pipe. The strips shall be peeled back, using pliers, perpendicular to the pipe, with uniform, gradual force being applied. If more than 5% of the stripped area is showing bare steel, polyethylene, bare epoxy primer, or air pockets, the sleeve shall be rejected.

11.5.4

A repair patch or a half sleeve (an approved sleeve cut into two lengthwise) applied in accordance with the Manufacturer's approved procedure shall be used to repair all peel test


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sites. Approved repair patches are described in Table 4.5. Placement of such repair materials shall take place only after the peel test strip is reheated and reapplied to the pipe.

12 Revision History

12.1 Revision 2.0, July 30, 2012

Changed title from “Coatings” to “Field Coatings for Below Grade.”

Developed stand-alone specification for coatings.


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Enbridge Northern Gateway Pipelines

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