IPC 2014-33740 [1], Pump Station Design, summarized the work Enbridge had completed on the design and construction of 65 new pump stations and the modification of a further 16 existing stations. The $4.0 billion dollar scope was completed over a 12-year period, with the last stations being completed in 2019. This paper documents the application of this body of work on the Keystone XL Pipeline project for TC Energy. This work included the design of 32 new pump stations.

The Keystone XL project experienced delays due to legal and regulatory challenges which gave TC Energy the opportunity to reevaluate their pump station design. The previous design was piping centric and had a significant footprint. The station design developed for Enbridge was more equipment centric, and owing to the compact layout, presented the potential for cost savings in excess of $140 million for their project. This paper provides a unique perspective with which to evaluate the design philosophies employed by comparing the two station designs developed independently.

While the basic design was proven, new work was completed to validate the new application. This effort demonstrated that these pump stations are a unique piping subset. The operating temperature is relatively modest, but the piping is exposed to high pressure and high flow rates (HPF). Prolonged operation with high turbulence and pressure can result in fatigue related failures. These HPF piping systems require additional tools for their design. These analytical techniques include:

• Erosion studies to validate limiting velocities and pipe sizing

• Dynamic piping analysis to minimize potential vibration due to beat frequencies and pressure pulsations

• Finite Element Analysis (FEA) of small-bore connections to minimize the potential for fatigue related damage.

• Computational Fluid Dynamics (CFD) studies to minimize the impact of pump suction turbulence on pump performance.

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