BOREALIS LD5 Stenungsund (Sweden) Lesson learned

CONSTRUCTION

BEFORE WORKS

Lesson learned: Stenungsund

AERIAL VIEW (1/2)

Lesson learned: Stenungsund

AERIAL VIEW (2/2)

Lesson learned: Stenungsund

GENERAL LAYOUT

Lesson learned: Stenungsund

PROJECT FEATURES

Borealis Stenungsund complex area is as a very unusual site for the construction of a polyolefines plant: a soil composed mainly of solid rock with some deep clay areas a very compacted layout at different levels inserted between the rock scarp at east side and the existing plant at west side LD5 plant are is very close to running existing plants The above, together with other other peculiarities, strongly influenced the overall plant design and construction. In this presentation however the topics addressed are supposed to be not directly related to the above characteristics and have been selected in order to be implemented in any other LDPE indipendenctly of the geographical location. In general the presentation is structured area wise where, for each one, description / characteristics, erection, sequence and observations / recommendations are described. Particular attention shall be addressed to the civil works which are the most important to keep in the right sequence the following disciplines.

Lesson learned: Stenungsund

AREA 400 SILOS AREA (1/9)

1) Subdivision of works: it was decided to divide the civil works in two parts; south package (Silos area) and north package (all the other areas). The reason to have two contractors simultaneously at Site was to share the risk between a well known contractor (NCC- south part), overloaded at that time with other ongoing Projects and Pihl (new contractor without a proved experience in the field of technological foundations). It would have been preferable to increase the scope of NCC for the entire south part (areas 400, 90 & 100 and pipe racks). We faced a non easy coordination issue to manage the border areas between them 2) The silos concrete structure was completed with two months of delay because of unexpected soil improvement that was required. to verify if there is a margin to reduce the size of the concrete columns and horizontal beams.

Lesson learned: Stenungsund

AREA 400 SILOS AREA (2/9)

3) The rain water drainage system was not included in the scope of civil contractor. We should add it in the scope (PVC welded pipes or similar) 4) The embedded plates have not been fully painted by the civil contractor (full painting cycle). We shall add it in the scope (sand blasting + 2 painting coats) 5) The temporary elevator to access to the top of the silos has to be included in the scope of the civil contractor and maintained till the final stair cases are erected (around two months after the civil completion of the main structure)

Lesson learned: Stenungsund

AREA 400 SILOS AREA (3/9)

6) The silos templates have to be transferred to the civil contractor. We received three sets of template from J&D facing several discrepancies (radius not as per drawing ). 7) The silos anchoring system should be changed from hook type to counter washer type (square plate 100 x 100 x 15mm). Due to the narrow gap of the main rebars it was very difficult or sometimes impossible to insert the hook type anchors 8) Embedded plated shall be replaced (In case of revisions or erection mistakes or late drawings submission) by external plates fixed by chemical anchors bolts (to be added in the scope of civil contractor as option in unit rates)

Lesson learned: Stenungsund

AREA 400 SILOS AREA (4/9)

9) Once the main concrete structure is erected the steel structure priorities are:
a) erection of the two stair cases up to top main concrete level. The upper part of stair cases shall not be erected interfering with the silos erection b) erection of the handrails at the main concrete elevation c) erection of the platforms and stairs under the silos. The erection shall be done by placing forklifts and mobile platforms (conventional mobile cranes are not advisable being the space very narrow). Due to the huge amount of items the supplier shall present a detailed sequence of delivery. We faced several problems in this area caused by missing handrails, platforms, etc. The activity can go in parallel with the silos erection (silos to one side and steel structure to the opposite)

Lesson learned: Stenungsund

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AREA 400 SILOS AREA (5/9)

d) the top connecting aluminum platforms (supplied by J&D) were not included in the mechanical contractor scope. It shall be added in the steel structure erection scope (300t crane is needed for lifting + 100t with man- basket) e) supply and Installation of top silos pipe supports (for Zeppelin systems) were not included in the mechanical contractor scope. It shall be added in the steel structure erection scope (300t crane is needed for lifting + 100t with manbasket) f) to verify from engineering point of view that buttery limits between the different suppliers (items 9d & 9e) are respected

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AREA 400 SILOS AREA (6/9)

10) Silos assembly observations

a) Its important to have a suitable assembly area well compacted of 10,000 m2 minimum. The area shall not be necessary close to the foundations since the silos are transportable via low bed b) the saddles to transport the silos (different from those needed to store the silos), shall be included in the scope of the mechanical contractor while those needed to store the silos (wooden saddles), shall be accounted in the silos supplier scope c) based on the experience in Stenungsund, with good weather conditions, the mechanical contractor can install one silo a day. It is advisable to assemble as much silos as possible mobilizing the main crane (600t crawler crane) when you have a buffer of at least 60% of the silos (finally inspected) and the remaining silos still under fabrication (to be completed in one month). Obviously this ideal solution would involve much more assembly area.
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AREA 400 SILOS AREA (7/9)

d) the degassing silos are the most critical ones for the high finishing requirements. Even experienced supplier like J&D faced several difficulties to comply with Borealis demand. We suggest to start the assembly with the storage silos first and at 50% of fabrication with the degassing silos (when you can keep the silos on the rollers without impacting the rest) e) the closing of the silos outlets shall be included in silos supplier scope (closing by temporary wooded flanges properly sealed) f) to keep pressure to silos supplier to get the auxiliary structures on time (upper platforms, vertical ladders, etc.)

Lesson learned: Stenungsund

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AREA 400 SILOS AREA (8/9)

g) it should be asked to the silos supplier to increase the size of the holes of degassing silos skirt bottom ring in order to fit precisely with the anchor bolts. For the other silos there is no problem being them fixed with clamps h) we shall verify that skirts erection is included in the mechanical contractor scope (they are not erected by the silos supplier in the assembly area) i) we shall, before the silos erection, when the civil scaffolding platform is still available, install a permanent internal shuttering (aluminum type) for the final grouting. If not installed as suggested, it will take a huge effort at later stage.

Lesson learned: Stenungsund

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AREA 400 SILOS AREA (9/9)

11) Silos erection

a) the erection of the silos was performed with 600t crawler crane (main crane) + 200t mobile crane (man-basket crane). The main crane erected all the silos from the south part shifting from west to east ( we started with degassing silos). It is suggested to postpone the U/G on that area after the heavy lifts b) in the mechanical contractor scope we shall include the installation of a temporary lift up to the top of silos. Stair cases even if erected destroy the legs if used more times a day c) the tilting of the degassing silos involved the installation of two trunnions (not foreseen by silos supplier). It shall be included in the silos supplier scope d) spreader beam, slings, etc. shall be provided by mechanical contractor, clearly mentioned in the subcontract requirements.

Lesson learned: Stenungsund

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AREA 090 MATERIAL HANDLING COMPRESSOR STATION

1) Its a simple slab with some foundations 2) We decided to install first all the equipments and after the steel structure to facilitate the mechanical erection 3) After the equipment installation we erected the steel structure up to the purlins 4) After that (keeping some openings) we erected the spools 5) After that we closed the roof and sides working in parallel with the piping assembly

STEEL STRUCTURES CONSTRUCTABILITY ANALYSIS

LD5 Stenungsund-Sweden AREA 090 PNEUMATIC TRANSPORT

Lesson learned: Stenungsund

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AREA 220 RTO

1) its a simple slab with some foundations 2) the package is composed of a burner, bag filter, fan & stack supplied in big items 3) the items should be delivered already preassemble with the maxim grade of prefabrication. This shall be depplydiscussed and clearly agreed with the supplier 4) based on the size of the items a suitable road shall be maintained. Surrounding U/G to be prioritized or postponed 5) refractory works are involved. Presence of vendor is mandatory 6) the mechanical contractor claimed extra hours being not fully aware about the scope. To ensure that contractual (during bidding also) is sufficiently detailed in order to enable the subcontractor to properly evaluate the job.

Lesson learned: Stenungsund

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AREA 100 SUB STATION (1/2)

1) Its a building with an high grade of finishing 2) U/G under the building to be prioritized 3) to complete floor wise giving priority to the cable cellar 4) We faced some problems with the hardening of the floors. Hardening of the floors does not replace the epoxy coating normally requested where electrical panels are installed. Both activities to be included in the civil scope. The epoxy painting shall be applied after cubicle installation

Lesson learned: Stenungsund

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AREA 100 SUB STATION (2/2)

5) secondary steel structure of the platforms around the building included in the civil scope. We suggest to transfer the scope to the steel structure supplier being more qualified for design understanding and installation. 6) HVAC secondary cooling units to be installed outside the electrical panels rooms. In Stenungsund a cooling unit had a water leak on the top of energized panels 7) transformers bays to be prioritized and completed with final painting (including the upper cladding roof) before transformers installation.

Lesson learned: Stenungsund

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AREA 030 EXTRUSION (1/7)

1) Its the most complicate building 2) It is suggested to simplify the design of building main concrete structure by adopting the same size of floor beams where possible. Saving of volume like this case would allow a significant saving of man hours. 3) Embedded plates information, if not promptly available, shall not hold the progress of construction. It is suggested to study an alternative solution by using external plated fixed with chemical anchor bolts.

Lesson learned: Stenungsund

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AREA 030 EXTRUSION (2/7)

4) It was noticed that openings and inputs where delayed by JSW (Extruder basic designer for civil scope). This shall be monitored well ahead and bypassed in case by core boring method 5) the internal intermediate hallow block walls shall be completed up to the first painting coat by civil contractor before handing over the area to the mechanical. Final painting coat to be executed in a second step when mechanical activities (included insulations) are completed; to be specified in the civil sub contract.

Lesson learned: Stenungsund

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AREA 030 EXTRUSION (3/7)

6) Sequence of works:
a) completion by civil of the main concrete structure and handing over of the upper area to steel structure contractor. In parallel the civil shall complete the internal finishing works giving priority to the ground floor b) installation level wise of the main equipment by the mechanical contractor using the contractual windows given by the steel structure contractor (to specify in the steel structure contract that erection shall proceed in parallel with the equipment installation). Some equipment shall be erected before closing the structure of the upper levels c) handing over of the metal deck floors from the steel structure contractor to the civil contractor for the concrete pouring. Openings and details to be provided on time to the steel structure contractor. This activity is very critical since it takes not less than a 1 working week by civil to have one floor ready for mechanical installation
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AREA 030 EXTRUSION (4/7)

d) once the steel structure and metal decks are completed, the priority shall be given to the mechanical contractor to install the equipment and the big spools at the upper levels e) at the ground floor the mechanical installation shall proceed with the main and satellite extruders and secondary equipment f) once the main equipment are installed, the cladding installation shall start giving priority to the side wall opposite to the access road
LD5 Stenungsund AREA 030 EXTRUSION

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STEEL STRUCTURES VS. EQUIPMENT INSTALLATION

Lesson learned: Stenungsund

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AREA 030 EXTRUSION (5/7)

7) Observations:
a) to keep all the mechanical piping erection of extruder package and cleanliness class (related to extruder only) to a single contractor. Its extremely important to have a minimum number of contractors inside the extruder due to the congestion of the area b) to prioritize the small bore fabrication and erection (bulk part) designed by TCM. The small bore piping quantities inside the extrusion are huge c) to include in the scope of the cladding erector (steel structure contractor) the openings and relevant finishing works (flashing, closing, etc.) . Mechanical contractor shall give the input by marking the openings. Any opening that shall be sealed has to be included in the scope d) to include in the scope of civil contractor the rain water drainage system (PVC welded pipes or similar)
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AREA 030 EXTRUSION (6/7)

e) to specify to the civil contractor that water proof membrane has to be installed following the mechanical erection sequence and therefore postponed after the mechanical installation to avoid damages f) In Stenungsund the piping detail design (spools & supports), for extruder package was developed by JSW itself as included, during procurement phase, in their scope: never more to be done, as it generates quality, delivery time and design problems with an economical impact much bigger that the initial apparent saving during purchasing the package. g) Extruder equipments where delivered well ahead. We kept the extruder equipment in the warehouse for more than one year. It would be more efficient to deliver the equipment s at the 50% of civil progress, approx two months before the starting of mechanical installation.

Lesson learned: Stenungsund

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AREA 030 EXTRUSION (7/7)

h) We have faced several problems with the packing list prepared by JSW. Items listed frequently were not found being delivered in another package and vice versa. To instruct the supplier that packing list shall strictly adhere to the content of the package and each item shall be traceable referring to drawings (in our hands). Treasure hunting shall be avoided i) We shall include in the contract of each contractor that housekeeping of the areas assigned if not maintained at the level required it will be carried out by the main contractor and cost reverted proportionally according to the judgment of main contractor. The extruder is a typical building where having in parallel different contractors the responsibilities of the house keeping are bounced back between them.

Lesson learned: Stenungsund

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AREA 050 HOT WATER HANDING (1/3)

1) Its a concrete structure with an upper part composed of several levels of steel structure 2) The concrete columns have the same size and equally distributed simplifying the method of construction 3) Sequence of works:
a) Before starting the building area 050 the pipe racks 129, 128 shall be completed. In particular the knot of the two pipe racks was very critical in Stenungsund b) The U/G under the pipe racks can be executed in a second step having enough space to work underneath the lower level of the rack c) Once the concrete structure is completed it shall be handed over to the mechanical contractor to start the installation of the equipment at the ground floor and to the steel structure contractor to start the erection of the upper levels (priority one)

Lesson learned: Stenungsund

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AREA 050 HOT WATER HANDING (2/3)

d) Before closing the first steel structure level n.5 equipment (vessels) shall be installed. A window of 4 working days is needed. The erection can be performed from the south side (Stenugsund layout) with a 300t mobile crane e) The steel structure erection can proceed up to the end without interruptions f) If the mechanical contractor is well prepared some big spools can be inserted during the steel structure erection g) Once the steel structure is completed the area shall be handed over to the mechanical contractor

4) Observations:
a) This is one of the biggest area after the pipe racks in terms of large bore quantities (~250t). Therefore prefabrication shall be prioritized taking into consideration the availability of the area. Priority one to be given for the spools at the ground floor (below the main concrete table anyway)

Lesson learned: Stenungsund

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AREA 050 HOT WATER HANDING (3/3)

b) On the upper level of the structure there are n.3 fin fan coolers supplied in loose parts (GE supplier in Stenungsund). This is a sort of meccano that was not enough detailed during the bidding phase. The level of drawing provided by the supplier was below the standard and we were forced to have the vendor at Site to supervise the erection (even GE vendors were confused during the assembly) c) The steel structure which supports the coolers can be fully assembled at the ground floor in an area nearby the building (if available) d) Once the steel structure is erected the fin coolers can be installed e) At the end a major cladding work is needed to close the entire structure. This activity takes time and qualified contractor is needed (it would be ideal to involve a company specialized in cladding erection)
Lesson learned: Stenungsund

LD5 Stenungsund AREA 050 HOT WATER HANDLING STEEL STRUCTURES VS. EQUIPMENTS

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AREA 040 HP RECYCLE GAS TREATMENT

CONSTRUCTABILITY ANALYSIS MEETING

LD5 Stenungsund AREA 040 H.P. RECYCLE GAS TREATMENT STEEL STRUCTURES VS. EQUIPMENT HEAVY LIFT

1) Its a concrete structure with an upper part composed of several levels of steel structure 2) The concrete columns have the same size and equally distributed simplifying the method of construction 3) Sequence of works:
a) the civil works shall be prioritized on pipe rack 128 and 126 and main shelter columns of area 010. Therefore area 040 shall be postponed to allow the access for the civil contractor b) once the steel structure of pipe racks 128 and 126 (first 5-6 rows) and the main shelter columns and purlins of the south side of building area 010 are erected, the civil works in area 040 can start c) after the civil completion the area shall be handed over to the steel structure contractor that can complete the entire erection (except some secondary members; see following point)

d) once the steel structure is completed it shall be handed over to the mechanical contractor to start the installation of the vertical heat exchangers. Some of the secondary steel structure relevant to the exchanger supports shall be installed in a second step otherwise the exchanger cannot be inserted. This activity shall be included in the scope of the steel structure contractor e) the erection of the heat exchangers is part of the heavy lift compain to be executed in parallel with the compressor erection

4) Observations:
a) the main piping erection is at the ground floor with several batteries of small bore steam traps b) the rest of erection involves the HP part supplied already fabricated (Bohler for Stenungsund ) c) the closing of the grating openings around the exchangers was not foreseen in the steel structure supplier scope. In general we should include a contractual paragraph where we state that any abnormal opening (above 200mm) shall be closed by the contractor (to be compensated except in hourly basis)
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Lesson learned: Stenungsund

AREA 010 COMPRESSOR AREA (1/5)

1) its for civil scope the main area of activities with two huge pedestals (Booster & Hyper Compressors) 2) Sequence of works:
a) the compressor foundations shall start first and they can go in parallel b) once the main foundation are completed secondary pedestals can start c) priority to be given to the steel structure foundations d) once the main foundation are completed, the area shall be handed over to the steel structure contractor to install the main frame keeping the roof open for the heavy lifts. Three sides of the structure can be completed including the perlins e) overhead crane to be installed before closing the roof

Lesson learned: Stenungsund

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AREA 010 COMPRESSOR AREA (2/5)

f) the heavy lifts will include the two compressors the two intercoolers and the farthest heat exchangers of area 040. The ABB motor of the hyper compressor (27 Mw) was supplied in two part disassembled (stator and rotor) which have been assembled at the ground floor g) after that the steel contractor can complete the erection of the building and the roof cladding. In Stenungsund to allow in parallel the activities at the ground floor we installed a temporary net under the roof at our cost. I would suggest to include this in the scope of the steel structure contractor h) the U/G in front of the building shall be anticipated during the Site Preparation phase (ideal period if drawings, materials and contractor are available) or postponed after the main mechanical installation (around 60% of the piping works)
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AREA 010 COMPRESSOR AREA (3/5)

3) Observations:
a) the tubular frame of the Hyper Compressor normally included in the scope of the civil contractor involves some tolerances that are not achievable by a civil contractor. I would suggest to descope it from the civil and shitting to the mechanical scope which shall include the machining of the bottom plates after the casting of the main pedestal. Please take care about this matter being not easy to find the right tools. Machining is mandatory to comply with vendor requirements b) the Booster piping package (Nuovo Pignone supplier) was not delivered prefabricated. Therefore we received loose pipes and fittings to be prefabricated on Site by the mechanical contractor which was not contractually foreseen. This activity shall be included in the mechanical contractor scope. The vendor scope of supply shall be extended to all possible pipes on board of the equipment. Site prefabrication of lubrication, hydraulic, etc. systems are strongly not recommended
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AREA 010 COMPRESSOR AREA (4/5)

c) the Hyper piping package (Burkhardt supplier) was not delivered prefabricated. Therefore we received loose pipes and fittings to be prefabricated on Site by the mechanical contractor which was not contractually foreseen. This activity shall be included in the mechanical contractor scope. Site prefabrication of lubrication, hydraulic, etc. systems are strongly not recommended d) the right weights of the Booster and Hyper Compressor packages shall be indicated in the subcontractor orders to avoid potential claims

Lesson learned: Stenungsund

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AREA 010 COMPRESSOR AREA (5/5)

N LD5 Stenungsund AREA 010 COMPRESSION SHELTER STEEL STRUCTURES VS. EQUIPMENT HEAVY LIFT

Lesson learned: Stenungsund

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AREA 020 POLYMERIZATION (1/4)

1) Its a main concrete wall structure with huge quantity of embedded plates 2) Sequence of works:
a) the sequence of construction shall start from south to north (LD5 layout) to complete before the area where the heavy components shall be installed b) the civil contractor shall work in parallel along all the side walls (optimization of the shuttering frames is only in the benefit of the civil contractor) c) the internal area close to the main steel structure shall be used by the steel structure contractor to place a small mobile crane and cherry pickers

Lesson learned: Stenungsund

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AREA 020 POLYMERIZATION (2/4)

d) the installation of the reactors structure (supplied by Bohler in Stenungsund) shall start from north to south. This activity is not a conventional steel structure erection and contractor may claim extra time to achieve the tolerance requested by the vendor. It shall be specified in the steel structure scope which are the vendor requirements e) a civil tower crane placed on rails along the corridor between area 020 and pipe racks 125 & 126 was provided by the civil contractor. The same crane was used by the mechanical contractor to lift the reactor pipes inside the bunker. Details about the size of crane can be provided separately (at least a crane of 3t at 30m) f) the heavy lift area is already foreseen in the Project layout and it has to be kept free when needed (we handed over the area with the option at our request to get it back in 10 calendar days)
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AREA 020 POLYMERIZATION (3/4)

g) the external pipe rack (welded along the polymerization walls) shall start as soon the site conditions allows it. It takes time being a lot of welding involved

3) Observations:
a) this is one of biggest area after the pipe racks in terms of big bore quantities (~350t). Therefore prefabrication shall be prioritized taking into consideration the availability of the area. Priority one to be given for the spools at the upper elevation (harps) b) the reactor package was stored indoor as per vendor request. We shall discuss this matter with the vendor before closing the order. Indoor storage is a very costly activity and I do not see any valid reason. When the pipes are lifted from the ground and properly sealed they can stay outside without impacting the internal quality (the pipes are internally protected by an oil film)

Lesson learned: Stenungsund

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AREA 020 POLYMERIZATION (4/4)

c) the reactor flanges (threaded flanges) where supplied separately for shipping convenience. The mechanical contractor claimed this activity as an extra work being not specified in the tender/contractual documents. This activity shall be included in the mechanical contractor scope d) the reactor jumpers (180 spool) composed by two flanges and two 90 elbows where supplied loose by the vendor. The mechanical contractor claimed this activity as an extra work being not specified in the tender/contractual documents. This activity shall be included in the mechanical contractor scope e) in general all the HP parts shall involve qualified personnel familiar with the standards of these pipe classes f) the tensioning device is included in the scope of vendor supply and was convenient to have a second set according to the number of joints to be tightened
Lesson learned: Stenungsund

CONSTRUCTABILITY ANALYSIS MEETING LD5 Stenungsund-Sweden AREA 20 SOUTH PART POLYMERIZATION

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AREA 300 WASTE WATER PIT

1) Its a deep pit where the rain and process water are collected 2) the position in Stenugsund of the pit was too close to the process areas (imposed by the Borealis Complex Management) . Therefore we have been forced to postpone the pit execution after the main mechanical erection was completed impacting later on the U/G and asphalt activities. It is strongly recommended to shift this pit at least 20m far from areas 040 & 050 in order to keep an access available to the process areas during the pit execution

Lesson learned: Stenungsund

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AREA 280 COOLING TOWERS AREA 250 PURGE GAS PURIFICATION

1) Its a main concrete wall structure 2) the scope of work for the mechanical contractor was clearly specified in the tender/contractual documents

1) Its a package (ISG was the supplier in Stenugsund) 2) the mechanical contractor claimed extra hours being not fully aware about the scope. To ensure that tender documentation have proper level of detail.

Lesson learned: Stenungsund

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GENERAL REMARKS (1/3)

1) Fire Proofing it should be analyzed if convenient to replace the fire proofing with concrete columns; the application of the fire proofing impacts the erection activities 2) U/G the main rings should not be located under the main roads. It would be helpful to have some dedicated corridors parallel to the main accesses. During the Site preparation we should include the erection of the main rings, if possible. 3) Cleanliness system it has to be considered as a special erection to be managed as a sort of mechanical installation. In Stenungsund a qualified contractor with previous experience in the same piping class was used and the final quality was very good. For a contractor not familiar with this type of erection we shall clearly explain which are the requirements during storage, handling, fabrication and erection and preservation of the plant portions with this level of finishing.

Lesson learned: Stenungsund

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GENERAL REMARKS (2/3)

4) High Pressure pipes & supports General
a) in general all the prefabricated HP pipes (PN 1600 / PN3200 / PN 3600) shall be shipped at Site with the screwed flanges already erected in the vendor workshop. b) Avoid the use of Norsok flanges for the reactor jumpers. c) to extend the prefabrication of PN 500 spools as much as possible in the vendor workshop d) a dedicated MR should be issued for the high pressure supports including all the tolerances required. Before official transmission to the subcontractor TPI should check the document and revert with their comments. Qualified subcontractor shall be used to prefabricate the supports (BERNECKER for example). A visit in the subcontractor workshop is requested at the beginning of prefabrication with TCM and TPI specialists to verify the full understanding of scope. At the beginning of installation at Site a visit of TCM/TPI specialist is requested to give the right suggestions and recommendations to the subcontractor. The same visit shall be extended at 50% and 90% of the erection progress. A clear description of the scope for the HP supports erection shall be included in the WR of the subcontractor mentioning the tolerances to be achieved and special requirements (this is a sort of mechanical installation not comparable with a normal support erection).
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GENERAL REMARKS (3/3)

e) Intercooler is delivered or in modules or in loose parts. In the loose case care must be taken for the installation of the Vertical jumpers between two consecutive tubes (already happen in previous project that no space was available to weld it).Vendors must confirm the feasibility of it. f) Special tools (tensioners, flexible hoses, pumps, various fittings) for the high pressure flange joints (PN500, 1600, 3200, 3600) must be purchased considering the construction/commissioning activities. We must consider always a full spare set especially for the reactors joints to work simultaneously with two teams. g) Special tools for the PN4000 tubing must include the cutters for the tubes since no other means (flame or electrical saw) are allowed to cut the pipe (is really strong material and std tools get easily broken). h) Verify with the manufacturer of the special tools and the supplier of high pressure fittings (flange,jacketed pipes, manifolds) if the tensioners are properly designed. Always happen (also in Sweden) that the purchased tensioners was not suitable for the 100% tensioning procedure due the short diameter of the reactor flanges. Counter check always

5) Method of measurement of pipe supports: the pipe supports shall be weighed according to the theoretical weight indicated in TCM drawing. The WR refers to verification of the supports weight at site 6) Cold insulation: pipes with cold insulation to have the minimum elbow radius and gap between lines to allow the installation of conventional PUR/PIR. The activity involves the storage area, interconnecting pipe rack, peroxide building mainly and tubing lines from peroxide to reactor bay. I would suggest to implement the WR with the NPRs (new price request) issued in Stenungsund to compensate the activities not covered by the standard codes

Lesson learned: Stenungsund

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