Lesson Learned Stenungsund

8/3/2019 Lesson Learned Stenungsund

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BOREALIS LD5 Stenungsund (Sweden)

Lesson learned

CONSTRUCTION


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BEFORE WORKS

Lesson learned: Stenungsund 2


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AERIAL VIEW (1/2)



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GENERAL LAYOUT



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Borealis Stenungsund complex area is as a very unusual site for theconstruction 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 scarpat 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

PROJECT FEATURES


.

In this presentation however the topics addressed are supposed to be notdirectly related to the above characteristics and have been selected in orderto be implemented in any other LDPE indipendenctly of the geographicallocation.

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 mostimportant to keep in the right sequence the following disciplines.


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1) Subdivision of works: it was decided to dividethe civil works in two parts; south package (Silos

AREA 400 SILOS AREA (1/9)


area) and north package (all the other areas). The

reason to have two contractors simultaneously atSite was to share the risk between a well knowncontractor (NCC- south part), overloaded at thattime with other ongoing Projects and Pihl (newcontractor without a proved experience in the fieldof technological foundations). It would have beenpreferable to increase the scope of NCC for theentire south part (areas 400, 90 & 100 and pipe

racks). We faced a non easy coordination issue tomanage the border areas between them

2) The silos concrete structure was completed withtwo months of delay because of unexpected soilimprovement that was required. to verify if there isa margin to reduce the size of the concretecolumns and horizontal beams.


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e ra n wa er ra nage sys em was no

included in the scope of civil contractor. We shouldadd it in the scope (PVC welded pipes or similar)

4) The embedded plates have not been fullypainted by the civil contractor (full painting cycle).We shall add it in the scope (sand blasting + 2painting coats)

5) The temporary elevator to access to the top ofthe silos has to be included in the scope of the civil

contractor and maintained till the final stair casesare erected (around two months after the civilcompletion of the main structure)


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6) The silos templates have to be transferred to



.template from J&D facing several discrepancies(radius not as per drawing ).

7) The silos anchoring system should be changedfrom hook type to counter washer type (squareplate 100 x 100 x 15mm). Due to the narrow gapof the main rebars it was very difficult orsometimes impossible to insert the hook typeanchors

8) Embedded plated shall be replaced (In case ofrevisions or erection mistakes or late drawingssubmission) by external plates fixed by chemicalanchors bolts (to be added in the scope of civilcontractor as option in unit rates)


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9) Once the main concrete structure is erected thesteel structure priorities are:



a) erection of the two stair cases up to top main

concrete level. The upper part of stair cases shallnot be erected interfering with the silos erection

b) erection of the handrails at the main concreteelevation

c) erection of the platforms and stairs under thesilos. The erection shall be done by placingforklifts and mobile platforms (conventionalmobile cranes are not advisable being the space

very narrow). Due to the huge amount of itemsthe supplier shall present a detailed sequence ofdelivery. We faced several problems in this areacaused by missing handrails, platforms, etc. Theactivity can go in parallel with the silos erection(silos to one side and steel structure to theopposite)


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e op connec ng a um num p a orms

(supplied by J&D) were not included in themechanical contractor scope. It shall be added inthe steel structure erection scope (300t crane isneeded for lifting + 100t with man- basket)

e) supply and Installation of top silos pipesupports (for Zeppelin systems) were not includedin the mechanical contractor scope. It shall beadded in the steel structure erection scope (300tcrane is needed for lifting + 100t with man-

basket) f) to verify from engineering point of view that

buttery limits between the different suppliers(items 9d & 9e) are respected


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10) Silos assembly observations

a) Its important to have a suitable assembly areawell compacted of 10,000 m2 minimum. The area



since the silos are transportable via low bed

b) the saddles to transport the silos (differentfrom those needed to store the silos), shall beincluded in the scope of the mechanical contractorwhile those needed to store the silos (woodensaddles), shall be accounted in the silos supplierscope

c) based on the experience in Stenungsund, withgood weather conditions, the mechanical

contractor can install one silo a day. It isadvisable to assemble as much silos as possiblemobilizing the main crane (600t crawler crane)when you have a buffer of at least 60% of thesilos (finally inspected) and the remaining silosstill under fabrication (to be completed in onemonth). Obviously this ideal solution wouldinvolve much more assembly area.


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d) the degassing silos are the most critical onesfor the high finishing requirements. Even



exper ence supp er e ace severa

difficulties to comply with Borealis demand. Wesuggest to start the assembly with the storagesilos first and at 50% of fabrication with thedegassing silos (when you can keep the silos onthe rollers without impacting the rest)

e) the closing of the silos outlets shall be includedin silos supplier scope (closing by temporarywooded flanges properly sealed)

f) to keep pressure to silos supplier to get the

auxiliary structures on time (upper platforms,vertical ladders, etc.)


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g) it should be asked to the silos supplier toincrease the size of the holes of degassing silos



s r o om r ng n or er o prec se y w e

anchor bolts. For the other silos there is noproblem being them fixed with clamps

h) we shall verify that skirts erection is included inthe mechanical contractor scope (they are noterected by the silos supplier in the assembly area)

i) we shall, before the silos erection, when thecivil scaffolding platform is still available, install apermanent internal shuttering (aluminum type)for the final grouting. If not installed as

suggested, it will take a huge effort at later stage.


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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 craneerected all the silos from the south part shiftingfrom west to east ( we started with degassingsilos). It is suggested to postpone the U/G on thatarea after the heavy lifts

b) in the mechanical contractor scope we shallinclude the installation of a temporary lift up tothe 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 theinstallation of two trunnions (not foreseen by silossupplier). It shall be included in the silos supplierscope

d) spreader beam, slings, etc. shall be providedby mechanical contractor, clearly mentioned inthe subcontract requirements.


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1) Its a simple slab with some foundations

2) We decided to install first all the equipments

AREA 090 MATERIAL HANDLING COMPRESSORSTATION


an a er e s ee s ruc ure o ac a e e

mechanical erection 3) After the equipment installation we erected the

steel structure up to the purlins

4) After that (keeping some openings) we erectedthe spools

5) After that we closed the roof and sides workingin parallel with the piping assembly

LD5 Stenungsund-Sweden

AREA 090

PNEUMATIC TRANSPORT

STEEL STRUCTURES

CONSTRUCTABILITY ANALYSIS


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1) its a simple slab with some foundations

2) the package is composed of a burner, bag filter,

AREA 220 RTO


3) the items should be delivered alreadypreassemble with the maxim grade ofprefabrication. This shall be depplydiscussed andclearly agreed with the supplier

4) based on the size of the items a suitable roadshall be maintained. Surrounding U/G to beprioritized or postponed

5) refractory works are involved. Presence ofvendor is mandatory

6) the mechanical contractor claimed extra hoursbeing not fully aware about the scope. To ensurethat contractual (during bidding also) is sufficientlydetailed in order to enable the subcontractor toproperly evaluate the job.


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AREA 100 SUB STATION (1/2)


s a u ng w an g gra e o n s ng

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 ofthe floors. Hardening of the floors does not replacethe epoxy coating normally requested whereelectrical panels are installed. Both activities to beincluded in the civil scope. The epoxy painting shall

be applied after cubicle installation


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AREA 100 SUB STATION (2/2)


around the building included in the civil scope. We

suggest to transfer the scope to the steel structuresupplier being more qualified for designunderstanding and installation.

6) HVAC secondary cooling units to be installedoutside the electrical panels rooms. InStenungsund a cooling unit had a water leak onthe top of energized panels

7) transformers bays to be prioritized andcompleted with final painting (including the uppercladding roof) before transformers installation.


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AREA 030 EXTRUSION (1/7)


1) Its the most complicate building

2) It is suggested to simplify the design of buildingmain concrete structure by adopting the same sizeof floor beams where possible. Saving of volumelike this case would allow a significant saving ofman hours.

3) Embedded plates information, if not promptly

available, shall not hold the progress ofconstruction. It is suggested to study analternative solution by using external plated fixedwith chemical anchor bolts.


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was no ce a open ngs an npu s w ere

delayed by JSW (Extruder basic designer for civilscope). This shall be monitored well ahead andbypassed in case by core boring method

5) the internal intermediate hallow block walls shallbe completed up to the first painting coat by civilcontractor before handing over the area to themechanical. Final painting coat to be executed in asecond step when mechanical activities (included

insulations) are completed; to be specified in thecivil sub contract.


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6) Sequence of works:

a) completion by civil of the main concrete


steel structure contractor. In parallel the civil shall

complete the internal finishing works givingpriority to the ground floor

b) installation level wise of the main equipment bythe mechanical contractor using the contractualwindows given by the steel structure contractor(to specify in the steel structure contract thaterection shall proceed in parallel with theequipment installation). Some equipment shall beerected before closing the structure of the upper

levels c) handing over of the metal deck floors from the

steel structure contractor to the civil contractorfor the concrete pouring. Openings and details tobe provided on time to the steel structurecontractor. This activity is very critical since ittakes not less than a 1 working week by civil tohave one floor ready for mechanical installation


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once e s ee s ruc ure an me a ec s arecompleted, the priority shall be given to themechanical contractor to install the equipmentand the big spools at the upper levels

e) at the ground floor the mechanical installationshall proceed with the main and satelliteextruders and secondary equipment

f) once the main equipment are installed, thecladding installation shall start giving priority tothe side wall opposite to the access road

LD5 Stenungsund

AREA 030 EXTRUSION

N

STEELSTRUCTURES

VS. EQUIPMENT INSTALLATION

N


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7) Observations:

a) to keep all the mechanical piping erection of


ex ru er pac age an c ean ness c ass re a e oextruder only) to a single contractor. Itsextremely important to have a minimum numberof contractors inside the extruder due to thecongestion of the area

b) to prioritize the small bore fabrication anderection (bulk part) designed by TCM. The smallbore piping quantities inside the extrusion arehuge

c) to include in the scope of the cladding erector

(steel structure contractor) the openings andrelevant finishing works (flashing, closing, etc.) .Mechanical contractor shall give the input bymarking the openings. Any opening that shall besealed has to be included in the scope

d) to include in the scope of civil contractor therain water drainage system (PVC welded pipes orsimilar)


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e) to specify to the civil contractor that waterproof membrane has to be installed following themechanical erection se uence and therefore


postponed after the mechanical installation to

avoid damages f) In Stenungsund the piping detail design (spools

& supports), for extruder package was developedby JSW itself as included, during procurementphase, in their scope: never more to be done, asit generates quality, delivery time and designproblems with an economical impact much biggerthat the initial apparent saving during purchasingthe package.

g) Extruder equipments where delivered wellahead. We kept the extruder equipment in thewarehouse for more than one year. It would bemore efficient to deliver the equipment s at the50% of civil progress, approx two months beforethe starting of mechanical installation.


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h) We have faced several problems with thepacking list prepared by JSW. Items listedfre uentl were not found bein delivered in


another package and vice versa. To instruct the

supplier that packing list shall strictly adhere tothe content of the package and each item shall betraceable referring to drawings (in our hands).

Treasure hunting shall be avoided

i) We shall include in the contract of eachcontractor that housekeeping of the areasassigned if not maintained at the level required itwill be carried out by the main contractor and costreverted proportionally according to the judgment

of main contractor. The extruder is a typicalbuilding where having in parallel differentcontractors the responsibilities of the housekeeping are bounced back between them.


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1) Its a concrete structure with an upper part

AREA 050 HOT WATER HANDING (1/3)


compose o severa eve s o s ee s ruc ure

2) The concrete columns have the same size andequally distributed simplifying the method ofconstruction

3) Sequence of works: a) Before starting the building area 050 the pipe

racks 129, 128 shall be completed. In particularthe knot of the two pipe racks was very critical inStenungsund

b) The U/G under the pipe racks can be executedin a second step having enough space to workunderneath the lower level of the rack

c) Once the concrete structure is completed itshall be handed over to the mechanical contractorto start the installation of the equipment at theground floor and to the steel structure contractorto start the erection of the upper levels (priorityone)


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d) Before closing the first steel structure level n.5equipment (vessels) shall be installed. A window



.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 steelstructure erection

g) Once the steel structure is completed the areashall be handed over to the mechanical contractor

4) Observations:

a) This is one of the biggest area after the piperacks in terms of large bore quantities (~250t).Therefore prefabrication shall be prioritized takinginto consideration the availability of the area.Priority one to be given for the spools at theground floor (below the main concrete tableanyway)


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b) On the upper level of the structure there aren.3 fin fan coolers supplied in loose parts (GEsupplier in Stenungsund). This is a sort of



meccano that was not enough detailed during

the bidding phase. The level of drawing providedby the supplier was below the standard and wewere forced to have the vendor at Site tosupervise the erection (even GE vendors wereconfused during the assembly)

c) The steel structure which supports the coolerscan be fully assembled at the ground floor in anarea nearby the building (if available)

d) Once the steel structure is erected the fincoolers can be installed

e) At the end a major cladding work is needed toclose the entire structure. This activity takes timeand qualified contractor is needed (it would beideal to involve a company specialized in claddingerection)

LD5 Stenungsund AREA 050 HOT WATER HANDLING

STEELSTRUCTURES VS. EQUIPMENTS

N


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AREA 040 HP RECYCLE GAS TREATMENT

1) Its a concrete structure with an upper partcomposed of several levels of steel structure

d) once the steel structure is completed it shall behanded over to the mechanical contractor to startthe installation of the vertical heat exchangers.

CONSTRUCTABILITY ANALYSIS MEETING

LD5 Stenungsund

AREA040H.P. RECYCLE GAS TREATMENT

STEEL STRUCTURES VS . EQUIPMENT HEAVY LIFT

N


equally distributed simplifying the method of

construction 3) Sequence of works:

a) the civil works shall be prioritized on pipe rack128 and 126 and main shelter columns of area010. Therefore area 040 shall be postponed toallow the access for the civil contractor

b) once the steel structure of pipe racks 128 and126 (first 5-6 rows) and the main shelter columnsand 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 thatcan complete the entire erection (except somesecondary members; see following point)

the exchanger supports shall be installed in a

second step otherwise the exchanger cannot beinserted. This activity shall be included in thescope of the steel structure contractor

e) the erection of the heat exchangers is part ofthe heavy lift compain to be executed in parallelwith 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 partsupplied already fabricated (Bohler forStenungsund )

c) the closing of the grating openings around theexchangers was not foreseen in the steelstructure supplier scope. In general we shouldinclude a contractual paragraph where we statethat any abnormal opening (above 200mm) shallbe closed by the contractor (to be compensatedexcept in hourly basis)


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1) its for civil scope the main area of activitieswith two huge pedestals (Booster & Hyper

AREA 010 COMPRESSOR AREA (1/5)


Compressors

2) Sequence of works: a) the compressor foundations shall start first and

they can go in parallel

b) once the main foundation are completedsecondary pedestals can start

c) priority to be given to the steel structurefoundations

d) once the main foundation are completed, thearea shall be handed over to the steel structurecontractor to install the main frame keeping theroof open for the heavy lifts. Three sides of thestructure can be completed including the perlins

e) overhead crane to be installed before closingthe roof


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f) the heavy lifts will include the two compressorsthe two intercoolers and the farthest heatexchangers of area 040. The ABB motor of the



hyper compressor (27 Mw) was supplied in two

part disassembled (stator and rotor) which havebeen assembled at the ground floor

g) after that the steel contractor can complete theerection of the building and the roof cladding. InStenungsund to allow in parallel the activities atthe ground floor we installed a temporary netunder the roof at our cost. I would suggest toinclude 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 contractorare available) or postponed after the mainmechanical installation (around 60% of the pipingworks)


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3) Observations: a) the tubular frame of the Hyper Compressor



contractor involves some tolerances that are not

achievable by a civil contractor. I would suggestto descope it from the civil and shitting to themechanical scope which shall include themachining of the bottom plates after the castingof the main pedestal. Please take care about thismatter being not easy to find the right tools.Machining is mandatory to comply with vendorrequirements

b) the Booster piping package (Nuovo Pignonesupplier) was not delivered prefabricated.

Therefore we received loose pipes and fittings tobe prefabricated on Site by the mechanicalcontractor which was not contractually foreseen.This activity shall be included in the mechanicalcontractor scope. The vendor scope of supply shallbe extended to all possible pipes on board of theequipment. Site prefabrication of lubrication,hydraulic, etc. systems are strongly notrecommended


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LD5 Stenungsund

AREA010

COMPRESSION SHELTER

STEEL STRUCTURES VS . EQUIPMENT HEAVY LIFT

N


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1) Its a main concrete wall structure with hugeuantit of embedded lates

AREA 020 POLYMERIZATION (1/4)


2) Sequence of works:

a) the sequence of construction shall start fromsouth to north (LD5 layout) to complete beforethe area where the heavy components shall beinstalled

b) the civil contractor shall work in parallel alongall the side walls (optimization of the shutteringframes is only in the benefit of the civilcontractor)

c) the internal area close to the main steelstructure shall be used by the steel structurecontractor to place a small mobile crane andcherry pickers


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d) the installation of the reactors structure(supplied by Bohler in Stenungsund) shall startfrom north to south. This activity is not a



conventional steel structure erection and

contractor may claim extra time to achieve thetolerance requested by the vendor. It shall bespecified in the steel structure scope which arethe vendor requirements

e) a civil tower crane placed on rails along thecorridor between area 020 and pipe racks 125 &126 was provided by the civil contractor. Thesame crane was used by the mechanical

contractor to lift the reactor pipes inside thebunker. Details about the size of crane can beprovided separately (at least a crane of 3t at30m)

f) the heavy lift area is already foreseen in theProject layout and it has to be kept free whenneeded (we handed over the area with the optionat our request to get it back in 10 calendar days)


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g) the external pipe rack (welded along thepolymerization walls) shall start as soon the site



conditions allows it. It takes time being a lot ofwelding involved

3) Observations: a) this is one of biggest area after the pipe racks

in terms of big bore quantities (~350t). Thereforeprefabrication shall be prioritized taking intoconsideration the availability of the area. Priorityone to be given for the spools at the upperelevation (harps)

b) the reactor package was stored indoor as pervendor request. We shall discuss this matter with

the vendor before closing the order. Indoorstorage is a very costly activity and I do not seeany valid reason. When the pipes are lifted fromthe ground and properly sealed they can stayoutside without impacting the internal quality (thepipes are internally protected by an oil film)


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c) the reactor flanges (threaded flanges) wheresupplied separately for shipping convenience. Themechanical contractor claimed this activity as an


CONSTRUCTABILITY

ANALYSIS MEETING


ex ra wor e ng no spec e n etender/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 suppliedloose by the vendor. The mechanical contractorclaimed this activity as an extra work being notspecified in the tender/contractual documents.This activity shall be included in the mechanicalcontractor scope

e) in general all the HP parts shall involvequalified personnel familiar with the standards ofthese pipe classes

f) the tensioning device is included in the scope ofvendor supply and was convenient to have asecond set according to the number of joints to betightened

LD5 Stenungsund-Sweden

AREA 20 SOUTH PART

POLYMERIZATION


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AREA 300 WASTE WATER PIT


water are collected

2) the position in Stenugsund of the pit was tooclose to the process areas (imposed by theBorealis Complex Management) . Therefore wehave been forced to postpone the pit executionafter the main mechanical erection wascompleted impacting later on the U/G andasphalt 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 theprocess areas during the pit execution


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AREA 280 COOLING TOWERSAREA 250 PURGE GAS PURIFICATION


1) Its a main concrete wall structure

2) the scope of work for the mechanicalcontractor was clearly specified in thetender/contractual documents

1) Its a package (ISG was the supplier in

Stenugsund)

2) the mechanical contractor claimed extra hoursbeing not fully aware about the scope. To ensurethat tender documentation have proper level ofdetail.


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1) Fire Proofing it should be analyzed ifconvenient to replace the fire proofing withconcrete 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 tohave some dedicated corridors parallel to themain accesses. During the Site preparation weshould include the erection of the main rings, if

GENERAL REMARKS (1/3)


.

3) Cleanliness system it has to be considered

as a special erection to be managed as a sort ofmechanical installation. In Stenungsund aqualified contractor with previous experience inthe same piping class was used and the finalquality was very good. For a contractor notfamiliar with this type of erection we shall clearlyexplain which are the requirements duringstorage, handling, fabrication and erection and

preservation of the plant portions with this levelof finishing.



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4) High Pressure pipes & supports General

a) in general all the prefabricated HP pipes (PN1600 / PN3200 / PN 3600) shall be shipped atSite with the screwed flanges already erected inthe vendor workshop.

b) Avoid the use of Norsok flanges for the reactorjumpers.

c) to extend the prefabrication of PN 500 spoolsas much as possible in the vendor workshop

d) a dedicated MR should be issued for the highpressure supports including all the tolerancesrequired. Before official transmission to thesubcontractor TPI should check the document and



.subcontractor shall be used to prefabricate the

supports (BERNECKER for example). A visit in thesubcontractor workshop is requested at thebeginning of prefabrication with TCM and TPIspecialists to verify the full understanding ofscope. At the beginning of installation at Site avisit of TCM/TPI specialist is requested to give theright suggestions and recommendations to thesubcontractor. The same visit shall be extended at

50% and 90% of the erection progress. A cleardescription of the scope for the HP supportserection shall be included in the WR of thesubcontractor mentioning the tolerances to beachieved and special requirements (this is a sortof mechanical installation not comparable with anormal support erection).



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e) Intercooler is delivered or in modules or inloose parts. In the loose case care must be takenfor the installation of the Vertical jumpersbetween two consecutive tubes (already happenin 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 purchasedconsidering the construction/commissioningactivities. We must consider always a full spareset es eciall for the reactors oints to work


5) Method of measurement of pipe supports: thepipe supports shall be weighed according to thetheoretical weight indicated in TCM drawing. TheWR refers to verification of the supports weightat site

6) Cold insulation: pipes with cold insulation tohave the minimum elbow radius and gapbetween lines to allow the installation ofconventional PUR/PIR. The activity involves thestorage area, interconnecting pipe rack, peroxidebuildin mainl and tubin lines from eroxide to


simultaneously with two teams.

g) Special tools for the PN4000 tubing mustinclude the cutters for the tubes since no othermeans (flame or electrical saw) are allowed to cutthe pipe (is really strong material and std toolsget easily broken).

h) Verify with the manufacturer of the specialtools 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 tensionerswas not suitable for the 100% tensioningprocedure due the short diameter of the reactorflanges. Counter check always

reactor bay. I would suggest to implement the

WR with the NPRs (new price request) issued inStenungsund to compensate the activities notcovered by the standard codes

Documents

Lesson Learned Stenungsund