3/2016 For Surface Protection

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SURFACE PROTECTION CUSTOMER MAGAZINE BY FSP 3/2016

Surface treating kerosene tanks requires skill and precision

➤ Fireproof coating for Neste Jacobs: safety first

➤ Volvo Penta factory in Sweden rises from ashes

➤ What does a development engineer do at FSP?

contents

For Surface Protection is the stakeholder magazine of FSP Finnish Steel Painting Oy, published three times a year.

Content and visual design Viestintätoimisto VCA Oy Printing house Savion Kirjapaino Oy Cover photo Antti Verkasalo Headquarters Kalliosolantie 3 FI-01740 Vantaa Tel. +358 9 278 6270 www.fspcorp.com

FOR

SURFACE PROTECTION Founded in 1964, FSP Finnish Steel Painting Oy is one of the leading surface treatment providers in Northern Europe. It offers surface treatment services for machinery, equipment, ships, bridges, storage tanks, steel structures and off-shore equipment on a turnkey principle. The company follows strict quality, environmental, occupational safety and health standards. In 2015, FSP's turnover was about Meur 23.

FSP employs over 200 surface treatment specialists in about 30 paint shops in Finland, Sweden, Norway, Estonia and Poland.

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Storing kerosene in environmentally friendly tanks

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Security and safety first: Neste and FSP complete fireproof coating

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Volvo Penta factory rebuilt: as good as new

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A day in the life of FSP's development engineer

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editorial

Investments as the source of growth Now

is a good time to look to 2017 and shed some light on the future of surface treatment. I will highlight three changing factors.

Firstly, there are several large projects in the works within the industry that strengthen the demand for surface treatment services. For example, the excavation work of the Pyhäjoki nuclear power plant project has begun.

Other significant investments already in action are e.g. the constructions of a new bioproduct factory in Äänekoski and a LNG terminal in Tornio that will open in 2018.

All of these have increased machinery and facility orders and the demand for industrial surface treatment services. Furthermore, the Finnish government has decided to start new projects, including building new bridges, that require expertise and large resources in addition to moveable equipment.

Secondly, our international trade in Northern Poland will expand further during the next year in our two paint shops. Both are in close co-operation with our clients: one at the Cargotec assembly plant and the other at the recently opened Hydroline Oy hydraulic cylinder plant.

We predict that our business in Poland will double during the next year, after the so called 'ramp up' process and new product lines.

Thirdly, the industry needs even more thorough surface treatment knowledge, design and quality control according to several standards. We are perfectly prepared for this because our Engineering unit offers international FROSIO inspections that meet the requirements of the NORSOK standard as well as other expert services related to surface treatment. The projects have entailed both offshore and onshore structures.

Dear reader, please turn the page and explore our latest company news and case stories. Furthermore, I would like to thank everyone at FSP for their contribution to the success of the company and our partners in co-operation for their confidence in our business. See you again next year!

I wish you a peaceful Christmas and success for 2017.

”We predict that our business in Poland will double during the next year.”

Best Regards,

Pentti Virtanen CEO FSP Finnish Steel Painting Oy

Follow up on our company news on Facebook and Linkedin, as well.

Click the link on the fspcorp.com main page or directly on Facebook and Linkedin.

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case

The four tanks coated at Helsinki-­Vantaa airport ranged from 300 to 1,300 cubic metres.

Air BP tanks received an environmentally friendly surface The four kerosene tanks of the refined oil product distributor Air BP Finland Oy have received a long-lasting coating by means of a faster and more environmentally friendly surface treatment system. FSP was responsible for carrying out the project on the Air BP premises in the immediacy of HelsinkiVantaa airport.

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case

Air BP Finland Oy chose FSP as the implementer of the surface treatment work because of their competitive offer, extensive resources and strong references.

The method used in this case was the surface treatment system in which the coat is sprayed on the old paint and rust. FSP has utilised the system extensively in its projects in Sweden, amongst others. It is also approved by the Swedish Transport Administration, Trafikverket.

The four tanks coated at Helsinki-Vantaa airport ranged from 300 to 1,300 cubic metres.

The tanks were constructed about 30 years ago.

The safety requirements in this project were strict because the work had to be done near the flammable aviation fuel tanks. Aviation petroleum is used as a fuel for jet engines. Thus, the tanks were carefully emptied before the work started.

Fire safety regulations and instructions were followed carefully in the immediacy of the tanks.

The work site was highly flammable and therefore, hot work and dusting were not allowed during the work phases. Shot blasting is highly dusting hot work which leads to the choice of using high pressure washing as the pre-treatment.

"We wanted to have the surfaces treated because of rust damage and image reasons. We are very satisfied with the result of the surface treatment work that FSP has conducted.

Occupational safety was a priority during all work phases. A representative from Air BP monitored all work phases due to safety reasons," Thomas Bergman, the operative manager of Air BP Finland Oy, explains.

Pre-treatment removed the impurities "We chose FSP as the implementer of the surface treatment work because of their competitive offer, extensive resources and strong references," Bergman says.

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The work began with constructing scaffolding around the tanks. At the pre-treatment phase all loose matter and rust were removed with high pressure washing.

"The 800-bar pressure cleaning removed the loose rust and cleaned the surfaces that were to be treated," Janne Heimonen, the FSP project manager, describes.

After the washing, the highly permeable clear varnish was applied on the rust that was strongly stuck on the surface. After this, the tanks were primed and top coated. The total amount of painted surface, including the railings, was 1,500 square metres.

The system encapsulates the rust In practice, the current system differs from the traditional maintenance painting in the sense that usually the old paint is removed completely by shot blasting. This system allows the clear varnish to permeate the rust and encapsulate it as it hardens. There cannot be any loose rust on the surface that will be treated.

The chemically hardened primer forms a physical adhesion to the steel and rust. Isolating the surface prevents corrosion reaction because the steel is not in electrical connection with oxygen and solution. Furthermore, the primer is not electrically conductive which means that it resists the electric current that the corrosion reaction requires.

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"The system is environmentally friendly which is an advantage. It only generates a small amount of old, hazardous waste paint and not at all shot blasting waste. Many of the old corrosion paints contain lead which is harmful to the environment," Heimonen continues.

Additionally, the system speeds up the lead time of the surface treatment because shot blasting and cleaning after are not required.

"The 800-bar high pressure washing used in the pre-treatment is faster than shot blasting and there is a lot less cleaning."

"The product is suitable for all objects requiring maintenance painting that are largely covered by rust," Heimonen summarises.

”We are very satisfied with the result of the surface treatment work that FSP has conducted," Thomas Bergman, the operative manager of Air BP Finland Oy, explains.

Air BP Finland Oy • manufactures refined oil products • registered office in Vantaa, operates also in Vaasa and Tampere in Finland • part of the international company BP • BP operates internationally in 50 countries

Environmentally friendly and fast Corrosion prevention is based on a good adhesion of the clear varnish, the effect of the encapsulating pigments of the primer and a resistance of environmental conditions.

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case

Fireproof coating improved safety The main executor of the Neste SDA project was Neste Jacobs Oy that produces technology, design and project management services and solutions. In this project the fireproofing of the steel structures was carried out by coating instead of the traditional way of concreting.

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Photo

: FSP

The elements to be fireproof coated were the load-bearing structures of the process equipment and piping. FSP was responsible for the fireproof coating of the framework of the air heat exchangers in the new industrial plant.

Pekka Okkonen, the surface treatment supervisor at Neste Jacobs says that the fireproof coating is becoming more common in process industry in the near future because of governmental regulations.

The safety instructions are stated in, for

example, Safety Decree Section 43, according to which the frames and other structures of the equipment containing hazardous chemicals that are likely to cause significant danger if they collapse, should be protected so that they endure the effects of heat radiation in case of fire.

"The fireproof coating ensures that the temperature of the structure does not exceed the critical temperature during the required fire resistance period. Thus, the spreading of the fire can be prevented. Furthermore, it enables controlled run

The elements to be fireproof coated were the load-bearing structures of the process equipment and piping.

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case

Photo: Kai Filppula

FSP has the ability to perform fireproof coatings everywhere in the Nordic countries by means of a transportable two-component pump and other equipment.

down of the systems, evacuation of the personnel and the operations of the fire brigade in the area," Okkonen explains.

In the event of fire, the fireproof coating expands and forms an insulating layer on the load-bearing structures. The thickness of the coating defines how long it protects the load-bearing structures in certain temperature before the bearing capacity of the structure decreases significantly. In addition, fireproof coating protects steel from corrosion.

FSP has the ability to perform fireproof coatings everywhere in the Nordic countries by means of a transportable two-component pump and other equipment.

The fireproof coatings improve fire safety and corrosion prevention and are suitable, among others, for offshore industry, oil refineries, shopping centres and all other premises and structures with steel, wood and concrete structures.

Multi-stage project "We chose FSP as our contractor because of their competitive offer.

The project is challenging for a contractor because a part of the surfaces of the steel profiles had to be covered during the coating process. The air heat exchanger element cannot be fastened on the fireproof coated steel, so there was a lot to cover," Okkonen continues.

The work progressed in phases. The prefabricated beams arrived primed at FSP's Kulloo paint shop. First, the surfaces of the steel beams were cleaned by solvent wash in order to remove all the grease and other impurities.

Next, the fireproof coating was sprayed on the surface of the steel beams with a two-component spray gun. The coating was finished with a paint that endures the demanding industrial conditions of the Neste premises.

The work included quality control which entailed the measurement of the coating thickness and a visual check after each coating phase.

FSP then delivered the fireproof coated steel beams to the Neste industrial plant.

The on-site work continues in the summer of 2017 "The whole project took about two months in the paint shop in Kulloo. We will complete the on-site work next spring on the spot, weather permitting," project manager Henri Kiminki says.

The job at the paint shop employed five to six surface treatment workers because several of the work phases had to be done at the same time with the spraying. The on-site work will employ the same amount of surface treatment workers.

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Neste Jacobs • produces technology, design and project management services and solutions • companies from oil, gas, petrochemical, chemical and biotechnology industries as customers • more than 50 years of experience in technology development, carrying out and maintaining investment projects and improving operations in Europe, North and South America, Asia and Middle East • Neste owns 60 per cent and Jacobs Engineering Group owns 40 per cent of the company • employs about 1,000 in-house employees and about 350 consultants

internationalisation

Volvo Penta factory as good as new FSP is currently touch-up painting and fireproofing the Volvo Penta factory in Gothenburg. The factory located on the Hisingen Island suffered a major fire in 2013, after which about a half of the factory had to be reconstructed. Now the renovations are nearly finished.

The main contractor for the Volvo Penta industrial engine factory is Ruukki. FSP has been the supplier for Ruukki in the extensive highway bridge project in Rotebro among others, and thus the reliable partner was also included in the factory project.

The person in charge of the project in FSP is Ismo Rรถnkkรถ and the surface treatment employs five people. The touch-up painting and fireproofing performed by FSP began in October 2016 and are estimated to be finished in April 2017.

"We have had similar projects in Ystad and Malmรถ in Sweden. We are familiar with the work and it requires extreme precision. Load-bearing steel beams and pillars are treated with fireproofing. The detailed painting specifications come from the customer's chosen paint supplier. Several layers of paint in several different thicknesses are applied depending on the size of the structure," Rรถnkkรถ explains.

order to treat each part as planned."

Before fireproofing, the surfaces are touch-up painted, which protects the points that are under most stress.

Extensive new construction After the fire in 2013, the Volvo Penta factory has only been partially in use: the part of the factory that was unharmed has been used for testing Penta industrial engines. The factory building is 15,000 square metres in total and is mainly made from brick. There are three floors in the building.

For example, the fact that the brick structures of the old factory were protected, affected the work schedule. Pulling down the brick structures was not allowed. Repairing the fire damage and reconstructing the factory took several years.

"Load-bearing steel beams and pillars are treated with fireproofing."

Fire resistance rating depends on the structure Fire resistance ratings indicate the required time that a structure of a certain size - for example, a rafter - should hold in the event of a fire. The ratings include R60 and R90 which require the steel structures to hold for 60 or 90 minutes before they start to bend.

"It is extremely important that the film thickness is as required. We follow 3D models in

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occupational case safety

Meet FSP's new development engineer FSP aims to continuously improve the productivity and occupational safety of the paint shops. FSP's development engineer Juli-Ann Rikkonen is responsible for this development task.

In practice this means that Juli-Ann Rikkonen visits FSP's paint shops and monitors their operations for a certain period of time.

"This visiting period includes monitoring the production on location, interviewing the employees of the unit, monitoring the sales, expenses and gross profit of the paint shop, recognising and analysing the problems arising from the operations and writing a report," Rikkonen explains.

"The paint shops and their personnel often have hidden potential which should be utilised in the best possible way for the customers and FSP," Rikkonen continues.

It's all about a customer oriented culture Our aim is to observe the daily processes that do not create any value and are in the way of a better result. She underlines that the target is to produce effective and reliable processes regardless of conditions.

"One of the most important goals for an organisation is a customer friendly culture in which the point is to understand the customers and their needs," Rikkonen says.

"I monitor daily production on-site and demonstrate the external and internal factors that have a negative impact on effective and smooth performance."

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Recognising the loss "I work in co-operation with the employees, supervisors and heads of units because they have the best knowledge in the operations and possible problems in the unit."

According to Rikkonen, the value chain is a series of actions that includes all the separate phases of a process that are required in order to deliver the product to the customer.

"When demonstrating the manufacturing and delivery processes of the product, the losses in different phases of the process can be recognised. The product should go through the production process without any stops or waiting time."

Consequently, the value chain should be questioned: the overly complicated factors and the unnecessary processes and features that do not bring any added value to the customer should be removed.

Occupational safety should be developed By analysing the value chain, the complete process chain of a product can be recognised and seen as a whole. The value producing phases of the process should be linked so that they create a continuous chain from the customer's order to the delivery of the product.

Rikkonen always pays attention to occupation-

�The paint shops and their personnel often have hidden potential which should be utilised in the best possible way for the customers and FSP.�

Juli-Ann Rikkonen visits FSP's paint shops and monitors their operations for a certain period of time.

Photo: Kai Filppula, Shutterstock

al safety in her work. Any factors threatening occupational safety are always dealt with. No matter what the subject of development, the development of occupational safety should also be considered.

"Transparency is one of the most important factors in pursuing perfection. It is beneficial to all parties, the suppliers, employees and customers, to see the complete supply chain in order to facilitate finding and creating value."

"The problems should be seen as an opportunity to develop working efficiency, quality, safety and comfort. A company must be prepared to solve any problems in order to continuously develop the processes."

Rikkonen majored in applied material science and is Master of Science in Materials Technology Engineering. She has also minored in industrial engineering in which she concentrated in her thesis.

"My thesis was commissioned by FSP and it discusses the ways to improve the operational productivity of paint shops.

My studies support the duties of a development engineer which focus strongly on industrial engineering."

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Photo: Daniel Stokowiec

news

Big smiles all-round, and why not?

Toni Karvonen, Hydroline's operative manager and Pentti Virtanen, Managing Director of FSP, are bringing Hydroline's production facility up to full capacity.

Production starts at FSP's Hydroline plant FSP and Hydroline introduced their partnership in the new Hydroline plant in Northern Poland, Stargard Szczeci´nski to a Finnish metal technology magazine Metallitekniikka at the beginning of December. FSP's managing director Pentti Virtanen and Hydroline's operative manager Toni Karvonen were present.

The two new modern surface treatment lines were introduced at the event. One of the lines is designed for cylinders and the other for large products of steel. FSP has two paint shops in Northern

Poland. One of them is located in the Cargotec assembly plant and the other at the recently launched Hydroline Oy hydraulic cylinder plant.

The production at the FSP Hydroline paint shop starts to full production after so called 'ramp up' process and product audits.

FSP estimates the business in Poland to double during 2017.

Compelling birch print for park bench legs

Photo: FSP

In the autumn of 2016 FSP received an interesting surface treatment order from Stara which is the construction service of the city of Helsinki. The idea was to give a long-lasting and compelling special effect coating for park bench legs.

The project included 30 cast iron park bench legs which were cleaned and treated by FSP. The bench legs were coated with white and tinted with black spots.

The aim was to coat the park bench legs to resemble the surface of a birch tree.

In addition to the visual aspects, the surface treatment gave the bench legs a long-lasting surface which will endure even the most extreme weather conditions.

Stara looks after the attractiveness of the parks in Helsinki. In the spring time Stara makes the parks presentable again after the winter, plants flowers and keeps the parks clean until the winter comes. About one third of the Helsinki surface area is covered by green areas, planted parks or natural parks.

The aim was to coat the park bench legs to resemble the surface of a birch tree.

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FSP sponsors World Vision This year FSP will donate Christmas money to World Vision. The donation marks the beginning of FSP's partnership with World Vision. The objective is to help the most disadvantaged children in the developing countries.

The donations help the water project in Ng'oswet, Kenya. The aim is to enable access to clean water for people, especially children, in the area. The challenge is that only very few people in the area have access to clean water. Because of this, the schools cannot offer lunch.

Vivid walls for sports hall

fspcorp.com Photo: Shutterstock

FSP's paint shop in Kangasniemi implements an impressive surface treatment project in which the walls of Hiukkavaara multifunctional sports hall in Oulu receive perforated plates that conduct light.

FSP is responsible for the surface treatment of the plates and includes also human figures, for example, referring to basketball and ice hockey into the walls. The walls will have compelling outer surfaces with large complexes: in total, FSP treats 20 wall plates that are 3m x 3m in size.

The customer is Liikelaitos Oulun Tilakeskus that manages and maintains the public buildings in Oulu. The completion of the work will take approximately two weeks. Lauri Leppänen, the head of the FSP Kangasniemi unit is responsible for the project.

FSP Finnish Steel Painting Oy Kalliosolantie 3 FI-01740 Vantaa Tel. +358 9 278 6270 www.fspcorp.com

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Š VASTAVALO.FI

A longer life span

Our industrial surface treatment, engineering and added-value services are well-acknowledged both in Finland and internationally.

We offer surface treatment services for machines, equipment, ships, bridges, storage tanks, steel structures, oil and gas drilling rigs on a turnkey basis. We help you save time and focus on your own core competence and its development.

We use non-polluting working methods, we recycle and we practise safe storage techniques. We follow quality, environmental, industrial safety and health standards ISO 9001, ISO 14001 and OHSAS 18001.

FSP FINNISH STEEL PAINTING OY | KALLIOSOLANTIE 3 | FI-01740 VANTAA | +358 9 278 6270 | WWW.FSPCORP.COM