Offshore EX Maintenance on FPSO Dhirubhai-1 Using Cold Work Solutions
On board the FPSO Dhirubhai-1, operating offshore India, a large-scale maintenance program was required to restore protective coatings in hazardous areas. The work needed to be carried out safely while the vessel remained fully operational. By selecting Safety Tools Allmet’s cold work solutions, the project was executed without the need for a hot work permit.
EX Compliance and Certifications
Given the presence of explosive atmospheres (EX Zone 1 and 2), conventional maintenance methods were not an option. Maintenance activities in hazardous offshore environments come with strict safety limitations. Tools that generate heat or sparks are typically restricted, as they increase the risk of ignition.
For this project, the key conditions were:
- Execution without interrupting ongoing operations
- Safe use in EX Zone 1 and 2
- Elimination of spark and heat generation
- No dependency on hot work permits
To meet these requirements, Safety Tools Allmet supplied a range of EX-certified cold work tools designed for safe operation in hazardous areas. The equipment package included a combination of angle grinders, straight grinders and Rough Boy units. All tools were DNV-certified and suitable for continuous use in offshore EX environments. The work was fully complaint with the HSE standards for offshore operations and did not require a hot work permit.
Scope and Application
The cold work tools were deployed across multiple high-risk areas on board the FPSO, including gas compressor modules, pump rooms, under-deck piping systems, the helideck and the turret structure. By using Safety Tools Allmet, the contractor was able to perform mechanical surface preparation in accordance with the ST 3 standard, without introducing ignition risks.
In total, approximately 6,020 m² of surface area was treated within a broader maintenance scope of 17,195 m². Following surface preparation, a three-coat protective system was applied using a combination of roller, brush and airless spray techniques, achieving a total dry film thickness of 350 microns.
Performance and Results
The project was executed over a two-year period, delivering consistent performance under offshore conditions. Average productivity reached 23.5 m² per day, including scaffolding activities.
Importantly, all work was completed without any reported safety incidents, while maintaining full compliance with offshore HSE standards. The ability to operate without hot work permits allowed maintenance to proceed without disrupting production.
The project execution and safety standards were positively evaluated by the client:
“Very good supervision and excellent QHSE compliance.”
— Chief Officer, Dhirubhai-1
Conclusion
This project demonstrates how cold work technology can support safe and efficient maintenance in hazardous offshore environments.
By removing the risks associated with sparks and heat, Allmet Safety Tools enabled continuous operations while maintaining the highest safety standards. It underlines the value of using purpose-built EX-certified tools when working in demanding conditions.
