Case Study for FPSO DHIRUBHAI-1

How Safety Tools Allmet Secured EX Maintenance on Aker FPSO Dhirubhai-1

Background and Challenge

FPSO Dhirubhai-1, previously owned by Aker and operated offshore in India, required extensive maintenance work in EX zones, without compromising production or safety. Surface treatment was carried out without the need for a hot work permit.

Safety and EX Compatibility Requirements

The work had to be performed in hazardous areas (EX zone 1 and 2), which excluded the use of traditional angle grinders and heat-generating tools.
The solution had to be:

• Spark-free and cold

• DNV-certified for EX use

• Suitable for continuous operation without interruptions

Certification and Approvals

• The tools were DNV-certified for use in EX zone 1 and 2

• The system required no hot work permit

• Fully compliant with applicable HSE standards for offshore operations

The Solution: EX-Certified Tools from Safety Tools Allmet

Safety Tools Allmet supplied complete sets of cold solutions, including:

• 9 angle grinders

• 7 straight grinders

• 4 “Rough Boy” units

This enabled mechanical surface treatment according to ST 3 standard without heat generation or spark formation.

Work Performed and Scope

The tools were used for surface treatment of 6,020 m² out of a total of 17,195 m² in the project. The areas included:

• Gas compressor areas

• Process modules

• Pump rooms

• Under-deck piping systems

• Helideck and turret structure

The coating system consisted of 3 layers of Jotun Jotacote Universal, applied using roller, brush, and airless spray. Total film thickness was 350 microns.

Results and Efficiency

• Productivity: 23.5 m² per day (including scaffolding work)

• No safety incidents reported during the project period (2 years)

• Full customer satisfaction, documented through feedback forms

Customer Feedback

“Very good supervision and excellent QHSE compliance.”
— Chief Officer, Dhirubhai-1

Conclusion

Safety Tools Allmet delivered a complete and safe solution for EX maintenance on board Aker FPSO Dhirubhai-1. Our tools enabled continuous operation, eliminated the need for hot work permits, and set a new standard for EX maintenance offshore.

This case demonstrates that technical safety and performance can be combined — when you use the right tools.

Below you will find images of the finished result after surface preparation using Safety Tools Allmet’s cold solutions.