Three decades before, in 1973, Mitsui Engineering & Shipbuilding built the Very Large Crude Carrier (VLCC) Takakurasan Maru. Subsequently, the vessel underwent a number of significant transformations, first being converted into a storage tanker and then, in 2000, into the Floating Production Unit (FPU) Zafiro Producer. Ultimately, the asset was relocated to the Zafiro Field, where it generated approximately 155,000 barrels of oil per day. However, by 2008, the deck required comprehensive reinstatement work. Fortunately, the innovative Sandwich Plate System enabled the team to complete the reinstatement project safely, efficiently, and to the highest structural standards, ensuring the asset’s continued operational integrity.

Throughout the project, the Zafiro Producer remained fully operational, maintaining production approximately 42 miles offshore in the Gulf of Guinea. During this time, the team applied Sandwich Plate System to the Main Deck using a combination of ABS-approved Cold Work SPS and conventional installation methods. Crucially, SPS experts and specialized equipment stayed on site for the entire duration, actively minimizing operational disruptions while ensuring full capacity.

This approach ultimately delivered several key advantages:

• Maintained uninterrupted FPU production
• Avoided costly shutdowns by completing repairs on station
• Significantly improved deck stiffness, corrosion resistance, and impact performance