Zaafarana Oil field is located in the north central Gulf of Suez off the coast of The Arab Republic of Egypt. The field is approximately 4 miles (6.5 km) from the coast in 189 feet (57 m) of water depth.The field consists of offshore platform and a Floating Production, Storage and off-loading facilities (FPSO) figure (1). The FPSO is located approximately 800 m from the platform to process and export the oil. FPSO is Power supply the production platform via a sub-sea cable. Crude received to FPSO from platform via 8ʺ oil pipe line figure (2).According to FPSO surveyor (DNV) class and IIP (In service inspection program), Special survey 5 (5 years period) have been carried out for FPSO, the survey included hull and machinery.After through hull survey and UTM gauging, it was found that; -Wastage and thickness diminutions vary from 5% to 28%.-Crack between two cargo tanksThe steel renewal and crack repairs are extensive, critical and risky to be done during FPSO in service, because it needs hot work, normally steel replacements are carried out at dry dock.This paper is discussing the methodology used to avoid the work in dry dock and secure DNV class certificate and to maintain the safe condition of the "FPSO" without disturbance or stopping oil production.