Reflex Marine FROG-9 User manual

FROG-9
User
Manual
Rev 05 | Issued 05-Mar-10

User Manual
FROG-9
Rev 05 Page2
Reflex Marine Ltd
Offshore Access Specialists
Purpose of Manual
This manual contains general instructions for the operation and maintenance of the FROG-9.
Safe and proper use of the FROG-9 is the responsibility of the user after having taken due regard of
the information provided in this document.
The user must ensure that all safety measures as required by relevant legislation and by good
operational practice are utilised for operations involving the FROG-9.
Adequate training must be provided for all personnel involved in the operation of the FROG-9 before
the commencement of operational use.
For the purposes of this manual RML will be deemed to mean Reflex Marine Ltd.
Please retain this manual for future reference. Additional copies may be obtained by contacting
Reflex Marine Ltd or by downloading the latest manual revision from
www.reflexmarine.com/support.
Revision Approval
Revision
Date Issued
Status
Approved
Name
Signed
01
07 Jan 08
Revised
RML Operations
Manager
02
22 Apr 08
Revised
RML Operations
Manager
03
07 Aug 09
Revised
RML Operations
Manager
04
30 Oct 09
Revised
RML Operations
Manager
Paul Wieczorek
05
05 Mar 10
Current
RML Operations
Manager
Paul Wieczorek
All information disclosed in this document is the property of Reflex Marine Ltd except where otherwise stated.
Reflex Marine Ltd reserves all patent rights, design rights, manufacturing rights, copyright and sales use rights
thereto, and to any article disclosed within this document except where such rights are expressly granted to
others or where not applicable to vendor proprietary parts.
© 2010 Copyright Reflex Marine Ltd, All rights reserved.
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User Manual
FROG-9
Rev 05 Page3
Document Revision & Control
To ensure that all changes to any of the documents contained in this manual are carried out and
distributed in a controlled and authorised manner:
i. Any proposed change in documentation must be submitted to the Reflex Marine Ltd
Operations Manager in writing for authorisation. This refers to all drawings and documents
contained in this manual.
ii. A record must be maintained of all documentation changes.
iii. A list of all revisions and amendments must be included in each controlled copy of this User
Manual.
iv. Upon revision of the FROG-9 User Manual, the manual will be distributed to the list of
document holders indicated below.
v. The control, revision and distribution of this manual will be the responsibility of the Reflex
Marine Ltd Operations Manager.
Revisions
Rev
No
Reason For Revision
Safety
Critical
Change
02
Section 2.3 - Para numbering corrected. Certification Pack contents corrected.
Section 5.6 - Revised recommended load distribution arrangement.
Section 6.1 - Ladder securing during inspection included.
Appendix D - Parts list and material specification included.
Appendix E - FROG-9 Markings included.
No
Yes
Yes
No
No
03
Page 23 - Point 8 wording revised.
Page 23 - Drawing revision status updated.
Page 26 - Part numbers in Table 1 & 2 updated.
Page 26 - Back up eye description changed.
Page 26 - Last two paragraphs added.
Page 12 - Guidance on wind speed changed.
No
No
No
No
No
Yes
04
Section 5.5 - Seating arrangement revised.
Section 5.6 - Seatbelt instructions added.
Section 5.7 - Rider instructions added.
Section 5.8 - Emergency stop procedure added.
Section 5.9 - PPE information added.
Section 6.0 - Whole section revised.
No
No
No
No
No
Yes
05
Section 2.1 - Include Operating temperature range into specification sheet.
Section 4.10 - Insert new section on Night time transfer operations.
Section 5.5 - Insert new section on Use of Tag Lines - update section numbers.
Section 5.7 - Insert new section on Luggage storage.
Section 5.10 - Insert images of emergency stop protocols.
Sections 6.5, 6.6. 6.7 - Update tables with photographic and documentation
recommendations.
Section 6.6 - Corrected M/U Torque for Main Lift-Eye bolts from 210 Nm
(incorrect) to 376 Nm (correct).
Section 6.8 - Correct loading / sand bag weights to 2900 kg to avoid confusion.
Appendix E - Insert new section Appendix E- Accessories.
No
No
No
No
No
No
Yes
No
No
Link to IndexLink to Index

User Manual
FROG-9
Rev 05 Page4
Distribution List
Controlled/uncontrolled copies of this manual are issued to the following:
Reflex Marine Ltd
Ref.
Status
Issued To
Date Issued
Format
Master
Controlled
RML Truro
J Cryan
05 Mar 2010
Electronic
RML 1
Uncontrolled
RML Truro
P Wieczorek
05 Mar 2010
Electronic
RML 2
Uncontrolled
RML Aberdeen
S Watson
05 Mar 2010
Electronic
Notification of this manual revision is sent to the following:
Reflex Marine Ltd
Ref.
Status
Issued To
Date Issued
Format
RML 3
Notification
RML Website
J Strong
05 Mar 2010
Electronic
RML 4
Notification
RML Sales Team Coordinator
C Richards
05 Mar 2010
Electronic
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User Manual
FROG-9
Rev 05 Page5
Table of Contents
Purpose of Manual..................................................................................................................................2
Revision Approval ...................................................................................................................................2
Document Revision & Control ................................................................................................................3
Revisions .................................................................................................................................................3
Distribution List.......................................................................................................................................4
Table of Contents....................................................................................................................................5
1 INTRODUCTION...............................................................................................................................8
1.1 Scope.......................................................................................................................................8
1.2 Introduction ............................................................................................................................8
1.3 Safety ......................................................................................................................................9
2 SPECIFICATION FROG-9.................................................................................................................10
2.1 Specification Summary..........................................................................................................10
2.2 Design....................................................................................................................................10
2.3 Certification and Documentation .........................................................................................11
3 OPERATING PARAMETERS ............................................................................................................12
3.1 Introduction ..........................................................................................................................12
3.2 Operating Parameters - Sea State.........................................................................................13
3.3 Operating Parameters - Additional Factors ..........................................................................13
4 TRANSFER PLANNING....................................................................................................................15
4.1 Risk Assessment and Method Statement .............................................................................15
4.2 Communications ...................................................................................................................15
4.3 Information Exchange...........................................................................................................15
4.4 Operational Planning ............................................................................................................16
4.5 Briefings ................................................................................................................................16
4.6 Supervision............................................................................................................................16
4.7 Transfer Log ..........................................................................................................................16
4.8 Emergency Transfers.............................................................................................................17
4.9 Training .................................................................................................................................17
4.10 Night Time Operations..........................................................................................................17
5 OPERATING PROCEDURE ..............................................................................................................18
5.1 Pre-Transfer Activity List.......................................................................................................18
5.2 Lifting ....................................................................................................................................18
5.3 Landing..................................................................................................................................18
5.4 Crane Operator Guidance .....................................................................................................19
5.4.1 Use of Shorter Slings .....................................................................................................19
5.4.2 Handling Eyebolt...........................................................................................................19
5.5 Use of Tag Lines ....................................................................................................................20
5.6 Seating and Load Distribution...............................................................................................20
5.7 Luggage Storage....................................................................................................................21
5.8 Seatbelt Operation................................................................................................................21

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Rev 05 Page6
5.9 Rider Instructions..................................................................................................................22
5.10 Emergency Stop Procedure...................................................................................................22
5.11 Personal Protective Equipment (PPE)...................................................................................23
5.11.1 Personal Flotation Devices (PFD’s)................................................................................24
5.11.2 Immersion Suits ............................................................................................................25
6 PERIODIC INSPECTION, TESTING AND MAINTENANCE.................................................................26
6.1 Introduction ..........................................................................................................................26
6.2 Definitions.............................................................................................................................26
6.3 Frequency of Inspection, Test and Maintenance..................................................................27
6.4 Pre-Operational Visual Check ...............................................................................................29
6.5 Visual Inspection ...................................................................................................................31
6.6 Examination ..........................................................................................................................34
6.7 Post Load Test Visual Inspection...........................................................................................38
6.8 Proof Load Testing ................................................................................................................41
6.8.1 Load Test Procedure .....................................................................................................42
6.8.2 Test Plate.......................................................................................................................42
6.9 Sling Replacement and Management...................................................................................43
6.9.1 Sling Set (Critical Part) Replacement.............................................................................43
6.9.2 Sling Set Management ..................................................................................................43
6.10 Critical Spares Kits and Replacement Parts ..........................................................................44
6.10.1 Spares Kits.....................................................................................................................44
6.10.2 All Other Replacement Parts.........................................................................................45
6.11 Unit Replacement Recommendation....................................................................................45
7 UNIT IDENTIFICATION ...................................................................................................................47
7.1 Product ID Numbers..............................................................................................................47
7.2 Part Numbers........................................................................................................................47
7.3 FROG-9 Serial Numbers ........................................................................................................47
7.4 Component Serial Numbers..................................................................................................47
8 HANDLING, SHIPPING AND STORAGE...........................................................................................48
8.1 Dimensions............................................................................................................................48
8.2 Handling & Transportation ...................................................................................................48
8.2.1 Forklift...........................................................................................................................48
8.2.2 Crane.............................................................................................................................48
8.2.3 Securing.........................................................................................................................48
8.2.4 Inspection......................................................................................................................48
8.2.5 Preparation for Road Transport....................................................................................48
8.2.6 Containerisation............................................................................................................48
8.2.7 Storage ..........................................................................................................................49
9 APPENDIX A –TRANSFER LOG.......................................................................................................50
10 APPENDIX B –DRAWINGS.............................................................................................................51
11 APPENDIX C –PARTS LIST AND MATERIAL SPECIFICATIONS.........................................................57
11.1.1 Definition According to Criticality.................................................................................57
11.1.2 Fastener Specifications .................................................................................................57
11.1.3 Certification...................................................................................................................57
12 APPENDIX D –FROG-9 MARKINGS................................................................................................60

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12.1 Essential Marking Requirements ..........................................................................................60
12.2 FROG-9 Seat Marking Plan....................................................................................................62
12.3 FROG-9 Column Marking Plan...............................................................................................63
13 APPENDIX E –ACCESSORIES..........................................................................................................64

User Manual
FROG-9
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1INTRODUCTION
1.1 Scope
This User Manual is for the nine passenger capacity FROG-9 (Model HC9-01).
Note: Throughout this manual the use of this symbol “ “ denotes safety critical
information.
1.2 Introduction
The FROG-9 Personnel Transfer Capsule (PTC) is a personnel transfer device designed to provide
increased passenger protection when carrying out the transfer of personnel between vessels and
installations.
Crane personnel transfers are carried out for a wide variety of reasons including routine, urgent
operational and emergency reasons.
The FROG-9 comprises the following two main assemblies; firstly, the stainless steel outer
framework containing polyethylene buoyancy panels, secondly, a spring-dampened seating
assembly mounted on a central column. All materials have been selected specifically to minimise
corrosion in the marine environment.
The outer framework protects passengers from impacts and contains the buoyant elements which
ensure the FROG-9 floats and is self-righting in water. At its base are keel weights which assist in
rapid self-righting.
The outer shell lands on three main peripheral feet which are supplemented by a further three
centrally mounted feet. All six feet provide shock absorption and ensure that the FROG-9 is stable on
uneven surfaces or when landing on a heaving vessel. The outer shell also has three large open
accesses that allow rapid unimpeded exit.
During transit passengers are seated and secured with full harnesses to protect them against
whiplash and falling. Seating is mounted on a sprung carriage to provide protection against heavy
landings.
The sling assembly is of a special design to prevent rotation.
Note: The regulations governing personnel transfer operations vary greatly from country to country and it is imperative
that operators of the equipment establish the relevant requirements for the area of operation.
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1.3 Safety
Personnel transfer is a safety critical activity. The following items must be observed to properly
control safe transfers.
i. Proper planning of the transfer operation is essential. Planning must include a risk
assessment and method statement which takes account of all environmental and
operational factors. Assessing the impact of these factors on operational risk is best done by
Competent Persons (see note below) experienced in use of the equipment and the local
conditions.
ii. It is imperative for the safe operation of the FROG-9 that each unit is periodically inspected
and tested in accordance with the procedures and schedules set out within this document.
iii. Operating parameters detailed in this document must be adhered to unless modified
following on-site risk assessment and method statement by competent, experienced
personnel.
iv. The FROG-9 must only be used with properly designed, maintained and appropriately
certified lifting equipment. (It should be noted that some national regulations require cranes
to be specifically certified for man-riding operations).
v. Supervisory personnel (including Deck Crews and Crane Operators) must be competent and
must only operate the equipment following proper instruction in its use. Crane Operators
should read the ‘Crane Operator Guidance’ contained within this document.
vi. Pre-operational checks as detailed in this document must always be performed prior to use
of the FROG-9.
vii. Transfer personnel must receive a proper briefing on the FROG-9 and the transfer operation.
viii. Transfer personnel must at all times be seated and properly strapped in using the harnesses
supplied.
ix. The FROG-9 must only be used as a personnel transfer device.
x. The FROG-9 must not be used as a work-basket.
Note: Competent Person
A Competent Person is a person who has appropriate practical and theoretical knowledge and
experience of the equipment. This will enable them to detect defects and weaknesses and to assess
their importance in relation to the safety and continued use of the equipment. It is essential that
the Competent Person is sufficiently independent and impartial to allow objective decisions to be
made.
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User Manual
FROG-9
Rev 05 Page10
2SPECIFICATION FROG-9
2.1 Specification Summary
Model No.
HC9-01
Payload
900 kg = 9 x 100 kg
(1984 lb = 9 x 220 lb)
Dimensions
Width 1
2794 mm
Width 2
3219 mm
Height
2877 mm
Weight
Max Gross Weight
2000 kg (4410 lb)
Tare Weight
1100 kg (2425 lb)
Manufacture
To ISO 9001:2000
Materials
Frame
SS 316 and A4 Stainless Steel
Central Column / Lift Eye
Duplex SAF 2205
Lift Eye Connection Bolts
17-4 PH H1075
Other Steel Components
SS 316 and A4 or A2 and Mild Steel Hot Dipped Galvanise
Buoyancy
Rotationally moulded MDPE shell with PU foam fill in lower
unit. Polystyrene central buoyancy.
Seat Base
40 mm Nidaplast 8
Seat Back
Trespa Meteon 6 mm
Operating Temperatures
Standard Model HC9-01
+50 deg C to -20 deg C
Suspension
Springs
1 x 17,224 N @ 0.32 m
3 x 8,612 N @ 0.32 m
Dampers
3 x Stainless Steel
40 mm cyl / 14 mm Rod
300 mm Stroke
2.2 Design
Verification
ABS Product Design Assessment Certificate No. 07-
LD299029-PDA.
Manufactured to ISO 9001:2000.
National Technical Standards
UK, BS449: Part2:1969: The Use of Structural Steel in
Building.
UK, BS2830:1994: Suspended Chairs and Cradles for the use
in the Construction Industry.
Link to Index