Reflex Marine FROG-XT Series User manual

USER MANUAL REV 1
UM-206(1)
Issue date: 13-Oct-2020
Original Instructions

UM-0206(1) 1 | P a g e
Introduction
This manual contains information for operating, maintaining and storing the FROG-XT series
of personnel carriers: XT4, XT6, and XT10. Appropriate training and pre-operational briefings
should be provided for all personnel involved in the use of this device.
Safe and proper use of the FROG-XT is the responsibility of the user, taking due
consideration to the information provided in this document. The user should ensure
compliance with all relevant legislation and good industry practice.
Risk awareness and planning
Crane transfers (like other forms of marine transfer) are complex operations and operators
must take account of a wide range of variables. By their nature, crane transfers require the
management of an interface between two separate organisations, most commonly an
installation and a vessel. It is essential that all the key risk factors are assessed, and proper
planning and preparation are completed. All personnel involved should be aware of their
roles and should have the necessary competence to perform them.
Best practice references
Offshore Personnel Transfer by Crane, Marine Transfer Forum.
http://www.marinetransferforum.org/resources
Offshore Personnel Transfer by Crane is comprehensive guidance and information on each
element of operation. It is for those researching, planning, managing or carrying out the
safest possible crane transfers.
10 Golden Rules: Personnel Transfer by Crane ,Reflex Marine,
http://www.marinetransferforum.org/resources
10 Golden Rules: Personnel Transfer by Crane provides a useful overview of the key risks
and considerations in planning crane transfer operations. Also available as video
presentation at https://youtu.be/JDljjCqr2Zw
Control of manual
This manual is controlled by Reflex Marine and may be revised from time to time. The latest
revision may be obtained by contacting RML or by downloading the latest version from
www.reflexmarine.com/support.
Note : For the purposes of this manual RML will be deemed to mean Reflex Marine Limited
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.
© 2020 Copyright Reflex Marine Ltd, all rights reserved.

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Contents
Introduction.................................................................................................. 1
1Product Specifications ............................................................................ 4
2Operating Parameters ............................................................................ 5
2.1 General...................................................................................................................................5
2.2 Recommended Operating Parameters...............................................................................7
2.3 Crane Transfer Planning Tool .............................................................................................8
3Using the FROG-XT ................................................................................. 9
3.1 Safety Features .....................................................................................................................9
3.2 Passenger Instructions.......................................................................................................10
3.3 Entry and Exit......................................................................................................................11
3.4 Deck Crew Instructions......................................................................................................12
3.5 Stretcher Mode....................................................................................................................13
3.6 Stretcher Installation..........................................................................................................14
3.7 Carrying Luggage................................................................................................................16
3.8 Lifting Assembly Connection –Rigging compatibility with Crane Hook......................17
3.9 Lifting Assembly Connection –XT4 and XT6..................................................................18
3.10 Lifting Assembly Connection –XT10 ...............................................................................19
3.11 Control of Lifting Assembly during Operations...............................................................20
3.12 Lifting Assembly –Height Clearance ...............................................................................20
4Inspection & Maintenance.................................................................... 22
4.1 Definitions............................................................................................................................22
4.2 Sourcing of Safety-Critical Parts.......................................................................................22
4.3 Supporting Documentation ...............................................................................................22
4.4 Care in use / Preventative maintenance .........................................................................23
4.5 Inspection Types.................................................................................................................25
4.6 Frequency ............................................................................................................................25
4.7 FROG-XT Inspection and Maintenance Schedules.........................................................26
4.8 Load Test Procedure ..........................................................................................................27
4.9 Data Plates...........................................................................................................................28
4.10 Pre-Operational Check .......................................................................................................29
4.11 Frog XT Inspection .............................................................................................................31
4.12 Report of Thorough Examination .....................................................................................35

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5Handling & Storage............................................................................... 36
5.1 Stock Inspections................................................................................................................36
5.2 Shipping and storage .........................................................................................................37
6Replacement Parts................................................................................ 39
6.1 Introduction.........................................................................................................................39
6.2 Parts identification..............................................................................................................39
6.3 Kits ........................................................................................................................................40
6.4 Accessories ..........................................................................................................................41
7Certificates............................................................................................ 42
7.1 EC Attestation of Conformity –Frog-XT4........................................................................42
7.2 EC Attestation of Conformity –Frog-XT6........................................................................43
7.3 EC Attestation of Conformity –Frog-XT10 .....................................................................44
8Contact Details...................................................................................... 45
9Revision notes....................................................................................... 46

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1Product Specifications
Table 1 Product Specifications
Model No.
XT4
XT6
XT10
Dimensions
(Nominal)
Width 1
2110 mm
2110 mm
4090 mm
Width 2
2110 mm
2110 mm
2660 mm
Height
2180 mm
2180 mm
2180 mm
Weight
Max Gross Mass
1000 kg
1240 kg
2120 kg
Tare Weight
500 kg
580 kg
970 kg
Payload
500 kg
660 kg
1150 kg
Materials
Frame
316 Stainless steel, A4 stainless fixings
Columns/ Plates
316 Stainless/ Duplex Stainless
Steel Parts
All stainless except for floor grating
Buoyancy
PE shell with Polyurethane (PU) closed cell foam fill.
Seat Base/ Back
Polyolefin shell filled with polystyrene closed cell balls
Landing Feet
EVA Foam
Operating
Temperatures
Standard Model
-20°C to +50°C
Arctic Model
-40°C to +50°C
Suspension
Springs
2 x
4 x
4 x
Coated heavy duty coil springs
Dampers
2 x
2 x
4 x
Stainless steel 400mm recoil dampers
Seating
Seats
4 x Full height
seats
6 x Full eight
seats
10 x Full height
seats
Harnesses
3 Point, Quick Release Buckle
Grab Handles
2 per buoyancy panel
Lifting Points
SWL
Main
1000 kg
1240 kg
1060 kg
Backup
1000 kg
1240 kg
1060 kg
Handling
1000 kg
1240 kg
1060 kg
Wire Rope Lifting
Assembly
Safe Working Load
1240 kg
1240 kg
Two-leg lifting
assembly: 2170
kg
Wire Rope
Anti-rotation, galvanised wire rope
Number of
Passengers
Standard
4
6
10
Stretcher Mode
1 + Stretcher
1 + stretcher
2 + 2 stretcher
Luggage Capacity
Light Luggage
Accessory available on request
Luggage Tray
Accessory available on request
Impact
Protection
Vertical impacts
4.5 m/s
3.7 m/s
Lateral impacts
2 m/s
Stability
Horizontal
35°, for a load of 1-max passengers.
Self-Righting
Up to 180˚ inverted to the vertical position
Certification
Class
Attestation of
Conformity
Certificate No.
MAC0000002 i01
Attestation of
Conformity
Certificate No.
MAC0000005 i01
Attestation of
Conformity
Certificate No.
MAC0000004 i01
Quality
System
Manufactured to ISO 9001:2015
Standards
National Technical
Standards
UK, BS EN 1993: Use of Structural Steel in Building.
Industry European
Standards
EC Machinery Directive
EN 14121-1, BS EN 12100-10
Load Test –ILO152 / LOLER

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2Operating Parameters
2.1 General
The FROG-XT range has been designed to ensure passenger safety in the most demanding
conditions.
There are many factors that affect the safe conduct of marine personnel transfers. These
include crew skill and experience, met-ocean conditions, landing areas, vessel station
keeping capability and response to sea conditions, visibility and line of sight. A combination
of many factors will determine the risk involved and careful planning is a prerequisite for
safe operations (see Introduction)
2.1.1 Sea State
The FROG-XT has a suspension and damping system which prevents passengers from
experiencing shock loads during landing and pick-up. The maximum recommended
significant wave height is based on the maximum relative velocity between the load and the
deck.
The calculated operational sea states detailed below are based on vertical impact speeds
and biomechanical considerations. They reflect the ability to withstand such impacts with
minimal risk of injury to the human body. However, there are many additional factors that
may affect the safety of crane transfer operations. These include vessel station-keeping,
crew competence, wind and visibility. The operator should always refer to general guidelines
on crane transfers operations to assess overall risks.
Technical note:
The calculation for relative velocity used here is based on the European offshore crane standard,
BS EN 13852-1:2013. Whereby the maximum anticipated relative velocity between a load and a
vessel deck, is given by the following;
Relative velocity = (0.5*Hook velocity)1+ √ (Vessel deck velocity 2+ Boom tip velocity 2)
1Equal to 1.67 m/s (100 m/min) for lifts below 5 tonnes. Higher crane hook speeds may be available, and it
follows that the higher the available crane speed the higher the possibility of a heavy landing or take off.
However, with a qualified Crane Operator, it is considered unlikely that the FROG-XT will be landed at full
hook speed on a deck rising at full speed.
If there are concerns about heavy landings, operators may wish to consider the following methods to reduce
risks; dry runs without passengers, landing in centre of deck where there is less vessel movement,
transferring fewer passengers to increase damping, using a hook speed indicator.

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Table 2 FROG-XT Operating Parameters
2.0
4.0
5.6
7.1
1.3
2.5
3.3
4.0
0 2 4 6 8
Vessel to
Vessel
F.P.S.O. to
Vessel
Semi-sub to
Vessel
Platform to
Vessel
Significant Wave Height (M)
FROG-XT4/XT6 Operational Parameters - Sea State
Platform
to Vessel
Semi-sub
to Vessel
FPSO/Drillship
to Vessel
Vessel
to Vessel
1.4
2.7
3.5
4.1
1.2
2.2
2.8
3.3
0 2 4 6 8
Vessel to
Vessel
F.P.S.O. to
Vessel
Semi-sub to
Vessel
Platform to
Vessel
Significant Wave Height (m)
FROG-XT10 Operational Parameters - Sea State
Platform
to Vessel
Semi-sub
to Vessel
FPSO/Drillship
to Vessel
Vessel
to Vessel
Note:
▪Recommended Operating Window –For an impact at worst case scenario* under these sea conditions, XT products are well within performance
range. Consideration of all risk factors and pre-job planning are still requisite.
▪Extended Operating Window - For an impact at worst case scenario* under these sea conditions, XT product performance has been designed,
tested, and validated to provide complete passenger protection. In such elevated sea states other risk factors will increase. A thorough risk
assessment and trials should be conducted to ensure. Contact Reflex Marine if you need assistance.
▪High Risk Operating Window –Operating in this window presents risk of exceeding XT product safety performance. For any operations in this
window, specific measurements of relative motion are recommended to ensure they are within safety margin. A thorough risk assessment and
trials should be conducted to ensure. Please contact Reflex Marine for any guidance.
*Relative velocity between load and landing deck based on European offshore crane standard, BS EN 13852-1:2013

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2.2 Recommended Operating Parameters
Table 3 Recommended Operating Parameters
Parameter
Recommendation
XT4 + XT6
XT10
Vertical Impact Protection
4.5 m/s : 14.8 ft/s
3.9 m/s : 12.10 ft/s
Lateral Impact Protection
2 m/s : 6.6 ft/s
Wind Speed
20 m/s : 40 knots
Frog-XT is very stable in high winds. However, crane
limits must be observed
Visibility
Crane Operator should have a clear view of the pickup
and set down areas.
Vessel Motion
10⁰Pitch and Roll
Vessel Station-Keeping Radius
5 m : 16 ft
Landing Area: Vessel
6m x 6m : 20ft x 20ft
8m x 8m : 26ft x 26ft
Landing area on vessel recommended equivalent to 2m
clearance all round.
Landing Area: Installation
4m x 4m : 13ft x 13ft
6m x 6m : 20ft x 20ft
Landing area on vessel recommended equivalent to 1m
clearance all round.
Landing Area: General
Smaller landing areas may be used provided a risk
assessment of factors such as deck hazards, weather,
sea state, vessel size, station-keeping is carried out.
Must be clear of any obstructions or hazards
Crane Requirements
Crane must be suitable for lifting personnel

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2.3 Crane Transfer Planning Tool
Reflex Marine has developed a Crane Transfer Planning that can be used to determine
whether the conditions are suitable for transfers to take place. There are four main sections
that need to be completed
i. Risk Assessment
ii. Pre-Transfer Checklist
iii. Passenger Log
iv. Post Transfer Review
The Crane Transfer Planning Tool can be found on the flash drive contained in your user
pack, or alternatively, you can download a copy from our website.
▪It is important that the conditions are assessed prior to every set of
transfers as conditions are never the same.
▪It is recommended that a trial run is always conducted as this provides
real-time feedback on the conditions.
▪The operator should always refer to general guidelines on crane transfers
operations to assess overall risks.
▪If there is ever any concern about the conditions or the safety of the
operations transfers should be stopped.
Key references
i. Offshore Personnel Transfer by Crane, Marine Transfer Forum,
http://www.marinetransferforum.org/resources
ii. 10 Golden Rules: Personnel Transfer by Crane, Reflex Marine,
https://www.youtube.com/watch?v=JDljjCqr2Zw

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3Using the FROG-XT
3.1 Safety Features
Protected Seating Position:
Seats are positioned directly behind the buoyancy panels providing maximum protection and
minimised sense of exposure. The arrangement of the seats and entry/exit points allow
rapid access and egress, allowing faster and more efficient transfers.
Fall Protection:
3-point harness system and grab handles protect from the risk of falling during transfer.
Vertical impact protection:
i. Seats mounted on a suspension system which consists of coil springs and recoil
dampers
ii. Semi-upright secure seat position, cushioned saddle seat
iii. Impact absorbing EVA foam feet
Lateral impact protection:
i. Stainless steel frame
ii. Buoyancy panels
iii. High backed headrest designed to reduce the risk of whiplash
iv. Grab handles and pommel shaped seat cushion for secure seating position
Flotation:
Buoyancy panels ensure the carrier floats with both passengers and stretcher above the
waterline. All XT transfer capsules are performance tested for the most extreme immersion
scenarios and self-right. All Frog-XT capsules self-right up to 180° inverted to the vertical
position in less than 10 seconds and will provide a stable floating platform in a wide range of
conditions. Frog-XT carriers are also tested for their responses to free-fall into water.

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3.2 Passenger Instructions
All passengers should be familiar with seating procedure and practice entry prior to
operations.
To make passenger entry more efficient, where possible, deck crew or passengers should
loosen all harnesses prior to entering the carrier.
ENTRY
1Take your allocated seat
2Fasten buckle. Tightening lower
straps, then upper straps
3Give thumbs up when ready
4Use handholds and keep feet inside
Exit
5Wait for instructions
6Exit and move to a safe area

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3.3 Entry and Exit
Passenger entry to and exit from should only be conducted with the carrier in a stable
position on deck as advised by the crane operator and vessel master to the deck crew
member in charge of the transfer operation.
All exiting passengers must be clear of the carrier before any new passengers attempt to
board.
Each individual seat has a dedicated entry/exit point to prevent confusion and ensure
efficient operation. All passengers must enter and exit in the same direction. Chevrons on
the buoyancy panels are present to indicate the direction of entry.
Entry
When advised to do so by the deck crew, passengers should proceed as directed to one of
the four entrances. When instructed, all passengers should step into the carrier and take the
seat to their left.
Passengers should ensure they are securely seated and ensure the seat harness is securely
fastened. Grab handles are provided on the tubular upright members either side of the
buoyancy panel and passengers should grip these firmly or the harness straps whenever
seated. Passengers should never place their hands near the load plate.
Exit
Following landing and when advised to do so by the deck crew, passengers should unfasten
the safety harness, stand and exit the carrier by the exit to their left.
Passengers should move clear of the carrier as directed by the deck crew, ensuring they
remain clear of the lifting assembly.
Passengers should remain alert to hazard posed by the lifting assembly (particularly in harsh
weather with high deck motions). The lifting assembly position should be managed by the
deck crew as required (see Deck Crew Instructions).

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3.4 Deck Crew Instructions
Briefings
Deliver passenger briefings prior to every transfer lift and contain the following information:
i. Location specific instructions;
ii. Potential hazards;
iii. Loading and unloading procedures;
iv. Seating position;
v. Emergency procedures.
Other Responsibilities
i. Highlight potential hazards to passengers e.g. trip hazards during entry/exit;
ii. Remain alert from any hazards as they arise and take appropriate action;
iii. Check that passengers’ harnesses are secure and correctly fitted;
iv. When the carrier is landed on deck, the wire rope lifting assembly may obstruct
passenger entry/exit points. Ensure passengers observe and remain clear of the wire
rope lifting assembly. It is recommended that Deck crew hold the lifting assembly in a
safe position, away from the carrier entrances.
v. Ensure passengers keep hands clear of any pinch points, as illustrated below.
Figure 1 Pinch Points
1. Keep hands away
from the load plate
2. When folding down
the seat beware of
pinch hazard
3. Keep hands away
from the suspension
system

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3.5 Stretcher Mode
All models in the FROG-XT range can be converted into
medevac mode to accommodate a stretcher. Specific seats
require to be folded down, upon which the stretcher rests.
The stretcher clamp has been designed to fit the Ferno
Model 71 Basket stretcher. Other stretcher models may
be compatible but not all stretcher types will fit. The specific
stretcher in use should be test fitted prior to being used.
Figure 2 Stretcher Positioning
FROG-XT4
Two seats behind buoyancy panels A
and D.
FROG-XT6
Three seats behind buoyancy panel A.
FROG-XT10
For one stretcher, fold down the three
seat backs behind buoyancy panels B
and C.
For two stretchers, fold down the three
seat backs behind buoyancy panels B
and C and the three seat backs behind
buoyancy panels E and F.
A
B
C
D
A
B
C
D

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3.6 Stretcher Installation
There are two types of stretcher clamps fitted to Frog-XT range products.
The following steps outline the procedure to convert the FROG-XT into stretcher mode
TYPE 1 Stretcher Clamp
1Remove hex screws on either side of the
seat as indicated, and fold down seat;
2Refit hex screws into the position shown;
3Slide in the stretcher, rest on the folded
seatback;
4Rotate clamp anti-clockwise 90 degrees
5Tighten thumbscrew
6Attach straps to anchor points

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Type 2 Stretcher Clamp
For units XT4-126 onwards.
1Remove thumbscrews on either side of
the seat and fold down seats;
2Place both thumb screws into place holder;
3Slide in the stretcher, rest on the folded
seatback;
4Insert stretcher handrail into clamp;
5Tighten thumbscrew;
6Attach straps to anchor points.

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3.7 Carrying Luggage
Floor mounted luggage baskets are available as an accessory, however, where practical,
passenger luggage should be transferred separately in a cargo box or basket. This will
minimise distraction and the risks from carrying out additional procedures whilst transferring
personnel.
The following recommendations should be considered when transferring luggage:
i. The weight of the passengers plus the luggage should not exceed the SWL.
ii. All luggage items should be handled by deck-crew, not passengers, to ensure
efficiency and ensure passenger awareness is focussed on personal safety.
iii. Luggage items should be secured prior to passenger boarding and removed after
passenger exit.
iv. For luggage secured in floor-mounted basket it is recommended no more than 15 kg
per person is loaded. Luggage should fit comfortably in the basket and remain secure.
Height of luggage placed underneath seat should be restricted to 20 cm (8”) so that it
will not impede the damping system. See Figure 4.
Figure 4 Floor-Mounted Luggage Basket - Height Clearance
v. Heavy or large materials such as tools, boxes, or equipment should be transferred
separately in suitable cargo box or basket.
Seat base compressed
Seat base at maximum height

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3.8 Lifting Assembly Connection –Rigging compatibility with Crane Hook
It is important to ensure that the crane hook being used is compatible with the master links provided in the XT Range Lifting Assembly.
The guide below is designed to help understand the sizes of crane hooks that are compatible.
If master links provided in standard lifting assembly are not compatible, please contact Reflex Marine to arrange a solution.
Gunnebo Safety Hook
WLL / Dim Spec (mm) B xG xH
GN Rope HK2S Eye Hook Standard
WLL / Dims(mm):B xG xH
Unit Type
Masterlink
Manufacturer Part No.
(Part Code) WLL
Dims (mm): A x B x C
1.5t
29x15x21
to
27.3 t
100x54x68
50t
103x89x116
to
100t
151x125x172
150
173x160x199
to
250t
264x220x310
XT4, XT6
CROSBY A347
(1257979) 5.8t
22x145x275
✔
✔
X
XT10
CROSBY A344
(1257215) 6.3t
22x145x275
✔
✔
X
Table: XT Range Lifting Assembly Standard Master Link / Crane Hook Compatibility

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3.9 Lifting Assembly Connection –XT4 and XT6
Figure 5 Lifting Assembly –XT4 and XT6
Lifting assembly is fitted to the FROG-XT
by initially lowering it through the letter
box opening at the top of the carrier.
The lifting assembly is fitted with two
different terminations.
The main leg (highlighted in red) is fitted
with a bow shackle.
The back-up leg (highlighted in blue) is
fitted with a spelter socket.
The main leg connects to the centre hole
in the load plate.
The backup leg connects to either the far
right or far left hole.
A handling line can then be fitted to the
other free hole in the load plate

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3.10 Lifting Assembly Connection –XT10
Figure 6 Lifting Assembly –XT10
Lifting assembly is fitted to FROG-XT10 by
initially lowering it through the letter box
openings at the top of the carrier.
As there are two pairs of legs, one pair
needs to go into each of the letterbox
openings at the top of the unit.
The main leg (highlighted in red) fitted with a
bow shackle connects to the centre hole on
each load plate.
The backup leg (Highlighted in blue) fitted
with a spelter socket connects to the outside
hole.
The remaining two holes towards centre of
unit are used for handling.