Reflex Marine FROG-3 User manual

FROG-3 User
Manual
Original Instructions For FROG Models:
FS-01 (320) Standard
FS-01 (340) Arctic
FS-01 (370) Tropical
Rev 19 | Issued 14-05-12

User Manual
FROG-3
Rev 19 Page2
Reflex Marine Ltd
Offshore Access Specialists
Purpose of Manual
This manual contains general instructions for the operation and maintenance of the FROG-3.
Safe and proper use of the FROG-3 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-3.
Adequate training must be provided for all personnel involved in the operation of the FROG-3 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
15.1
05 Oct 05
Revised
RML Operations
Manager
15.2
20 Sep 06
Revised
RML Operations
Manager
15.3
19 Sep 07
Revised
RML Operations
Manager
16
25 Jan 10
Revised
RML Operations
Manager
Paul
Wieczorek
17
10 Jun 10
Revised
RML Operations
Manager
David Brittan
18
03 Sept 11
Revised
RML Operations
Manager
David Brittan
19
01 May 12
Current
RML Lead Engineer
Production & Quality
Paul Onions
PO
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.
Link to Index

User Manual
FROG-3
Rev 19 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 Lead
Engineer –Production & Quality 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-3 User Manual, the manual will be distributed to the list of
document holders indicated below. The control, revision and distribution of this manual will
be the responsibility of the Reflex Marine Ltd Lead Engineer –Production & Quality.
Revisions
Rev
No
Reason For Revision
Safety Critical
Change
15.2
Old Sections 3.52 and 3.53
Operational guidance on night time operations and PPE recommendations.
Old Sections 4.1, 4.3, 4.4
Revision to inspection and maintenance terminology.
No
No
15.3
Old sections, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5
Revision to inspection and maintenance procedures to update part
numbers and offer sling set replacement frequency guidance (12 months).
Yes
16
The Frog Client Technical Manual has now been replaced with this FROG-3
User Manual. This manual is more focused on providing User Information
in a format consistent with the other Reflex Marine Ltd products. The
significant changes are listed below.
Re-organisation of all sections of previous CTM into a standard Reflex
Marine Ltd User Manual format.
Deletion of Risk Register and Risk review papers which are ancillary to the
manual. (These are still available as separate document downloads from
www.reflexmarine.com/support).
New Sections added :
Section 5.6 - Seating and Load distribution added
Section 5.7 - Luggage Storage
Section 5.8 - Seatbelt Operation
Section 5.9 - Rider instructions added
Section 5.10 - Emergency stop procedure added
Revised Sections
Section 6 - Inspection, Testing and Maintenance.
The whole section has been revised to align recommended inspection and
maintenance to the ‘degree of use’and provide guidance on unit lifetime
and retirement policy. Improved inspection checklist templates are
No
No
No
No
Yes
Link to Index

User Manual
FROG-3
Rev 19 Page4
included for a range of recommended inspection points.
17
Minor edits
Section 2.1 Model No from HC9-01 to FS-01
Section 5.12.2 vi: Change from remove nut to slacken nut
Corrections
Sections 6.5 & 6.6 and 6.7 –Inspection Check Lists Forms
Point 2 : delete “through the lifting bolt retaining sleeve” – not
relevant to Frog 3
Point 4 : Replace ‘alignment’ with ‘anti-rotation’
Point 5 : Delete word ‘clevis’ – not relevant for Frog 3
Point 6 : Change ‘alignment roll pin on older models’ to ‘keel plate
nut roll pin on older models’ - clarity
Point 6 : Delete ‘tamper proof seal’ not present.
Section 6.10.1 : Kit Listings
Critical Parts Kits for Low Temperature M40 Frogs : Add sling cover.
Restraint Harness Kit Numbers corrected
Include latest drawing FS-GA1 Rev B showing correct text for SWL = 330 Kg
Include latest drawing FS-GA2 Rev B : showing tamper proof seals fitted
Include latest drawing FS-GA3 Rev B : previously omitted showing current
seat arrangement
Include latest drawing F-ASY-11 Rev B ; change of word Ferrule to Thimble
Appendix C : Parts Listing
F -01 –049 : Buoyancy fitting button head screws : Correct the
material description to 304 Stainless steel
F-01 –221 : Seat assembly anti rotation bolt : Correct the material
description to 17-4PH 15% chrome alloy steel.
No
No
No
No
No
No
No
No
18
Overview of Major Revisions
Original Instructions added to cover page as per Machinery Directive
Alternative Operating Limit Methodology added
Clarified SWL and Passenger Loading Limitations (330Kgs and 270Kgs
limits)
New EC type examination and ABS PDA cert added
New ‘Ultra High’ Usage Category defined with corresponding
inspection frequencies.
Parts Kits updated and new kit numbers
The parts listings have been removed from the User Manual. Parts
listings will in future be available online (or directly from Reflex Marine)
, where the parts list for the serial number of each Frog can be
matched
Revised Sections
Section 2.1: FROG model numbers updated
Section 5.4.2: References to new drawing and part numbers
Section 5.7 Revised to advise that oversized luggage should be
transferred as a separate lift.
Section 5.12.2: Buoyancy reconfiguration diagram updated to remove
references to old P/Ns
NO safety
critical changes
occur in this
revision. All
changes are
enhancements
to the
documentation
and the advice
regarding Frog
3 operation
and
maintenance.

User Manual
FROG-3
Rev 19 Page5
Section 5.12.4: Torque setting for buoyancy fixings added.
Section 6.3: Inspection frequency table has been updated to include an
ultra-high usage category
Section 6.4:
The support drawings detailed in the guidance notes have been
updated to the new part numbers.
New separate anti-rotation fitting check added.
New separate spring check added
Diagram 4b corrected to include a tamper proof seal
Section 6.5:
New separate check for the anti-fouling bracket and shackle spacer
added
New separate spring check added
New alignment cross bolt check added
General formatting changes
Section 6.6:
Dye penetration test advise added to point 1
Back up eye torque setting added
Thread lubricant application requirements added to Keel Nut check
Separate anti-fouling bracket & shackle spacer check added
Separate spring check added
Separate sliding sleeve cross bolt check added
General formatting changes
Section 6.7:
Separate spring check added
Separate sliding sleeve cross bolt check added
Section 6.8
Load test held for 5 mins.
Section 6.8.2
Model numbers updated
Section 6.10.1
New part numbers for spares kits
Thread lubricant added to relevant parts kits
1 x tamper proof seal added to the parts kits that contain type 2
keel assemblies
Single slings have been replaced with new sling kits
Section 11.3
Parts lists have been deleted from the User Manual
Appendix B:
Drawings have been updated with new assembly drawings.
Drawings referring to previous Frog 3 models have been removed
to avoid confusion.
Appendix F :
New CE marking and ABS Type approval certificates attached for all
units beyond FS:412
19
Section 6.3 Table 3:
New ‘Very Low’ Usage Category defined with corresponding
inspection frequencies.
Load Test requirements also revised.
No
Link to Index

User Manual
FROG-3
Rev 19 Page6
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
14 May 2012
Electronic
RML 1
Uncontrolled
RML Newbury
P Onions
14 May 2012
Electronic
RML 2
Uncontrolled
RML Aberdeen
S Watson
14 May 2012
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
14 May 2012
Electronic
RML 4
Notification
RML Sales Team Coordinator
K Hallowes
14 May 2012
Electronic
Link to Index

User Manual
FROG-3
Rev 19 Page7
Table of Contents
Purpose of Manual..................................................................................................................................2
Revision Approval ................................................................................................................................... 2
Document Revision & Control.................................................................................................................3
Revisions .................................................................................................................................................3
Distribution List....................................................................................................................................... 6
Table of Contents....................................................................................................................................7
1 INTRODUCTION............................................................................................................................. 10
1.1 Scope..................................................................................................................................... 10
1.2 Introduction ..........................................................................................................................10
1.3 Safety ....................................................................................................................................11
Note: Competent Person ...................................................................................................................... 11
2 SPECIFICATION FROG-3................................................................................................................. 12
2.1 Specification Summary..........................................................................................................12
2.2 Design.................................................................................................................................... 13
2.3 Certification and Documentation .........................................................................................14
3 OPERATING PARAMETERS ............................................................................................................15
15
3.1 Introduction ..........................................................................................................................15
3.2 Operating Parameters - Sea State.........................................................................................16
3.2.1 Site Specific Frog Transfer Operating Parameters ........................................................17
3.3 Operating Parameters - Additional Factors ..........................................................................17
4 TRANSFER PLANNING....................................................................................................................18
4.1 Risk Assessment and Method Statement .............................................................................18
4.2 Communications ...................................................................................................................18
4.3 Information Exchange...........................................................................................................18
4.4 Operational Planning ............................................................................................................19
4.5 Briefings ................................................................................................................................19
4.6 Supervision............................................................................................................................19
4.7 Transfer Log ..........................................................................................................................19
4.8 Emergency Transfers.............................................................................................................20
4.9 Training .................................................................................................................................20
4.10 Night Time Operations..........................................................................................................20
5 OPERATING PROCEDURE ..............................................................................................................21
5.1 Pre-Transfer Activity List.......................................................................................................21
5.2 Lifting ....................................................................................................................................21
5.3 Landing..................................................................................................................................21
5.4 Crane Operator Guidance .....................................................................................................22
5.4.1 Use of Shorter Slings.....................................................................................................22
5.4.2 Sling Leg Arrangement and Observed Snagging Issue .................................................. 22
5.5 Use of Tag Lines ....................................................................................................................23

User Manual
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Rev 19 Page8
5.6 Seating and Load Distribution...............................................................................................23
5.7 Luggage Storage....................................................................................................................24
5.8 Seatbelt Operation................................................................................................................25
5.9 Rider Instructions.................................................................................................................. 26
5.10 Emergency Stop Procedure...................................................................................................26
5.11 Personal Protective Equipment (PPE)................................................................................... 27
5.11.1 Personal Flotation Devices (PFD’s)................................................................................ 28
5.11.2 Immersion Suits ............................................................................................................29
5.12 Stretcher Mode.....................................................................................................................30
5.12.1 Converting FROG-3 to Stretcher Mode (Figure 7) ........................................................30
5.12.2 Stretcher Mode Conversion Procedure ........................................................................30
5.12.3 Positioning the Stretcher ..............................................................................................32
5.12.4 3-Seat Mode Conversion Procedure............................................................................. 32
5.12.5 Stretcher (Optional) Accessory .....................................................................................33
6 PERIODIC INSPECTION, TESTING AND MAINTENANCE .................................................................34
34
6.1 Introduction ..........................................................................................................................34
6.2 Definitions.............................................................................................................................34
6.3 Frequency of Inspection, Test and Maintenance..................................................................35
6.4 Pre-Operational Visual Check ............................................................................................... 37
6.5 Visual Inspection ...................................................................................................................39
6.6 Examination ..........................................................................................................................42
6.7 Post Load Test Visual Inspection...........................................................................................46
6.8 Proof Load Testing ................................................................................................................49
6.8.1 Load Test Procedure .....................................................................................................50
6.8.2 Inspection Data Plate ....................................................................................................50
6.9 Sling Replacement and Management...................................................................................51
6.9.1 Sling Set (Critical Part) Replacement.............................................................................51
6.9.2 Sling Set Management ..................................................................................................51
6.10 Spares Kits and Replacement Parts.......................................................................................52
6.10.1 Spares Kits.....................................................................................................................53
6.10.2 All Other Replacement Parts......................................................................................... 57
6.11 Unit Replacement Recommendation....................................................................................57
7 UNIT IDENTIFICATION ...................................................................................................................58
7.1 Product ID Numbers..............................................................................................................58
7.2 Part Numbers........................................................................................................................ 58
7.3 FROG-3 Serial Numbers ........................................................................................................ 58
7.4 Component Serial Numbers.................................................................................................. 58
8 HANDLING, SHIPPING AND STORAGE ...........................................................................................59
8.1 Dimensions............................................................................................................................ 59
8.2 Handling & Transportation ...................................................................................................59
8.2.1 Forklift...........................................................................................................................59
8.2.2 Crane .............................................................................................................................59
8.2.3 Securing.........................................................................................................................59
8.2.4 Inspection......................................................................................................................59
8.2.5 Preparation for Road Transport....................................................................................60

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8.2.6 Containerisation............................................................................................................ 60
8.2.7 Storage ..........................................................................................................................61
8.2.8 Feet Deformation During Storage.................................................................................61
9 APPENDIX A –TRANSFER LOG.......................................................................................................62
10 APPENDIX B –DRAWINGS.............................................................................................................63
11 APPENDIX C –PARTS AND MATERIAL SPECIFICATIONS................................................................70
11.1 Parts ......................................................................................................................................70
11.2 Definition According to Criticality......................................................................................... 70
11.3 Fastener Specifications .........................................................................................................70
11.4 Certification...........................................................................................................................70
12 APPENDIX D –FROG-3 MARKINGS................................................................................................ 71
12.1 Essential Marking Requirements ..........................................................................................71
12.2 Decal - Vinyl Stickers - Located on Outside of Buoyancy Units.............................................72
12.3 Decal - Vinyl Stickers - Located Inside of Lower Buoyancy Units..........................................72
12.4 Decal - Operating Instructions - Located Inside of Upper Buoyancy Units........................... 72
12.5 Decal - Operating Instructions - Located on Seat Back.........................................................73
12.6 FROG-3 Column Marking Plan .............................................................................................. 74
13 APPENDIX E –ACCESSORIES.......................................................................................................... 75
Skid Trolley....................................................................................................................................75
Strobe Light...................................................................................................................................75
Stretcher (MedEvac) .....................................................................................................................75
75
Protective Cover............................................................................................................................75
75
Rigid Luggage Box .........................................................................................................................75
Multi-Lingual Operational Briefing DVD’s..................................................................................... 75
14 APPENDIX F –INDEPENDENT CERTIFICATION .............................................................................. 76
14.1 EC Type examination certificate (from unit number FS 412 onwards).................................76
14.2 ABS Product Design Assessment Certificate (from unit number FS 412 onwards) ..............77

User Manual
FROG-3
Rev 19 Page10
1INTRODUCTION
1.1 Scope
This User Manual is for the three passenger capacity FROG-3 (Model FS-01).
Note: Throughout this manual the use of this symbol “ “ denotes safety critical
information.
1.2 Introduction
The FROG-3 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-3 can accommodate a stretcher to transfer injured
personnel in a protected environment.
The FROG-3 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-3 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 tripod feet that provide shock absorption and ensure that the FROG-3
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.
Link to Index