7. MATTRESS INSTALLATION
2.1 APPLICABLE CODES AND STANDARDS
Execution Plan
Page: 2
1.0 INTRODUCTION
The purpose of this document is to provide International Grout Operations with a suitable procedure to cover all necessary standards, specifications and methodologies required to successfully manufacture FLXMAT (pre-cast concrete mattress) to client specification.
2.0 REFERENCES
2.1 APPLICABLE CODES AND STANDARDS
FLXMAT may be used to provide support or stabilisation to the subsea pipelines or other locations or instances described in the project specific scope of work. The necessary standards to be used in conjunction with the fabrication of the mattresses are given below:
Code or Standard Title Remark
BS 1881 Pt 108 Methods for Testing Concrete Method of Making Test Cubes from Fresh
Concrete Followed by CONMIX LTD
BS 1881 Pt 111 Methods for Testing Concrete Method of Normal Curing of Test
Specimens (20ºC Method) Followed by CONMIX LTD
BS 1881 Pt 116 Methods for Testing Concrete Method for Determination of the
Compressive Strength of Concrete Cubes Followed by CONMIX LTD BS 4027 Specification for Sulphate Resisting
Portland Cement Followed by CONMIX LTD
BS 5328 Methods for Specifying concrete
including Ready Mixed Concrete Followed by CONMIX LTD ASTM C33 Specification for Concrete Aggregates Followed by CONMIX LTD ASTM C39 Test Method for Compressive
Strength of Cylindrical Concrete
Specimens Followed by CONMIX LTD
ASTM C150 Specification for Portland Cement Followed by CONMIX LTD
Execution Plan
Page: 3
2.2 INTERNAL QA/QC DOCUMENTS
Quality Assurance is overseen on site by an experienced International Grout Operations representative throughout the duration of the project. The Supervisor will ensure the correct Quality Checks have been made to each individual mattress guaranteeing the final product matches client request stated within the purchase agreement.
IGO Documentation Description Remark
IGO DPR Daily Progress Report Daily event recordings onsite IGO ITP Inspection Test Plan – Project
Specific
IGO QAQC Plan QR1 – Quality Report 1 (Assembly checklist) QR2 – Quality Report 2 (Casting checklist)
2.3 PROJECT SPECIFIC ENGINEERING DOCUMENTS
FLXMAT Engineering is conducted in house using International Grout Operations Engineers. Mattress design and Engineering is always complete and agreed with client prior to construction commencement.
The following documentation refers to client requested specific engineering requirements.
IGO Documentation Description Remark
FLXMAT Construction
Approved FLXMAT drawing for construction
Construction does not commence until client has approved final design.
See ITP for more details
IGO Lift Rope Verification FLX LIFT
Calculation to verify lifting point conform to DNV Rules for Planning and Execution of Marine Operations (1996) – Part 2 Ch 5/6
2.4 EXTERNAL CERTIFICATION AND DOCUMENTATION
FLXMAT is made from 3 main components (HDPE Mould, PP Rope and Concrete). Rope Mill Test Certification is very important so that International Grout Operations Engineers can verify the correct rope has been used according to DNV Pt2, Ch5. Polypropylene Rope is purchased specifically for each project from an approved vendor. Similarly, concrete is purchased and delivered onsite by preferred supplier. Delivery dockets are collect by the supervisor and recorded. Concrete compressive strength tests are conducted at vendor’s laboratory. Final results from laboratory tests are sent to International Grout Operations and filled accordingly. The following summarises relevant external documents
Execution Plan
Page: 4
Document Description Remark
Polypropylene Mill Test Certificate
Certificate that proves a specific rope diameter Minimum Breaking Load (MBL)
Required to ensure FLXMAT lifting rope conform to DNV Pt2, Ch5
Concrete Mix Design
1 page document that includes all relevant properties including strength, type of cement, slump aggregate size etc..
Mix design is required to be pre-approved by client prior to commencement of FLXMAT casting.
Concrete Delivery Dockets Delivery receipt to confirm grade and volume of concrete entering site.
Compressive Strength Tests
A test conducted whereby sampled cylinders are cast and crushed at certain period of curing.
See Section 2.1 for applicable codes and standards for testing.
3.0 SCOPE OF WORKS
The following table represents the physical requirements for each type of FLXMAT to be constructed.
FLXMAT Qty End/Side
Lift Long.
Rope Ø Lat.
Rope Ø Concrete
Mix Drawing Ref
6x4x0.5m 30 END 22mm 16mm C13DNS
0029-05-2010B- DWG-071110-01-REVA
5x3x0.3m 23 SIDE 16mm 16mm C13DNS
0029-05-2010B- DWG-071110-01-REVC
4.0 FLXMAT MANUFACTURE ACTIVITIES 4.1 PRE-EXECUTION ACTIVITES
Prior to the execution program the final design and price is agreed upon and a purchase order is received by International Grout Operations outlining a date for completion or mattress delivery. The project manager will then organise freight of components (if necessary) schedule a starting date. An experienced supervisor is nominated and sent to location for site establishment. Work will continue to finalise all relevant documentation necessary to commence work according to International Grout Operations quality procedure.
Execution Plan
Page: 5
4.2 SITE ESTABLISHMENT
Upon the supervisor arriving to site a project brief is given from the project manager outlining the scope of works. All approved documentation is given to the supervisor in order to commence the fabrication according to this Execution Plan. The supervisor will firstly check all stock numbers of shells, clips and rope to ensure there are enough quantities of each to complete the order. If the quantities are incorrect the Supervisor will alert the Project Manager immediately to rectify the situation. The supervisor should have the following items in mind when initially setting up site.
Suitable area for FLXMAT Assembly
o Select shaded or enclosed area if possible (avoids heat exhaustion)
o Select high ground is possible (avoids potential flooding, which is uncomfortable to staff) o Enable forklift entrance/exit if possible (reduces heavy man handling of objects)
Suitable area for FLXMAT Casting
o Fall of land when considering flooding (water must run away from work area) o Monitor unsettled dust during windy conditions (risk of eye injury to staff) o Avoid any rocky outcrop or remove if possible (reduces the risk of trip hazards)
o Sufficient room for concrete trucks entering/exiting site (traffic management and safety) 4.3 FLXMAT ASSEMBLY
Following points refer to assembling each mattress up until casting.
1. FLXMAT shells are laid out and clipped together either on ground level or on specially built clipping tables.
2. The bottom half of the mattress is clipped together until the length and width match that of the construction drawing.
Execution Plan
Page: 6
3. Lateral and longitudinal ropes are pre-cut to determined length as noted on the construction drawing.
4. Lateral and longitudinal ropes are installed throughout the bottom half of the clipped mattress according the roping detail shown on construction drawing.
5. Lifting ropes are set to designed length as per construction drawing. Perimeter top shells are fastened first in order to contain rope lattice.
6. Rope ends are terminated using an open splice which should always be positioned toward the centre of the mattress and centre of shell. If design includes edge lift ropes then these should be installed as per instruction noted on mattress construction drawing.
7. Once all longitudinal and lateral ropes are tight remaining central blocks are clipped together to complete the mattress.
Shells must be positioned carefully to locate each clip’s top half ensuring a positive connection.
8. The mattress is then lifted and relocated to the casting area via folk lift or a team of men. The mattress is carefully positioned on polythene sheet. The newly laid mattress is inspected and undergoes QR1 (Quality Record 1). QR1 is a set of quality checks required to be carried out prior to casting each mattress. On approval of QR1 the assembled mattress is clearly marked according to Section 5.4.
Execution Plan
Page: 7
4.4 FLXMAT CASTING
1. Concrete is ordered by Supervisor ensuring the correct mix design is conveyed to the nominated vendor. The quantity is calculated based on the number of empty mattresses anticipated to be cast.
2. The concreting team prepare the initial casting location with shovels, trowels, vibrators, wheelbarrows, shadow boards and buckets.
3. The concrete truck is directed to drive alongside the assembled mattresses with chute full extended to aid filling distant blocks. The shadow boards mask all areas not requiring concrete guiding flow directly into each block.
4. Each mattress block is vibrated until full and no additional settlement is noticed.
5. Shadow boards are continually relocated as the process moves forward allowing the finishing team to trowel off the newly filled mattress and wash down any excess concrete. Lifting rope shall be washed free of any concrete spillage.
6. The mattress should be allowed to cure for a minimum of 3 days prior to lifting or confirmation of min. 14 MPa strength.
Execution Plan
Page: 8
4.5 FLXMAT STORAGE AND HANDLING
1. Mattresses are only lifted with a suitable lifting frame of known capacity. Prior to lifting the supervisor will check with International Grout Operations Engineering that nominated frame and rigging is suitable to lift cured mattresses.
4.6 ONSITE SAFETY REQUIREMENTS
All personnel shall attend any required site induction program to become familiar with the site and client method of operation. Personnel shall comply with all client rules and regulations. Company equipment includes a comprehensive first aid kit. Personnel will be briefed during the initial site induction on the hazards of manufacturing FLXMAT and handling cement products. The IGO supervisor will be responsible for site safety and conduct regular toolbox meetings with all personnel
The following PPE (Personal Protective Equipment) is required for the 3 Manufacturing activities outlined above.
Manufacturing
Activity Minimum PPE Requirement Optional
FLXMAT Assembly Covered steel capped boots, coveralls and sun protection. Gloves FLXMAT Casting Covered steel capped boots, eye protection, coveralls,
gloves and sun protection and gloves Hardhat FLXMAT Handling Covered steel capped boots, eye protection, coveralls,
gloves and sun protection, gloves and hardhat 5.0 FLXMAT QA/QC ACTIVITIES
5.1 FLXMAT QUALITY PROCEDURE
Prior to commencement of manufacturing (PRE-EXECUTION) the following documentation must be approved by client.
Inspection Test Plan
Mattress Construction Drawing
Lift Rope Verification
Execution Plan
Rope Certification
Concrete mix design
Execution Plan
Page: 9
During assembly and casting activities the quality of FLXMAT is built around the ongoing surveillance of the below documents. Project activities are monitored by International Grout Operations and/or Client depending on the rank of the inspection surveillance code listed within the approved ITP.
QR1 (Quality Record 1)
QR2 (Quality Record 2)
Daily Progress Report (DPR)
Concrete delivery docket
Concrete Compressive Strength Results
As-Built weight records
In summary to maintain an organised quality program the following chart describes the simple process.
Approve and file
5.2 FLXMAT CONCRETE TESTING
Concrete vendor will take 12No. test cubes each day from random trucks delivered to casting yard (6No.
cubes are allocated for each 7 day and 28 day tests respectively). All test cube samples are taken at the batching plant and stored in the dedicated laboratory where all testing is performed.
5.3 FLXMAT MARKING PROCEDURE
Each precast concrete mattress shall be permanently marked with the following data:
Individual Serial Number
Contract Number
Execution Plan
Page: 10
6.0 INSPECTION AND REPAIR PROCEDURE
During assembly of the mattresses all shells and clips are inspected for faults. If a shell has any cracks or is deficient they are immediately discarded, and similarly clips are discarded if they are deficient. Any clips that are not holding shells together satisfactorily are reinforced with screws.
After casting all mattresses are inspected by the International Grout Operations site supervisor and the inspection details are recorded within QR1. The mattresses are checked for any casting deficiencies that may compromise integrity. If after curing the mattress integrity is found to be affected or faults exist that impinge safe handling or risk mattress longevity, it will be discarded immediately.
7.0 FLXMAT DELIVERABLES
The following documents make up and complete the Manufacturer Record Book (MBR) Manufacturer Record Book
1.0 FLXMAT Execution Plan
2.0 FLXMAT QA/QC Records
2.1 Signed ITP
2.2 Compiled QR1 (Quality Report 1)
2.3 Compiled QR2 (Quality Report 2)
2.4 Concrete Delivery Dockets
2.5 Concrete Compressive Strength Test Results
2.6 As-Built Weight Records
2.7 Onsite Daily Progress Reports (DPR)
3.0 FLXMAT Engineering
3.1 Concrete Mix Design
3.2 Mattress Construction Drawings
3.3 Lift Rope Verification
4.0 FLXMAT Rigging and Installation Procedure
5.0 FLXMAT Brochure
MATTRESS LIFTING ROPE VERIFICATION FLX-ENG-LIFT
The following calculations assess the mattress rope MBL for offshore lifting and are completed in accordance with DNV Rules for Planning and Execution of Marine Operations (1996) - Part 5&6
Variables: Remark
Load Factor [γf] Assume 1.3
Consequence Factor [γc] Assumed 1.3 whereby sling failure would not incur a total loss Splicing/Bending Factor [γr] Assumed 1.0 when splice consumed in concrete block
Wear Factor [γw] Assume 1.0
Material Factor [γm] Assume 3.0 for fibrous rope
Maximum Breaking Load [MBLActual] Actual Maximum Breaking Load of the rope supplied Methodology:
The minimum required MBL is calculated by the following:
MBL required = Maximum Dynamic Rope Load x Nominal Safety Factor
Maximum Dynamic Rope Load is back calculated from rope properties and lift geometry Dynamic load = (Mattress mass [MT] x DAF x Skew load) Nominal Safety Factor [γst]
- γst = γc.γr.γw.γm.γf
Finally for the lifting rope to be safe the following equation must be satisfied 53No. 6x4x0.3m Concrete Mats
Factor of Safety [FOS] ≥ MBLSpecified / MBLRequired Calculation:
Concrete Density [ρc] 2400 kg/m3 Total Submerged Mass [MSUB] 6.23 t
Concrete Grade (Min) 40 MPa Lift Rope Particulars
Nominal Safety Factor 5.070
Lift Rope Properties
Type of Rope Lifting Particulars
Diameter of Rope [Dr] 22 mm Dynamic load 23.13 t
Angle of Sling [θs] 20 ° Required MBL 3.66 t
Consequence Factor [γc] 1.3 FOS (Over Designed by-) 1.856 PASS
Splicing/Bending Factor [γr] 1.0
Wear Factor [γw] 1.0
Material Factor [γm] 3.0
Load Factor [γf] 1.3
Breaking Load [MBLActual] 6.8 Te
Lifting Properties
Dynamic Amplification Factor [DAF] 2.00
7/11/2010 JD
FOROOZAN
Development Operations & Production Enhancement
Crossing Installation Procedure For Export Pipeline
Document Number
Sheet NO.
Page 18 of 23
Project Facility Discipline Document Sequence Revision
FE560 GEXP PL PR 1727 D0
Attachment 3: GERIMAL SPECIFICATION
Halani International Ltd
.DSV Gerimal
Particulars given are entirely without warranty as to correctness and interested parties must satisfy themselves by inspection of the vessel
PRINCIPAL PARTICULARS
Registry : Kingstown St. Vincent Call Sign : J8B3528
Official No. : 10001
Year Built : 1981-Refurbished in Aug 2007 Class : American Bureau of Shipping Notation : ?A1, ?AMS, ?DPS-2
Type : Diving Support /accommodation 76 Pax Vessel Class No. : 8125016
IMO No. : 7932240 Hull No. : 837
Flag : St. Vincent & Grenadines, Kingstowns
DIMENSION
Transverse T Thruster, TT 1300, 500KW. electric drive, 485kW Stern 2nos:-2 x Kamewa Ulstein Transverse, TT 1300, 500KW
PERFORMANCE
Fixed System in E/R: C02 Firemain : 2”
Fire Detection Sys. : Heat & Smoke detectors Fireman’s Outfit : 4 nos Satellite Comms : FLEET 77
Tel – 00873 761155141 Fax –00873 761155142 Satellite EPIRB : 1 X McMURDO E-3
SART :2McMURDO RT9-3
VHF Radio : 3 x Sailor Compact Rt2048 Portable VHF Radio : 6 x Motorola GP 340 : 3 x ICOM IC GM 1500E
Magnetic Compass : Saura keiki
AIS :JRC KHS 182 Ballast/Drill Water : 473.9 M3 Freezer : 10 m3 Chiller : 9.5 m3
Mud : Delete
DP2 DYNAMIC POSITIONING SYSTEM
DP System : KPOS DP 21, Dynamic Positioning System KPOS-2 3 Gyro compass 2Wind Sensor 3MRU 2DGPS 2UPS 1 LW TAUTWIRE MK15 1 HIPAP – 450 2K-POS – OS 2 JOY-OT C WING - OT
Halani International Ltd
..DSV Gerimal
Particulars given are entirely without warranty as to correctness and interested parties must satisfy themselves by inspection of the vessel DECK EQUIPMENT
Windlass : IP 66 / IM 10001 Anchor : 2 x 1.18t
Anchor Chain : 9 shackles each side Main Crane : 40t @ 5.5 m 18t @ 9.0m 6.5t @ 20.0m 4.7t @ 24.0m Auxiliary Crane : 0.5t Gangway : 1 Nos
LIFE SAVING APPLIANCE Search Lights : 3 nos Floodlights : 2 x overboard Liferafts : 4 x 45 persons
6 x 25 persons
Lifebuoys :12Ring Buoys with smoke floats and signal lights Life jackets : 150 Ncs
Rescue boat : 1 x Watercraft R-5 Air Breathing App : 4 nos
EEBD : 6 nos
Parachute Distress : 12 Smoke Signal : 6
FOROOZAN
Development Operations & Production Enhancement
Crossing Installation Procedure For Export Pipeline
Document Number
Sheet NO.
Page 19 of 23
Project Facility Discipline Document Sequence Revision
FE560 GEXP PL PR 1727 D0
Attachment 4: CRANE CHART
13
Counterweight: 53.0 t, Carbody weight: 10.0 t
Note:
Ratings according to EN13000.
Ratings shown in are determined by the strength of the boom or other structural components.
Refer to notes P12.
FOROOZAN
Development Operations & Production Enhancement
Crossing Installation Procedure For Export Pipeline
Document Number
Sheet NO.
Page 20 of 23
Project Facility Discipline Document Sequence Revision
FE560 GEXP PL PR 1727 D0
Attachment 5: DIVING PROCEDURE
SAT DHRUV
12 MEN SATURATION DIVING SYSTEM
SPECIFICATION
SAT DHRUV 2 12 MEN Saturation Diving System Specification
TABLE OF CONTENTS PAGE
General Description 3 Summary of the Module Inventory 3
Diving System Components 4 1. Three Men Diving Bell 4 2. Single Lock Decompression Chamber (4-man) DDC-013 5 3. Single Lock Decompression Chamber (6-man) DDC-021 6 4. Single Lock Hyperbaric rescue Chamber (12-man) HRC 6 5. Single Lock TUP Chamber with four spool connection doors 7 6. Environmental Control System (in Life Support Equipment Container) 8 7. Hot Water System-electric (in Life Support Equipment Container) 8
8. Saturation Control Container 9
9. Bell Dive Control Container 9
10. Electrical Distribution Panel (in Sat/Bell Container) 9
11. HRC Trunk 9
12. Potable Water System (in Life Support Equipment Container) 10
13. Umbilical Module 10
14. Spool Piece between Chambers (DDC013 & DDC 021) 10
15. Spool Piece between TUP & Chamber (DDC 013) 10
16. Spool Piece between HRC & TUP 10
17. Spool Piece TUP to Diving Bell mating clamp 10
18. Sanitary System 11
19. ‘A’ Frame Assembly 11
20. Clump Weight System 11
21. Hydraulic Bell Winch 11
22. Newly build Hydraulic Power Pack Module 11
23. Main Bell Umbilical Power Sheave 12
24. Workshop/Spares Container 12
25. HRC Control Van 12
26. Certification 12
SAT DHRUV 3 12 MEN Saturation Diving System Specification
General Description
The saturation diving system is of modular construction, meaning that the major components of the diving system are built into individual crash frames which will also allow the system to be configured in different configurations to make maximum use of the space available on the barge or proposed dive ship. The saturation diving complex and associated equipment is capable of supporting a 12 man diving team in 1 x 4 plus, 1 x 3 man bunk &12 sitting HRC & 1 x 6 men chambers to a maximum working depth of 200 meters. The design and certification for the diving system will be for a maximum design pressure of 200 meters.
The diving bell will be equipped for three divers. It will be used for saturation mode only. The bell has one side mating position. The bell will be handled by a simple ‘A’
Frame assembly, with two hydraulic rams and the trolley will bring the bell in to the side mating position. For deployment, the bell will be trolley out and will be hoisted in to the catcher deployment system, the ‘A’ Frame will be boomed out to the launch position.
The handling system for the bell will also incorporate a hydraulic bell winch and a Hydraulic driven clump weight winch. The hydraulic main bell winch will be the primary means of recovery and deployment. This will use the hydraulic motor as the primary means of operating the winch and the air motor will be the secondary means of operating the winch and the clump weight winch will act as another means of recovery. The operation of the hydraulic handling system and winches will be from the hydraulic control consul, which is situated on top of the living chamber (DDC 013) Skid package.
Summary of the Module Inventory
1. Single Lock Decompression Chamber (4-man) DDC 013 2. 6 Man Living Come Out Chamber (DDC023)
3. Diving Bell (3 man)
4. 12 x Man Hyperbaric Rescue Chamber with (1 x 3 bunk) living chamber (HRC)
5. TUP (Transfers under pressure) with spool four doors for chambers connection.
6. Four Environmental Control System (in Life Support Equipment Container) 7. Two Hot Water System-electric (in Life Support Equipment Container)
8. Saturation Control container with Potable Water System hot & cold water supply to all chambers.
9. Bell Dive Control Container with client office.
10. Bell Umbilical Basket C/W 250m new Main bell umbilical 11. Electrical Distribution Panel (in Sat / Bell dive Container) 12. HRC Trunk on TUP
13. Bell mating trunk on TUP.
14. DDC-013 mating trunk on TUP.
15. DDC-021 mating trunk on DDC-013.
16. Sanitary System
17. ‘A’ Frame Assembly with bell trolley assembly.
18. Clump Weight System
19. Hydraulic Bell Winch
SAT DHRUV 4 12 MEN Saturation Diving System Specification
20. Hydraulic Power Pack Module
21. Main Bell Umbilical hyd. Power Sheave 22. Hydraulic clump weight winch.
23. Workshop/Store Spares container
24. Secondary Divers Hot water unit diesel powered 25. HRC control unit with chillier unite
26. Life Support Equipment Container Transit frame
Diving System Components
1. Three Men Diving Bell
The diving bell will be equipped for three divers. It will be used for saturation mode only. The bell has one side mating position. The bell will be handled by a simple ‘A’
Frame assembly with two hydraulic rams and the trolley will bring the bell in to the
side mating position.
SAT DHRUV 5 12 MEN Saturation Diving System Specification