7. MATTRESS INSTALLATION
2.2 IGO INTERNAL SAFETY TESTING DOCUMENTS
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1.0 INTRODUCTION
The purpose of this document is to provide International Grout and client with a suitable procedure to safely handle FLXMAT precast concrete mattresses. Mattresses are lifted, loaded and stacked a number of times prior to installation hence the importance of maintaining a consistent safe lifting practice.
2.0 REFERENCES
2.1 APPLICABLE CODES AND STANDARDS
The following standards are followed to ensure a safe and suitable lift is achieved onshore and offshore.
Code or Standard Title Remark
DNV Pt 2 Ch 5&6 DNV Rules for Planning and Execution of Marine Operations (1996)
Required for the design of FLXMAT lifting points.
BS EN12079-1999 Offshore containers. Design, construction, testing, inspection and marking inspection Bodies for lifting equipment.
2.2 IGO INTERNAL SAFETY TESTING DOCUMENTS
The following documents are refer a minimum requirement IGO adhere to for any Offshore piece of equipment intended for Oil Field use.
IGO Documentation Description Remark
IGO Annual Programme
for Safety Testing IGO Offshore Equipment 2.3 SPECIFIC CERTIFICATION DOCUMENTS
The following certification will be consolidated and submitted to the Client just prior to delivery or rental of each suitable installation frame.
Certification 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
IGO Lift Rope Verification
Calculation to verify lifting point conform to DNV Rules for Planning and Execution of Marine Operations (1996) – Part 2 Ch 5/6
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Proof Load (PL) Test Certificate
Non Destructive Test (NDT) to prove structures integrity and design. Also includes wire sling test certificate.
Witnessed by 3rd Party certification body Visual Inspection (VI)
Report (Installation Frame)
Overall Visual Inspection to check frame is in correct working order. Also includes wire sling visual inspection report.
Conducted by 3rd Party Inspector
Visual Inspection Report
(Rigging) Overall Visual Inspection to check
rigging is in correct working order. Conducted by 3rd Party Inspector
3.0 INSTALLATION FRAMES 3.1 HEADER FRAME
The header frame is the structural part of the lift comprising of 4 padeyes and two main longitudinal members. The longitudinal members are designed for both end and side lift applications.
3.2 RELEASE BEAMS
Release beams are interchangeable sections that enable the header frame to lift either a side or end lift mattress. They are designed for ROV and Diver release subsea. The release beam is activated by an open/close lever. The lever is always situated on the corners of the header frame.
Lower bolt/lug
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3.3 TYPES OF INSTALLATION FRAMES
International Grout have an array of Installation Frames suitable for almost any mattress sizes requested.
Installation frames are best broken into two categories.
End Lift – Release beam located either end
Side Lift – Release beam located along each side
Release beam bolted to each end
2No. Release beams bolted to each side
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3.4 MATTRESS AND FRAME ASSEMBLY
Below pictures represent the distinct difference between an “End Lift” and “Side Lift” scenario.
Above – End Lift Above – Side Lift 4.0 CERTIFICATION REQUIREMENTS
The below table outlines International Grout company standard for testing and inspecting offshore installation frames. (KEY: Y-Years, M-Months)
ITEM Frequency
Proof Load Test 6Y
Visual Inspection (Frame) 4Y Visual Inspection (Rigging) 6M
5.0 PROJECT SUPPLIED INSTALLATION FRAME
The following table represents the physical details of the designated frame(s) to be mobilized for this project.
Equip. ID End/Side Lift Total Length Total Width LPF007 SIDE 6m 3m Mattress/Frame GA Drawing: 0029-05-2010B-DWG-051210-01
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6.0 FLXMAT HANDLING PROCEDURE 6.1 PRE-EXECUTION ACTIVITES
Prior to any lift the IGO supervisor must check with the IGO Engineer that the piece is equipment is been used for the correct application. Additionally, the supervisor must check with the equipment manager that all certification is in line with Section 4.0 of this procedure. The final assembly must be in accordance to the drawing stated in Section 5.0. All cranes must be specified within their working limit.
6.2 RIGGING THE INSTALLATION FRAME
1. The selected frame is connected to crane hook via oblong link and 4 legged wire sling. Rigging Supervisor instructs crane operator to lower and place frame directly above mattress intended for relocation.
2. Once the frame comes to rest rigging personnel assist by connecting mattress lifting rope to installation frame. One end of a flat eye webbing sling is permanently fixed to the bottom lugs of the beam. The other end is threaded through the opening of the mattress and looped into the pin and guide assembly. The lever is pushed into the closed position so that all points are contained within the pin and guide assembly.
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3. All points should be doubled checked prior to giving the crane operator instructions to commence lifting the mattress. Tag lines should be place on two opposing corners to help control orientation once the mattress leaves the ground. All personnel not required for relocating the mattress should stay well clear of the task at hand. Rigging personnel are prohibited from entering directly beneath a live load under any circumstance.
6.3 DE-RIGGING THE INSTALLATION FRAME
4. When placing the mattress, the supervisor and crane operator communicate until a satisfactory position is achieved. The mattress and frame are lowered together until all webbing slings become loose. Rigging personnel open the lever release and ensure each webbing eye is completely clear from the release beam.
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5. The crane operator slowly lifts the frame. The supervisor and rigging personnel watch closely to make sure the webbing slings do not snag or catch as frame pulls away from the mattress. If snap hooks are used as opposed to the lever system care must always be taken that each link is connected and disconnected when intended.
6.4 INSTALLING MATTRESSES SUBSEA
1. Steps 1-3 of Section 6.2 shall be followed offshore when rigging installation frame on deck.
Rigging team should additionally check that safety pin is engaged prior to over boarding each mattress. The safety pin ensures that the release beams cannot become loose at any stage of the installation.
2. Frame shall have two locating beacons (one at each end) to aid placing the frame subsea. Beacons should be place well inside frame exterior in case of impact during over boarding and recovery.
3. The lever on each corner shall have a floating monkey’s fist to assist ROV/diver locating and pulling lever when the time comes. Once the installation team correctly place the mattress at the intended location the ROV/Diver is instructed to open the safety pin and release the mattress.
4. ROV/Diver must check that all webbing slings are loose with no weight acting on them before given approval to commence recovery. As the frame slowly pull away from the mattress the ROV/Diver must constantly monitor that the webbing slings are clear of all obstructions and potential snagging points.
5. The frame is recovered and placed on the next mattress for installation and the process continues.
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6.5 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 handling FLXMAT. 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 handling concrete mattresses.
Activity Minimum PPE Requirement
FLXMAT Handling Covered steel capped boots, eye protection, coveralls, gloves and sun protection, gloves and hardhat
6.6 FLXMAT WEIGHING PROCEDURE
At the time of moving or loading out FLXMAT the crane which has a computerised load cell will record the individual weight of each mattress lifted. For instances where crane does not have accurate load cell and external dedicated load cell will be installed between the lifting hook and sling’s master link to record mattress weights. Each mattress serial number including weight will be tabulated in a report and included within the Manufacturer Record Book (MRB).
7.0 INSTALLATION FRAME DELIVERABLES
The following documents are included within the Manufacturer Record Book (MBR) Manufacturer Record Book
4.0 FLXMAT Rigging and Installation Procedure Approved Final 5.0 Installation Frame Certification
5.1 Proof Load Test Certificate (Frame and Wire Sling) Info 5.2 Visual Inspection (Frame and Wire Sling) Info 5.3 Visual Inspection (Rigging – Soft Slings) Info