DOCUMENT CONTROL SHEET

GUIDELINES FOR MARINE OPERATIONS

Loadout

May 2003

Rev.

Date

Reformatted version of original document

Reason For Issue

VK

DB

AJS

Author Checked Approved

LOC Doc. Title

Loadout

LOC Ref No.

LOCG-GEN-Guideline-001

LOC Field

Marine Operations Guidelines

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Loadout

LOCG-GEN-Guideline-001 Rev. 0

TABLE OF CONTENTS
PAGE
1.

2.

3.

4.

INTRODUCTION

1.1. Scope of Guidelines

1.2. Definitions

1.3. Reference Documents

1.4. Certificates of Approval

PLANNING OF OPERATIONS

2.1. General

2.2. Loadout Manual

2.3. Safety Procedures and Contingency Plans

2.4. Site Surveys

2.5. Anchoring, Mooring and Fendering

2.6. Environmental Criteria

2.7. Weather Forecasting and Environmental Monitoring

LOADS AND ANALYSIS

3.1. General

3.2. Weight and Weight Distribution

3.3. Stability Requirements

3.4. Skidding Loads

3.5. Skew and Deformation Loads

3.6. Load Factors

SYSTEMS AND EQUIPMENT

11

4.1. General

11

4.2. Jacking Systems and Winches

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4.3. Multi-Wheel Trailers

11

4.4. Lifted Loadouts

12

4.5. Barge and Ballast System

13

4.6. Power Supply

13

4.7. Grillage and Seafastenings

14

OPERATIONAL REQUIREMENTS

15

5.1. General

15

5.2. Operational Recording

15

5.3. Barge or Vessel Handling

15

5.4. Testing and Measuring

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LOCG-GEN-Guideline-001 Rev. 0

INTRODUCTION

1.1.

Scope of Guidelines

1.1.1

These guidelines are a basis for the planning, design and operational aspects of
loadouts, which are subject to approval by a Marine Warranty Surveyor. The purpose of
them is to specify appropriate standards, based on sound engineering and good marine
practice, in order to ensure that the loadout procedure at all times meets an acceptable
level of safety.

1.1.2

The guidelines are based on experience over the large number of previous projects.
However, as knowledge advances in specific areas, it is recognized that these
guidelines may need to be modified to meet alternative or new proposed methods of
operation. The general criteria is that the overall level of safety should not be reduced by
the introduction of novel or alternative proposals.

1.1.3

The Marine Warranty Surveyor will review and comment on all relevant specifications,
proposed loadout or load-off reports and procedures, choice of systems and equipment.
Information shall be made available to the MWS in sufficient time to enable completion
of these reviews well before the planned operations.

1.2.

Definitions

1.2.1

Loadout Contractor: the company responsible for a loadout of a cargo onto a barge or
vessel, or a load-off of a cargo from a barge or vessel.

1.2.2

MWS: Marine Warranty Surveyor and/or Marine Warranty Survey Company.

1.2.3

Module: A unit of cargo such as a jacket, integrated deck, topside components, preassembled units, items of equipment or parts thereof.

1.2.4

Contingency Plan: Pre-considered response to a deviation from an intended course of

action.

1.2.5

Grillage: The temporary structural members that support the Module and distributes the
vertical static and dynamic loads over the barge or vessel framing.

1.2.6

Seafastenings: Shall in general mean the temporary structures or tie-downs that secure
the module for transportation and berthing forces.

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1.2.7

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Skidded Loadout: The module is pushed (by jacks) or pulled (by winches) onto a barge
or vessel, supported on a skid way.

1.2.8

Trailer Loadout: The module is supported on multi-wheel trailers for the movement onto
the barge. The trailers may be self-propelled or may be pushed or pulled onto the barge.

1.2.9

Lifted Loadout: The module is lifted onto a barge.

1.3.

Reference Documents

1.3.1

The MWS review of technical documents will include checks to current editions of
relevant national standard or codes.

1.4.

Certificates of Approval

1.4.1

A Certificate of Approval will be issued on site, immediately prior to the operation, by the
attending representative of the MWS when he is satisfied that the preparations for the
loadout are complete and that the weather forecast is satisfactory.

1.4.2

As a pre-requisite to the issue of a Certificate of Approval the associated calculations

and operations manual are to be reviewed and approved by the MWS well before the
planned start of operations.

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PLANNING OF OPERATIONS

2.1.

General

2.1.1

A comprehensive loadout manual shall be prepared by the Loadout Contractor and

issued for review and approval by the MWS. This shall be submitted in sufficient time for
MWS to comment on it and for any resulting amendments to be incorporated in the
manual and put into effect prior to the loadout operation itself. An engineering manual,
which covers the structural analysis of the module and the loadout supporting system,
shall also be prepared.

2.1.2

All planning shall be based, where possible, on the assumption that it may be necessary
to interrupt or reverse the operation.

2.1.3

The planning shall be based on the use of well-proven principles, techniques, systems
and equipment to ensure acceptable health and safety levels and prevent loss of human
lives and major economic losses.

2.2.

Loadout Manual

2.2.1

The loadout manual shall include a description of the procedure to be adopted and
details of the equipment to be used for the operation.

2.2.2

Information and details of the following items shall be included:

Loadout Procedure

Schedule

Description of the Module including weight and center of gravity

Organization and communication

Site information

Environmental criteria and weather forecasting procedure.

Water depth, tide tables and current speed data

Loadout equipment, such as

Trailer type, number, capacity and ground bearing load
Pulling and retrieval winch systems
Hydraulic push/pull systems
Crane type, crane radius curve
Lift rigging details and certification

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Ballast pump type, number, capacity and arrangement

Link spans/bridging ramp

Description of barge/vessel, grillage and seafastening

Barge/vessel movements and procedures

Mooring arrangements before, during and after load out

Fender details

Recording and monitoring procedures including monitoring of barge heel and trim during
loadout

Module set down and shimming requirements

Barge ballast and trim for welding of seafastenings

Check lists

Contingency plans

Safety procedures

Calculations for relevant items, such as:

Strength of skid way on land
Pulling winch arrangement capacity and anchor point capacity
Trailer axle and wheel loading and ground capacity
Quay strength
Link span/bridging ramp
Ballasting of barge
Mooring capacity and limiting environmental criteria
Structural strength of module and any temporary loadout beams
Lifting point and lift rigging design

2.2.3

Associated Drawings
The schedule which is included in the loadout manual shall clearly show the timing of the
loadout and ballasting operations, related to tidal variations, including identification of
points which may be critical in event of a late start or delays during loadout.

2.2.4

The schedule shall also include reference to the time taken to secure the seafastenings
on completion of loadout and to the actions to be taken thereafter.

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2.3.

Safety Procedures and Contingency Plans

2.3.1

Safety procedures shall be developed and included in the loadout manual. The manual
shall also address any possible need to deviate from the established procedures.
Contingency plans shall be included in the manual, detailing the actions to be taken in
the event of the equipment failure, deterioration in weather conditions and any other
unforeseen delays and relevant considerations.

2.3.2

The organogram shall clearly show the line of communications between the parties
involved in the loadout. The people responsible for deciding to commence or halt a
loadout shall be clearly shown.

2.4.

Site Surveys

2.4.1

The loadout route at the fabrication site shall be documented by drawings, civil
engineering data and calculations to verify that the capacity along the route is sufficient
to resist the anticipated loads.

2.4.2

The seabed at the loadout quay shall be surveyed prior to loadout to ensure sufficient
under keel clearance exists, both during and after loadout, and that no obstructions exist
which will interfere with the operations. A minimum underkeel clearance of 0.5m shall
be maintained at all times. The effects of silting shall be considered and the sounding
charts shall be clearly marked with the date when the survey was undertaken. The
number of sounding points shall be sufficient to give adequate definition and to ensure
that any high spots have been identified. The effects of abnormally low tides, swell and
barometric pressure shall be taken into account.

2.4.3

All elevations shall refer to Lowest Astronomical Tide (LAT) as well as any local datum.

2.5.

Anchoring, Mooring and Fendering

2.5.1

During loadout, the barge or vessel shall be held in position by moorings that are
designed to hold the barge in position in the extreme wind, current and wave conditions
anticipated during the operation. A specification of the mooring arrangement and all the
equipment shall be included in the loadout manual. Generally, polypropylene or nylon
ropes will not be acceptable as part of the positioning mooring system unless used as a
contingency.

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2.5.2

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The calculated maximum loads in the mooring wires, blocks, bollards and other rigging
shall not exceed the safe working load (SWL) of any component.

2.5.3

The pulling and holding capacities of any mooring winches shall be clearly stated; the
holding capacities must be at least 10% greater than the calculated maximum applied
loads. The strength of the foundations of the winches shall also be documented.

2.5.4

In general, the use of anchors should be avoided. However, if anchors are necessary in
the mooring arrangement, they shall be set and tested prior to loadout. The test load
shall be at least 1.25 times the calculated maximum applied load for that particular
mooring line, in both the intact and one line broken case. Procedures for testing shall be
proposed by the Loadout Contractor for approval by the MWS.

2.5.5

A sufficient number of fenders in good condition shall be provided to prevent damage

arising from contact between the barge or vessel and the quayside.

2.5.6

The barge or vessel shall not be moved from the loadout position after loadout until
sufficient seafastenings have been installed. See also Section 4.7.

2.5.7

After the loadout has been completed and initial seafastenings have been installed, the
barge or vessel shall be moored safely until sailaway. The moorings in the post loadout
position shall be designed to withstand the 10-year return period extreme environmental
conditions with any one line broken.

2.6.

Environmental Criteria

2.6.1

Limiting wind speeds and wave heights for the loadout operation shall be defined and
agreed in order to ensure the safety of the proposed operation. The choice of limiting
conditions will depend on several parameters, such as the site, the duration of the
operation, tidal range and the type of loadout being performed. If the loadout quay is
sheltered the effect of waves may be considered to be negligible.

The possible

exposure of the loadout quay to long period swell waves should be considered.
2.6.2

Generally, for trailer or skidded loadouts the limiting forecasted wind speed should be
Beaufort Force 5 (equivalent to 10 m/s). The forecast shall be of a duration which is
equal to the planned length of the operation plus allowances for contingencies and, if
applicable, moving the barge to a safe mooring after load out.
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2.6.3

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For lifted loadouts other values may be appropriate, depending on the equipment to be
used.

2.7.

Weather Forecasting and Environmental Monitoring

2.7.1

Prior to commencement of loadout, a favorable weather forecast shall be obtained from

a recognized meteorological agency. The forecast shall be of sufficient duration to cover
the loadout installation of initial seafastenings and, if applicable, movement of the barge
to a safe mooring.

2.7.2

Weather forecasts shall be obtained at 12-hour intervals for all the duration of the
operations.

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LOADS AND ANALYSIS

3.1.

General

3.1.1

The stresses and deformations of the module and any temporary supporting structure
during loadout shall be shown to be in accordance with appropriate Standards or Codes
of Practice such as those given in section 1.3. Wherever possible, the design should be
carried out to the requirements of one code only.

3.1.2

Calculations demonstrating the integrity of the barge or vessel shall be prepared for
each critical stage of the loadout of the module.

3.1.3

For grounded or skidded loadouts the strength of the barge or vessel, in particular the
longitudinal bulkheads, shall be documented.

3.1.4

The grillage design and layout shall take account of any limitations imposed by the
loadout method.

3.2.

Weight and Weight Distribution

3.2.1

The loadout arrangement shall be based on the best estimate of weight, derived from
the weight control system. Final load distribution into the loadout support structures or
hydraulic trailers should be confirmed after module weighing, prior to loadout.

3.2.2

At the planning stage suitable contingencies shall be added to allow for variations in
weight and center of gravity position. The following values may be used:

Weight contingency: 10 %

Shift of centre of gravity: longitudinal: 1.0m, transverse: 0.5m

3.3.

Stability Requirements

3.3.1

During loadout the barge or vessel onto which the module is loaded shall have a
minimum value of metacentric height (GM) of l.0m.

3.3.2

The barge or vessel shall have a minimum freeboard of 0.5 meters. Where there is a
risk of waves coming on deck, open manholes shall be protected by upstands (tophats)
or other means to prevent the possibility of down flooding.

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3.4.

Skidding Loads

3.4.1

Skidding loads are the loads required to move the module, and may result from friction,
inertia and the slope of the skidding or rolling surface.

3.4.2

The values used for friction coefficients shall be proposed by the Loadout Contractor and
documented where necessary by test results or previous experience.

3.5.

Skew and Deformation Loads

3.5.1

If the module is supported at more than three points without any load equalization
system, the module may be skewed (i.e. deformed).

3.5.2

Vertical skew or deformation loads shall be computed taking account of the following
items as appropriate:

The stiffness of the Module and its supporting structure

Skidway tolerances

Movements of the barge or vessel (heel and trim)

Settlement of the ground

3.5.3

Horizontal skew loads may also be generated if the prime mover loads are applied
asymmetrically about the module centerline e.g. where one winch fails during a skidded
loadout and the loadout continues with one winch only.

3.5.4

The module structure and temporary loadout beams shall be checked for horizontal
skew loads taking account of the following items as appropriate:

The stiffness of the module and its supporting structure

Break-out friction forces

Rolling friction

Drag forces from non-self propelled trailers

Pulling forces from winches

3.6.

Load Factors

3.6.1

Where a Load and Resistance Factor Design (LRFD) method is used the following
LRFD load factors shall be used for load out:

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Gravitational:

1.3

Deformation:

1.0

Skew:

1.0

3.6.2

The use of the load factors of 1.0 for the deformation and skew cases requires that the
operational procedures followed during loadout are such as to ensure that the
deflections assumed in the structural analysis are not exceeded in practice.

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SYSTEMS AND EQUIPMENT

4.1.

General

4.1.1

All equipment used should be in good condition and well maintained. It will be inspected
by the MWS representative prior to issue of Certificate of Approval.

4.1.2

The equipment used shall be in accordance with the manufacturer's operating

procedures and specified safe working loads and in compliance with relevant codes and
practices.

4.1.3

A braking system, capable of arresting module movement is required at all stages of the
loadout.

4.1.4

A pull back system, which can retrieve the module in a contingency situation, shall be
provided unless it can be demonstrated that, with the module partly onboard, the barge
can be kept level with the quay through a complete tidal cycle.

4.2.

Jacking Systems and Winches

4.2.1

An adverse longitudinal barge or vessel slope of at least 1% shall be considered when

assessing required winch, jack and braking capacities.

4.2.2

The computed load on jacking or winching system shall not exceed the certified safe
working load of the system. Both breakout (i.e. start up) and moving conditions shall be
assessed.

In computing the SWL of winch systems, due allowance shall be made for

splices and bending of wire ropes, and friction losses in sheaves.

4.2.3

The arrangement of the winching system shall permit the entire module to be moved
from the quay onto the barge or vessel without re-rigging.

4.2.4

It shall be demonstrated that, in the event of failure of any one component or subsystem,
the jacking or winching system shall continue to function effectively.

4.3.

Multi-Wheel Trailers

4.3.1

Multi-wheel trailers shall be used in accordance with the manufacturer's specification.

For the following, the values recommended by the manufacturer shall not be exceeded:

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Axle loadings

Trailer spine beam shear and bending stresses

Trailer deflections

4.3.2

The hydraulic system of the trailers should generally be connected such that the trailers
are in three groups, thereby providing three-point support system. The position of center
of gravity of the module shall be within the triangle defined by centres of the three
groups and shall be at least 1 metre from the side of this triangle.

4.3.3

The required minimum vertical distance through which each of the trailers axles is able
to move (i.e. the travel) shall be calculated taking account of the following:

Ground level and incline of link span/bridging ramp

Trailer deflections

Module deflections

Allowances for barge or vessel heel and trim

4.3.4

It is recommended that when planning the operation, the maximum foreseeable travel
shall be at least 100 mm less than the value allowed by the manufacturer of the trailers.

4.3.5

The module shall be positively restrained to prevent movement relative to the trailers.

4.4.

Lifted Loadouts

4.4.1

For lifted loadouts the Loadout Contractor shall make available for inspection and
approval by the MWS:

Certificates for the crane

Crane radium curve (i.e. crane capacity as function of outreach)

Lifting and rigging arrangement

Certificates for all equipment in the rigging arrangement including spreader beams,
slings, shackles and padeyes

Barge or vessel handling and mooring procedures

If the crane is a floating crane then its stability/ballast details during the lifting shall be
provided

NDT records for padeyes/trunnions to be used during loadout

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4.5.

Barge and Ballast System

4.5.1

A ballasting schedule shall be prepared, showing that the barge or vessel can be safely
de-ballasted and/or ballasted to receive the module without over stressing the module or
barge/vessel.

The ballast system shall have sufficient capacity to compensate for the

worst combination of change of load and tide rise or fall during the operation.
4.5.2

To ensure adequate contingency in the event the loadout is halted the ballast system
should have adequate capacity to compensate for tide changes through a complete tide
cycle.

4.5.3

Sufficient spare pumps shall be provided to allow for pump malfunctions and the action
to be taken in the event of pump failures shall be documented. The ballast system shall
have a minimum reserve pumping capacity of 50%.

4.5.4

For a loadout onto a cargo barge it is recommended that a ballast system, with its own
power supply, is installed, this system being independent of the barges integral ballast
system. Normally, the cargo barges own ballast system shall not be used during a
loadout, except as a contingency, or included in the calculation of the reserve capacity.
However, some very large barges have sophisticated integral ballast systems, with
redundancy of pumps and power supplies. It is generally not necessary to install a
separate system when using the barges.

4.5.5

All equipment shall be tested, and shown to be fully operational, prior to the loadout.

4.6.

Power Supply

4.6.1

The power supply system shall have adequate capacity to supply all equipment, which
may be used during the loadout for continuous running at maximum rating.

4.6.2

If the ballast pumps and other equipment share a common power supply, for example
the local electricity supply, a back-up power supply shall be provided which can be
brought into action quickly in order that the loadout can be completed in a safe manner.

4.6.3

The power supply system shall be designed to keep the essential equipment running in
the event of one of the following:

One power unit breaks down

Failure of the common energy supply

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4.7.

Grillage and Seafastenings

4.7.1

If the grillage is pre-installed on the barge, dimensional checks shall be carried out prior
to loadout to ensure that the module can be set down safely within agreed tolerances.

4.7.2

If the grillage is loaded out with the module the relative alignment of the grillage and
barge frames and bulkheads shall be estimated by measurement prior to loadout.

4.7.3

For trailer loadouts, the planned position of the module and need for, or adjustments to,
shimming shall be checked when the module weight has been partially set down onto
the grillage.

Complete set down should not take place until satisfactory shimming and

positioning has been achieved and accepted by the MWS. If there are more than four
module support points, shimming shall be carried out with the barge ballasted such that
the deflected shape of the barge is the same as the transportation condition.
4.7.4

Prior to loadout, all preparations for installation of seafastenings should be completed.

Erection of seafastenings should commence as soon as practicable after the module has
been set down and should be installed in such a sequence that the module is fully
restrained in minimum time, and that no unnecessary stresses are introduced into the
module structure.

4.7.5

During installation of the seafastenings special care shall be taken to prevent damage to
the module.

4.7.6

The barge or vessel shall not be moved from the loadout position after loadout until
sufficient seafastenings have been installed. These seafastenings should be capable of
withstanding horizontal forces equal to 10% of module weight taken in any direction and
applied at the center of gravity of the module.

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OPERATIONAL REQUIREMENTS

5.1.

General

5.1.1

Prior to the decision to start a loadout operation a readiness review meeting should take
place on site. The purpose of the meeting is to ensure the following:

The loadout equipment is functioning and has been tested

The procedure to be followed is confirmed

The weather forecast is favorable for the planned duration of the of the operation
including an allowance for contingencies

5.1.2

The results of module weighing are satisfactory and have been accepted by all parties
Checklists shall be prepared and completed to ensure all preparations have been carried
out satisfactorily.

5.1.3

For operations consisting of several predefined stages, a decision based on similar

principles to the commencement of the loadout shall be made prior to the
commencement of each stage.

5.2.

Operational Recording

5.2.1

During the operation a record of events should be kept by the Loadout Contractor. A list
of the events and activities, which are to be recorded, shall be included in the loadout
manual.

5.2.2

The log should also record deviations from agreed procedures and breakdowns or other
delays to the operation.

5.3.

Barge or Vessel Handling

5.3.1

Movements of the barge or vessel at the fabrication site shall be carried out in
accordance with any relevant harbor regulations. Harbor authorities should be notified
prior to any moves.

5.3.2

If the barge or vessel is to be operated outside the conditions for which it is approved by
the Classification Society, the MWS shall be advised and the Classification Society shall
be notified.

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5.3.3

After the loadout is completed, a regular watch shall be provided to ensure the following:

Security of moorings

Barge draft, heel and trim

5.3.4

LOCG-GEN-Guideline-001 Rev. 0

In adverse weather conditions the barge or vessel watch shall be continuous. A suitable
number of spare mooring lines of adequate size and in good condition shall be available
on site.

5.3.5

If sub-zero temperatures are expected, the Loadout Contractor shall take action to avoid
freezing of water in the tanks and on deck. Similar precaution should be taken with
cooling liquids within barge or vessel machinery.

5.3.6

The barge or vessel shall not be moved from the loadout quay after loadout until
sufficient seafastenings have been installed. See Section 4.7.

5.4.

Testing and Measuring

5.4.1

Prior to loadout, all systems and equipment that will be used during the loadout shall be
checked and shown to be in accordance with the approved documentation.

5.4.2

The pull/push system for a skidded loadout shall be commissioned and tested prior to
loadout to verify that the system has sufficient capacity.

5.4.3

Equipment shall be provided for monitoring barge or vessel heel and trim.

During the

loadout, the following parameters shall be monitored:

Draft of barge or vessel

Heel and trim of barge or vessel

Ballast tank quantities

Tide level

Movement of module onto barge or vessel

5.4.4

Where the vessel deflections or alignment to the quay are critical these shall be
monitored using surveying equipment and targets on the vessel. The power supply shall
be tested with all systems, which shall be supplied, running at maximum rating.

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5.4.5

LOCG-GEN-Guideline-001 Rev. 0

Ballast systems shall be function tested immediately prior to loadout. This test shall be
witnessed by the attending surveyor.

5.4.6

Loadout paths on the barge or vessel and the final position of the module over the
grillage should be clearly marked.

5.4.7

A dimensional survey of pre-installed grillages and seafastening shall be checked

against the Module as-built dimensions.

5.4.8

Pre-fabricated grillages and seafastening NDT records shall be made available for
inspection by the attending surveyor prior to loadout.

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