Module Load-Out & Load-In Procedure:

SPMT and Barge Operations

1. Purpose & Scope

This procedure outlines the safe and efficient transfer of modules for the Das Island project.
It covers the load-out of modules from the fabrication yard onto cargo barges using Self-
Propelled Modular Transporters (SPMTs), their marine transportation by tugs, and the
subsequent load-in at Das Island to their final installation points. This document
demonstrates our commitment to thorough planning, safe execution, and compliance with
all Company standards and project specifications.

Detailed engineering documents, including specific ballasting, mooring, and stability

calculations for each operation (considering barge type, module movement, tide, and
position), will be submitted separately for approval.

2. Key Terms & Definitions

For clarity, here are the main terms and abbreviations used in this procedure:

• Company: COMPANY.
• Contractor: CONTRACTOR.
• Sub-Contractor: The Load-out, Load-in and installation Sub-Contractor.
• MWS (Marine Warranty Surveyor): An independent third-party expert appointed to
review and approve marine operations, ensuring they meet safety and industry
standards.
• Module: A pre-fabricated section of the Das Island facility, designed for transport and
installation.
• Load-Out: The process of moving a module from its fabrication site onto a cargo barge.
• Load-In: The process of moving a module from a cargo barge onto the installation site
at Das Island.
 • SPMT (Self-Propelled Modular Transporter): Computer-controlled, multi-axle trailers
used for transporting heavy and oversized loads.
• Cargo Barge: A flat-decked vessel used for transporting modules by sea.
• Ro-Ro (Roll-on/Roll-off) Position: When the barge is positioned with its bow or stern
facing the quay, allowing SPMTs to drive directly onto or off the deck via a ramp.
• Ballasting: The process of taking in or discharging water (ballast) into/from barge
tanks to control its draft, trim, and heel.
• Grillage: A temporary support structure on the barge deck that distributes the
module's weight evenly.
• Seafastening: Structural elements used to secure modules to the barge deck for safe
marine transport.
• Deadweight (DWT): The total weight a vessel can carry, including cargo, fuel, water,
and provisions.

3. Reference Documents & Standards

Following are the key reference documents and standards:

• AD278-90-G-3216: Specifications for Load out, Transportation, And Installation -

Onshore
• Project-Specific Documents:
o Specification for Load-out, Transportation and Installation of DAS Island
Modules
o Dimensional Control Procedure
o QC Inspection and Test Plan for Offshore Construction Works
o Structural Fabrication and Erection Procedure
o Surface Preparation and Painting Procedure
o Applicable Drawings and Calculations (for module details, load-out/in
arrangements, mooring, ballasting, etc.)
3.1 Project-Specific Engineering & Planning Documents

In addition to the general reference documents, the following project-specific engineering

studies and critical data will be developed, reviewed, and approved prior to the
commencement of operations:

Route Simulations: Detailed analysis and visualization of the SPMT travel path on the
fabrication yard, over the ramp, and on the barge deck, including turning circles and
clearance checks.

Trailer Bending Check: Structural analysis of the SPMT configuration to confirm its integrity
and ensure it can safely support and transport the module without overstress or permanent
deformation.

Barge Details & Information: Comprehensive data for each specific cargo barge, including
its general arrangement, tank capacities, hydrostatic curves, lightship weight, and structural
drawings. This information is critical for all marine calculations.

Bathymetric Survey: Detailed survey reports of the seabed conditions and water depths at
both the load-out and load-in quayside locations, ensuring adequate under-keel clearance
for the barge throughout the operation.

4. Operational Overview & Key Principles

Module transfer operations will use a roll-on/roll-off (Ro-Ro) method with SPMTs. Modules
will be moved from their temporary supports directly onto or off the cargo barge.

4.1 General Arrangements & Planning

• Scope & Method: Focus on module load-out/Load-in via SPMTs.

• Module Protection: Provisions for packaging and protecting loose/vulnerable module
parts.
• Packing Lists: Detailed packing lists are prepared and ready before tow departure.
 • Company Presence: No load-out without Company Representative; provide 48-hour
advance notification.
• Additional Requirements: Project-specific requirements are subject to COMPANY
approval.
• Cargo Movement: Land transportation from fabrication site to quayside is part of
load-out scope.
• Environmental Limits: Agree on limiting wave heights, wind speeds, and current with
COMPANY and MWS.
• Vessel Motions: Account for motions induced by passing vessels.
• HSE Compliance: Compliance with COMPANY HSE
• Equipment & Certification: Specialist Sub-Contractor provides all SPMT equipment,
materials, manpower, etc., and that SPMTs and ancillary equipment are certified by
an COMPANY approved TPA.
• Barge Positioning: The cargo barge will be aligned with its bow or stern facing the
quay, perpendicular to the quay wall, to facilitate Ro-Ro operations.
• Drawings: Specific load-out/load-in arrangement drawings for each module will be
issued and submitted for approval prior to the operation.
• Notification: Company and MWS will receive at least one month's advance notice of
planned load-out/load-in operations.
• Under Keel Clearance: The water depth at the quayside will always provide a
minimum of 0.5m under-keel clearance for the cargo barge.
• Temporary Supports: Modules will rest on temporary supports at the fabrication yard
and be transferred to prepositioned grillages on the barge.

4.2 Environmental & Equipment Management

• Tidal Management: While the average tidal range in Abu Dhabi Port is 6 feet,
operations are designed to be largely independent of tide. Portable diesel ballast
pumps on the barge deck will actively manage the barge's level.
o Predicted tide charts (e.g., for Das Island and Fabrication Sub-Contractor jetty)
will be referenced.
 o Actual tide readings will be verified against predictions 48 hours prior to
operations, with continuous monitoring during the transfer.
• Weather Conditions: A 48-hour weather forecast (wind, wave height) will be
thoroughly checked before starting. Operations will be postponed if severe adverse
conditions (e.g., average wind speed exceeding 20 knots as per mooring calculations)
are predicted.
• Equipment Readiness:
o All equipment (SPMTs, ballast pumps, winches) will be properly maintained,
regularly serviced, and fuel tanks filled.
o Diesel-driven combustion engines will be inspected. Plant mechanics will be on
standby throughout the operation.
o Standby pumps and spare parts will be available in case of breakdown.

4.3 Monitoring & Quality Control

• Continuous Monitoring: Competent personnel will continuously monitor:

o Module transfer progress.
o Winch and ballast pump performance (Chief Mechanics and Plant Engineer).
o Barge parameters (trim, heel, draft, tank ullages).
• Levelness Control: Surveyors will use optic transit levels to monitor barge levelness.
The Load-out Manager will use this data to instruct precise ballasting/de-ballasting to
maintain specified tolerances:
o Level relative to quay: +/- 50mm
o Maximum Heel: +/- 40mm
o Maximum Trim: +/- 300mm
• Sea-fastening: Pre-fabricated seafastening items will be positioned on the barge for
ease of installation once modules are in place. All materials will conform to approved
drawings. NDT (Non-Destructive Testing) will be performed on all welded seafastening
joints.
• Marine Traffic: Nearby marine traffic will be notified to reduce speed to a maximum
of 6 knots during load-out/load-in.
5. Organizational Structure & Responsibilities

The entire load-out/load-in operation will be under the direct control of the Load-Out
Manager.

5.1 Key Roles & Support

• Load-Out Manager: Overall command and final decision-making authority, supported

by an engineering team (Naval and Structural Engineer).
• Load-Out Engineer: Manages module loading, and barge ballasting/de-ballasting as
instructed by the Load-Out Manager. Assisted by the Rigging Superintendent.
• Rigging Superintendent: Oversees rigging, and directs Rigging General Foreman and
Foreman.
• Rigging General Foreman & Foreman (Pumps): Leads rigging teams, operates and
controls pumps/hoses for ballasting.
• Chief Mechanic & Assistant Chief Mechanic: Monitors and maintains all mechanical
equipment; ensures fuel and spares availability.
• Fabrication Crew: Takes tank soundings, tide levels, and barge drafts, reporting data
to the Load-Out Engineer.
• Surveyors (2 Dedicated): Continuously monitor barge trim and heel using Theodolites,
reporting readings to the Load-Out Manager.
• Safety Officer: Ensures site safety, monitors personnel access, and confirms all safety
precautions are followed.

5.2 Emergency Succession Plan

In the event of an absence or injury to a senior team member, responsibilities will be

immediately redistributed as follows:

• Load-Out Manager: Covered by Load-Out Engineer

• Load-Out Engineer: Covered by Rigging Superintendent
• Rigging Superintendent: Covered by Rigging General Foreman
• Chief Mechanic: Covered by Assistant Chief Mechanic
 • Rigging General Foreman: Covered by Rigging Superintendent or Chief Mechanic
• Rigging Foreman (Pumps): Covered by Chief Mechanic or Rigging Superintendent

5.3 Safety & Briefings

• Emergency Response: In an emergency, operations will immediately stop, be

reassessed for safety, and if unsafe, the area will be evacuated.
• Personnel on Barge: Only authorized load-out team personnel wearing work vests will
be allowed on the barge during operations.
• Pre-Operations Meetings:
o A 24-hour pre-load-out meeting will be held with all team members to confirm
plans and establish contingency measures.
o A site-specific toolbox talk will be conducted before starting any operation.

6. Procedure: Load-Out, Load-In, & Emergency Retrieval

6.1 Module Load-Out Operation (Fabrication Yard)

1. Barge Preparation & Mooring:

o Receive, inspect, and clean the cargo barge. Remove hatches, and set up
ballast pumps, mooring aids, winches, and preposition grillage/seafastening
supports as per approved drawings.
o Position the barge in Ro-Ro configuration, perpendicular to the quay wall.
Moor the barge using winch lines to quay wall bollards, as per approved
mooring calculations.
o Install transfer ramps between the barge and quayside.
2. Ballasting System Readiness:
o Perform a trial run of the ballasting system and pumps to ensure proper
function. Note: External diesel ballast pumps will be used if the barge lacks an
internal system. Ballast pump arrangements will follow the approved layout.
 o Adjust barge ballast to the pre-load-out condition to suit tidal variations,
maintaining the specified level limits (as above).
3. Module Preparation & Transfer:
o Mark the SPMT route and module's final position on both the barge and the
jetty.
o Position SPMT trailers under the module's temporary load-out frames.
Complete lashing as required.
o Jack-up the SPMTs to lift the module clear of its supports. Drive the SPMTs with
the module towards the quay wall edge.
4. Final Checks & Authorization:
o Pause at the transfer ramp for a final inspection. Verify barge trim and
condition, module and trailer integrity, and current tide.
o Crucially, obtain final approval from the Marine Warranty Surveyor (MWS)
to proceed.
5. Module Roll-On:
o Drive the SPMTs from the quayside onto the barge via the transfer ramp.
o Continuously ballast the barge as per approved calculations to maintain the
specified barge level limits throughout the transfer.
6. Module Set-Down & SPMT Retrieval:
o Once the module is in its final position on the barge, lower it onto the
prepositioned grillage.
o After the module's weight is fully transferred to the grillage, retrieve the SPMT
trailers.
7. Seafastening & Final Preparations for Tow:
o Immediately begin installing minimum required seafastening (approx. 30%) to
secure the module for short-term stability.
o Remove the load-out ramp and install fender between the jetty and the barge
stern.
o Upon MWS approval of the minimum seafastening, turn the barge alongside
the quay for full seafastening.
o Complete the remaining seafastening works as per approved drawings.
o Perform NDT on all seafastening welded joints as per the Project NDT plan.
 o Adjust barge ballast to the final tow-out condition and secure all tank covers.
o Conduct a final inspection by Company and MWS on all seafastening and the
barge's transportation ballast condition.

6.2 Module Load-In Operation (Das Island)

1. Barge Arrival & Mooring:

o Upon arrival at Das Island, moor the cargo barge in the Ro-Ro position at the
load-in jetty, as per the approved mooring arrangement.
2. Ballasting System Readiness:
o Set up the pre-load-in ballast conditions.
o Position the transfer ramps between the barge and quayside.
o Perform a trial run of the ballasting system and pumps.
o Adjust the barge ballast to suit tidal conditions, maintaining the specified level
limits.
3. Module Preparation for Offloading:
o Position SPMT trailers under the module's seafastening frames. Jack up the
SPMTs until the trailer bed is in full contact with the module's load-out
supports.
o Proceed with the systematic removal of all seafastening elements.
o Jack up the SPMTs to lift the module clear of the grillage.
4. Final Checks & Authorization:
o Verify barge trim and condition, module and trailer integrity, and current tide.
o Obtain final approval from the Marine Warranty Surveyor (MWS) to
commence load-in.
5. Module Roll-Off:
o Drive the SPMTs with the module from the cargo barge onto the quayside.
o Continuously de-ballast the barge as per approved calculations to maintain the
specified barge level limits throughout the transfer.
6. Module Set-Down & SPMT Retrieval:
 o Once the module is fully transferred from the barge onto the jetty, it will be
either directly transported to its final installation location or moved to a
temporary laydown area.
o Lower the module onto prepositioned supports preferably at the final location
or under some constraint at the planned temporary laydown area.
o After the load is completely transferred to the supports, retrieve the SPMTs.

6.3 Emergency Retrieval System

Any decision to abort a load-out/load-in and initiate an emergency retrieval will be made by
the Load-out Manager in consultation with the MWS.

• SPMT Failure: In case of SPMT power pack failure, drive gears of affected units will be
disengaged. Hydraulic power will be supplied from adjacent power packs to retrieve
the module.
• Ballasting System: The same ballasting system used for routine operations will be
used in reverse for emergency retrieval.

7. Attachments (To be provided after Award)

1. Pre-Load-Out/Load-In Checklist
2. Risk Assessment
3. Organization Chart
4. Load-Out/Load-In Arrangement Layout
5. Mooring Arrangement
6. Fendering Arrangement
7. Ballasting Calculations
8. Pump Layout
9. Tidal Level Prediction / Tide Table
10. Jetty Level Detail
11. Load-Out Ramp Detail
12. Trailer Detail
13. Ballast Pumps Certification
14. Mooring Winches Certification
15. Route Simulations Report
16. SPMT Trailer Structural Analysis / Bending Check Report
17. Barge Particulars & General Arrangement
18. Bathymetric Survey Reports (Load-Out & Load-In Sites)