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GLOBAL OFFSHORE ENGINEERING


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0 Client: DRILLING COMPANY INTERNATIONAL
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@J Class: CLASS NK
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C Scope: FULL CONDITION SURVEY
E Period: 11.04. - 02.05.2015.
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JACK UP DRILLING UNIT
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Ref. No.:

Project:
2016-0401_DCl-1

16003_DCl-1 II
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3 Date: 16.05.2016. FULL CONDITION SURVEY 2016.
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MANAGEMENT AND DDCUMENTATIDN


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A I DOCUMENT DETAILS
DCl-1/FULL CONDITION SURVEY

Document title: DCl-1- FULL CONDITION SURVEY

Vessel:
SELF ELEVATING MOBILE OFFSHORE DRILLING UNIT
Name:
DCl-1
Class:
CLASS NK
Scope:
FULL CONDITION SURVEY
Period:
11.04.2016. - 02.05.2016. OFFSHORE,
Location:
SOUTH PARS PHASE 20 2016-
Ref. No.:
0401_DCl-1
Revision:
A
Date:
16/05/2016.

Client: DRILLING COMPANY INTERNATIONAL

Author:

Global Offshore Engineering (Split Office)

Issue record:

Date Rev Reason for issue Checked Approved


16.05.16. A First issue
B I RECOMMENDATIONS PRIORITY LABELS
DCl-1/FULL CONDITION SURVEY

For easier prioritizing of jobs all findings and recommendation will be categorized in 3 categories:

With critical recommendation will be labelled all findings that can lead to health or life
threatening situation and/or major failure of equipment. Critical findings are to be rectified
as soon as possible.
Class related items will also be marked as critical with notation "CLASS"
Items to be cleared before wet tow will be marked with notation "WET TOW"
With medium recommendation will be marked all findings that can lead to failure of
equipment or serious repair but in some longer period of time. Also all suspicious areas
will be marked as important which after closer examination can be label as critical later.
MEDIUM
These findings are highly recommended to be rectified as soon as possible but it is up to
owner to decide about priority of this task.

Minor recommendation is the one where Class is not involved and it is up to owner to
accept this recommendation. This recommendation will not cause any sudden equipment
MINO
failure but it will make job easier and simpler and can extend lifetime of involved R
equipment.
C I PROJECT CONTENT
DCl-1/FULL CONDITION SURVEY

VOLUME 0: SURVEY INFO AND WORKSCOPE LIST

VOLUME 1: MARINE AND HULL

VOLUME 2: DRILLING

VOLUME 3: MACHINERY

VOLUME 4: ELECTRICAL AND COMMUNICATIONS (incl. Thermography) VOLUME

5: SAFETY, LIFE SAVING APPLIANCES AND FIRE/GAS PROTECTION


VOLUME 6: RISK ASSESTMENT

VOLUME 7: MANAGEMENT AND DOCUMENTATION

VOLUME 8: UPGRADE RECOMENDATION

VOLUME 9: DROPPED OBJECT SURVEY REPORT

VOLUME 10: DIAGNOSTIC MEASUREMENT REPORT

VOLUME 11: ENGINE EMISSIONS REPORT

VOLUME 12: RECAPITULATION OF NDT FINDINGS AND NDT REPORTS


Contents
MANAGEMENT ......................................................................................................................................................................................................... 1
1.1 PREVENTIVE MAINTENANCE SYSTEM ................................................................................................... 2

1.2 MATERIAL MANAGEMENT SYSTEM ........................................................................................................ 5

1.3 SAFETY MANAGEMENT SYSTEM ............................................................................................................ 7

1.4 MANAGEMENT OF CHANGE .................................................................................................................... 8

2 DDCUMENTATIDN .................................................................................................................................................................................................... 9
2.1 CLASS & STATUTORY CERTIFICATES ................................................................................................. 10

2.2 CREW CERTIFICATES ............................................................................................................................ 12

2.3 DRAWINGS, PLANS, MANUALS & RECORDS ...................................................................................... 13

2.4 MANDATORY PUBLICATIONS ................................................................................................................ 15

VOLUME 7
1 MANAGEMENT
Vessel: Self Elevating MODU

Name: DCl-1
Class: ClassNK
Scope: Full condition survey
Ref. No.: 2016-0401_DCl-1
Revision: A

Date: 16/05/2016.

VOLUME 7 2
2)
3)

1.1 !PREVENTIVE MAINTENANCE SYSTEM


DCl-1/FULL CONDITION SURVEY

The current PMS program is company made program to support and document the maintenance on the rig.
Although still in its early stages of development, it is not user friendly and does not give a good overview of the
equipment or maintenance done, mainly down to two factors,

1) Lack of crew participation on entering non-planned maintenance and repairs.


1) Lack of assets, proper job cards and routines in line with OEM recommendations.

There does not seem to be a logical numbering system so assets cannot be tied back to the equipment of
system they belong to easily. The asset record should contain much more information i.e. manufacturer, model
number, serial number and location to name a few.

Data inputting should be standardised so asset records have the same amount of information when available in
the same format.

The job cards the system generates are mainly daily check lists which are not really Planned Maintenance but
a daily check, and the history of the relevant assets are full of daily check lists, rather than pertinent records of
proper maintenance as per the OEM, and breakdown/unscheduled repairs.

The system generates job cards for equipment, but it should be for the asset. For example, generator is
equipment group, generator# 3 is the asset the job is being performed on.

Complete
d

W0/16/DCll/00094 2016I01/06 p,..,enuve D. Co

W0/161DC11J00106 201610ll07 Preventive Dally Comp~t

I W0/16/001/1)()117 2016/01/08 Proventrff D

I W0/16/DCll/1)()132 2016/01/09 Prf'ffntrve n omp1~


1

W0/16/DCll/1)()149 2016/01/10 Preventive Da,ly mp I et


NI

P~: l ol 11

Emergency generator history shows 110 jobs completed this year, all of which would never have been done
due to asset not running.

VOLUME 7 3
History for port crane shows no jobs done this year on the asset. 4)

WOMnt~ wq 1'rn<11l!,,111i: ~l1dU•i t'-fom,


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l'•evcht1v<'I ll,ti'.y I c~m11,h•t,•d

nt1ve {laity I <;1)111r,l(•l('d

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History for Submersible pump main deck has 1140 records of daily checks.

VOLUME 7 4
5)

• Loratlon;

WO No;

WO To Date:

• Type

Status: ~It • Responsible Departm

d Count 0

History shows same pump has never had a breakdown or repair.

This type of history is meaningless and does not give a true picture of the assets performance or troubles,
which are an invaluable part of minimising future failures and for troubleshooting when they do occur.

There are no counter based job cards in the system which can be used to save money and ensure assets are
serviced at the OEM's recommended intervals, these time based services should have a list of spare parts
required to perform the tasks and that these parts are reserved against the task in the stores system, so the
task can be performed completely and at the correct time.

The company based system has a lot of shortcomings and this in turn is affecting the efficient maintenance of
the vessel and the possibility of reducing downtime breakdowns.

If the current system cannot be brought up to an acceptable standard quickly, and the crew properly trained in
is use, with 24-hour participation with regard to inputting data the system will fail.

There are many proven purpose build maintenance and materials programs on the market and the cost of such
a program is far outweighed by the saving in proper equipment maintenance and downtime. As for any
program it is just that, a program and the data out is only as good as the data in, so a properly trained
administrator of the program is a must, with a logical numbering system, along with crew training and
participation.

FINDINGS RECOMMENDATION
Inadequate PMS software Upgrade I modify current PMS program to
comply with acceptable standard or acquire
industry proven purpose built program
Insufficient crew training and participation Ensure proper training for PMS
administrator and other users

VOLUME 7 5
1.2 !MATERIAL MANAGEMENT SYSTEM
DCl-1/FULL CONDITION SURVEY

The vessel does not have a dedicated store room and spare parts are stored in stores office on level 3, two
containers on level 4 and larger items where there is deck space .

• •

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C
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The storage containers are well laid out and all parts are tagged with relevant information and locations are
logically marked. A few random quantity checks proved stock control is well managed.

Rubber goods are stored in a dedicated shelf in Store C but by the door. The container is air conditioned.

VOLUME 7 6
The MMS program is well laid out and search fields help find parts per equipment quite easily, although slow
due to being an online system. Manifests are easily generated and stock movement between locations well
controlled.

One shortcoming is no provision for minimum and maximum quantities and flagging when stock is low, so
leaving storekeeper to reorder manually.

Another benefit would have department heads have access to view their equipment in the system and ensure
all required spare parts are available with the correct stock levels thus minimizing downtime due to lack of
spare parts.

Items from the critical spares list should be identified as such in the system and reordered when minimum
stock level is hit.

There are various reports generated by the system which give a good overview of what the system is capable
off.

A lot of parts are marked as found on Rig, I presume this was from when DCI took over management. A
complete inventory check should be carried out and all unidentified parts clarified and entered against
a asset
n .

FINDINGS RECOMMENDATION PRIORITY


No link between MMS and PMS program Link MMS to PMS as to ensure equipment is
MEDIUM
associated with spare parts stock
No provision of minimum quantities Ensure minimum quantities are assigned to
MEDIUM
critical spares and flagged when low
Unidentified parts found Inventory check and revision MINOR

VOLUME 7 7
9)
6)
8)
7)

1.3 isAFETY MANAGEMENT SYSTEM


DCl-1/FULL CONDITION SURVEY

In order to comply with ISM Code, Safety Management System should be implemented and maintained on
board the vessel. A provisional Certificate of Compliance was issued in November 2014 pending issuance of
final certificate which was not found on board the vessel during the survey. A valid Safety Management
Certificate was found but has to be supplemented with valid DoC.

DOCUMENT OF COMPLIANCE
- ST-14DB-
Mllt1PANDOC
1Jen9"1tof(·-ptuittttfar
•·ETY MANAGEMENT CERT..-!CATE

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THFSAFETYOFUFEATSl:.A. 1'174, Hamen..kd.. \Jn.Jo,~-V..-,ufh<~afhRcpabi~r:Lf'-
by J\'!PPON KA.UT KVOKAl
\lot111..,umhon-dnlha,:m11,1
J)fi.f.P SEA OFFSHOR.l l'fft:RNA TIOSAL COkP. --11

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No.208!. 28th Honr, Gros~coor Commrrdal ltt1"tr,
She.lkh7,lJtdRu..d,Dubai.U.A.£. nrrr,r .\ on,110Rt ll'ITl.R!I/ HIO"l<\LCORr.

Cnmc-,y odclw.ifk1.noo number IMO .56l0110 "lt1.!00I.ZV11!Flon,,f;..,..,,. •• ,r1·nm ••••• ,.. ••


1·rfl,ur, ~ho,,U.1.io1nlR.t.-l,Oub:u,l.A.L

1111SlSTOCl:RTlt"\ THAT1hl:Safety~fa11agementS),1tmor 1hcCtJmPllllyh.ubceo audned 111d tb,,t ,t

-
wmp&i<:& with th(, reqll.lreme,,t,; ,,r 1hc lniema111:mal Manageme111 Code for OIi: Safe ()pcratj.QII ol
SfliJNI .-.d for Pollunoo Ptnrntion · ISM Code) tor the t~pe, of ~hiJ)I !med below (4deteM~) THlir.l~TOl")'NTln• TIIATtbc,~i.,l! \bn.1,:1,mnn \~,1.,..,,ufrhc ",h,phuhttn •uJn.,J
..i'""f'ltnd1,,tull~ wmph •• ,th thcn.-qu,rcmcnt•r>fthclSMl'~.,.d1h('rdcnn1 pn>1oi~c,l 1hc Jluk,
for1t,,, ,\uJ,1 ~,,J Rt11i'>ll"4t,vn .,f!M,kt~ \f~.~..,!tl~nl S)he'ni,;. follv •• 111;:
erif"'4tM'WI Llul tl>c Do,.,umtnl ofComph.,n<o I',,,. thol l'umpM~ ,, llppl.:1~ I<) thJJ r:-pc ,,1· st.,p
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The Safety Management Manual is required to be kept on board, however none was found during the survey.
Furthermore, designated person ashore (DPA) has to be appointed and communication between the rig and
company headquarters established. There seems to be nobody on the rig familiar with the systems and
requirements. SMS register has to be kept and monthly reports sent to the DPA for a review and feedback. No
non-conformance or near miss reports are being made.

FINDINGS RECOMMENDATION PRIORITY


Interim Document of Compliance expired Ensure a valid Document of Compliance is
MEDIUM
issued and kept on board
Safety Management Manual not found on board Ensure a copy of manual is kept on board MEDIUM
NoDPA Ensure DPA is appointed and well versed
withSMS MEDIUM
SMS register not found Develop and maintain register MEDIUM
Personnel not familiar with SMS Ensure crew is trained and familiar with the MEDIUM
system

VOLUME 7 8
1.4 !MANAGEMENT OF CHANGE
DCl-1/FULL CONDITION SURVEY

Management of Change, or MOC, is a best practice used to ensure that safety, health and environmental risks
are controlled when a company makes changes in their facilities, documentation, personnel, or operations.

It was observed that management of change is not established on the rig. It is recommended that measures
are implemented regarding:

 Equipment, facilities and processes


 Operation, maintenance, inspection procedures
 Training, personnel and communication
 Documentation

Procedures for managing these changes should be written and regularly reviewed to reduce the risk
associated with any changes.

FINDINGS RECOMMENDATION PRIORITY


Management of Change not existing Procedures to be established and
implemented MEDIUM

VOLUME 7 9
2 DDCUMENTATIDN
Vessel: Self Elevating MODU

Name: DCl-1
Class: ClassNK
Scope: Full condition survey
Ref. No.: 2016-0401_DCl-1
Revision: A

Date: 16/05/2016.

VOLUME 7 1
0
2.1 lcLASS & STATUTORY CERTIFICATES
DCl-1/FULL CONDITION SURVEY

The following Class & Statutory certificates were found on board:

CERTIFICATE ISSUED BY DUE DATE


Certificate of Class NK 20 NOV 2016
Certificate of Installations Registration Class Permanent 06
Certificate of Registry NK DEC 2016
International Tonnage Certificate Class Permanent 20
International Load Line Certificate Panama NOV 2016 20
MODU Safety Certificate Panama NOV 2016 07
Radio Station license NK on behalf of Panama JAN 2021
Minimum Safe Manning Panama Permanent 20
IOPP Certificate Panama NOV 2016 20
IAPP Certificate Panama NOV 2016 20
ISPP Certificate NK on behalf of Panama NOV 2016 20
Crane Test Certificate NK on behalf of Panama NOV 2016
Short Term Document of Compliance NK on behalf of Panama 08 APR 2016
NK Class (expired)
Safety Management Certificate NK
NK Class
Class 10 NOV 2019

Support documents:

Lifeboat and Lifeboat release gear #1 - IESCO


10 OCT 2016
annual inspection certificate
Lifeboat and Lifeboat release gear #2 - IESCO
10 OCT 2016
annual inspection certificate
FRC Boat annual inspection certificate IESC 10 OCT 2016
O
Inflatable Life Raft - certificate of reinspection IESC 16 NOV 2016
CO2 installation - certificate of inspection O
Helideck Fire Fighting Foam System - inspection IESC 10 OCT 2017
O
certificate IESC
O
Foam analysis report and inspection
IESC
certificate O
Certificate of Crane's Condition Survey - PS IESC
Certificate of Crane's Condition Survey - STBD O
Offshore Personnel Transfer Device inspection IESC
IESC 10 APR 2016
report O
Radio Survey Report Sphinx Marine Ltd. 16 DEC
SART - annual test certificate Sphinx Marine Ltd. 2016 02
SSAS - annual test report Sphinx Marine Ltd. DEC 2016
02 DEC
2016

VOLUME 7 1
1
FINDINGS RECOMMENDATION PRIORITY
Short term Document of Compliance expired Renew certificate and ensure valid copy is kept
MEDIUM
on board
BCLC Certificate not found Make necessary arrangements to ensure
MEDIUM
certificate are issued as soon as possible
GMDSS Shore Base Maintenance Certificate not found Ensure certificate is kept on board and visibly
MINOR
displayed in radio room
Annual Safety Inspection report not found Arrange for authorized inspectors by Panama
Maritime Authority and organize inspection at
the earliest opportunity
EPIRB annual test certificate not found Ensure certificate is kept on board
MINOR

Class and Statutory Folder poorly organized Organize folder with original certificates and
MINOR
list of certificates with due dates

VOLUME 7 1
2
2.2 lcREW CERTIFICATES
DCl-1/FULL CONDITION SURVEY

Every floating unit is subject to various maritime lows and regulations imposed by either International Maritime
Organization (IMO) or specific country requirements. In addition, every drilling unit has to comply with
applicable regulations in terms of drilling operations.

The aim of this survey was to determine major discrepancies with applicable rules and standards including
requirements for crew training and competency assessments. Since there is no Crew Certificates register kept
on board, it was difficult to determine the exact status of necessary documents. In general, all crew members
and visitors should have at least valid BOSIET and Offshore Medical Certificates. There is justified concern
that significant number of crew members doesn't hold these certificates.

Key personnel such as OIM, Barge Master and Chief Engineer should have additional training certificates in
order to comply with IMO Resolution A 1029(28).

Personnel with assigned duties on the muster list should hold generally STCW (Vl/2, Vl/4 & Vl/6-2) or CoP
corresponding certificates valid 5 years max.

Here are some recommended training courses (in addition to BOSIET and STCW mandatory training):

 IWCF Well Control


 Helicopter Landing Officer (HLO)
 Offshore Helideck Assistant (HDA) -
 Offshore Helideck Team Member (HDTM) -
 Dangerous Goods Awareness by Sea/Air
 Dangerous Goods (training for storekeeper)
 Crane Operator I Banksman I Rigger LOLER training
 CAA helideck training
 MetObserver training

FINDINGS I RECOMMENDATION
I
Significant number of crew members doesn't hold valid Ensure all crew members and visitors have
Offshore Medical certificate valid medical examination certificate

I
Significant number of crew members doesn't hold valid Ensure all crew members and visitors have
BOS/ET or equivalent certificate valid BOS/ET or equivalent certificate

No Crew Certificate register Develop and properly maintain crew


certificates register
Compliance with IMO STCW requirements not confirmed I Confirm compliance and ensure all relevant
certificates are available on board
I
Well Control training - insufficient number of drilling Ensure drilling personnel hold adequate well
personnel found with appropriate well control training control certificates MEDIUM

I
Industry recommended training and certificates not Ensure offshore training recommendations
implemented on board are adopted MINOR

Training and drill matrix not found Develop and implement training and drill
MINOR
matrix

VOLUME 7 1
3
2.3 !DRAWINGS, PLANS, MANUALS & RECORDS
DCl-1/FULL CONDITION SURVEY

Drawings database is very good and complete. Only remark is given for the documentation follow up and
management of change. There has been changes made to the rig systems and components without revising
the corresponding drawings.

The Safety Plan, Fire Plan and Escape Route Plan are visibly displayed in accommodation area.

Operating Manual is found on board but not approved by NK Class and still having old name of the rig on the
cover. Stability book, however, was reviewed and approved by NK Class.

Status of Administration required manuals, logs and records:

 Operating Manual - needs to be updated/revised and submitted for approval


 Stability book - found to be in order; no update required unless major modifications are to be
made
 Construction Booklet - found to be in order
 Safety Management System manual - not found
 Ship Security Plan - not found
 SOPEP manual - found
 Garbage Management Plan - found
 Garbage Record Book - found but with no entry
 Oil Record Book - found in order
 Accident I Incident Reports - not found
 Near-miss Reports - not found
 Record of Emergency Drills - not found
 Medical Log - found in order
 Radio & Helicopter Log - not found
 ODS Log Book - not found
 Safety and Emergency Procedures - not found apart from short section in OM

In addition, Hazardous Areas Equipment Register was not found on board. It is a requirement to compile a
register of electrical equipment in hazardous areas. Every piece of equipment on this register is to be
inspected by a COMPEX certified technician and a report raised with deficiencies and their seriousness.

Also, there was no record found of an Earth Loop Diagram and Earth layout diagram (except for the derrick
structure. No Insulation Resistance readings or lmpendence test record were found on board either.

Maintenance records are very vague and the Preventive Maintenance System is in an early stage of
development.

Lifting register was not found on board and needs to be established as soon as possible. Register should
include, among other things, all locations and capacity of pad eyes with load tests. Preferably it should be as
per LOLER standard and requirements.

All relevant documentation should be kept on board readily available for inspection and use. Management of
change needs to be established as soon as possible to ensure that up-to-date documentation is maintained.

VOLUME 7 14
FINDINGS RECOMMENDATION PRIORITY
Modifications to rig systems and components done without Update drawings
MEDIUM
revising corresponding drawings
Management of Change not existing Procedures to be established to verify an
effective system to control drawings and ensure MEDIUM
that up-to-date documentation is maintained

Operating Manual not up to date and class approved Update I revise OM and submit for approval
MEDIUM

Safety Management System Manual - not found Ensure a copy of manual is kept on board
MEDIUM

Ship Security Plan - not found Develop and implement SSP


MEDIUM

Garbage Record Book - not maintained Ensure record book is maintained regularly
MINOR

Accident I incident reports - not found Ensure reports are raised and kept on board
MINOR

Near-miss reports - not found Ensure reports are raised and kept on board
MINOR

Record of emergency drills - not found Ensure emergency drills are exercised regularly
MINOR
and records maintained
Radio & Helicopter Log Book - not found Provide Log Book and ensure records are
MINOR
maintained
ODS Log Book - not found Provide Log Book and ensure records are
MINOR
maintained
Safety and Emergency Procedures - not found Develop and implement proper procedures
MEDIUM

Hazardous Area Equipment register - not found Compile a register and ensure inspection is
carried out as soon as possible
Lifting Register - not found Establish lifting gear register and ensure is
updated periodically

VOLUME 7 1
5
2.4 !MANDATORY PUBLICATIONS
DCl-1/FULL CONDITION SURVEY

As per Administration requirements, the following documentation is required to be kept on board the vessel:

• SOLAS {2014 Consolidated Edition)


• MARPOL 73/78 (2011 Consolidated Edition)
• IMDG Code
• MODU Code 2001
• Load Lines {2011 Edition)

• LSA Code
• FSS Code
• STCW {2011 Edition)

• COLREGS (2003 Edition)


• ISM Code
• ISPS Code
• International Code of Signals
• IAMSAR Manual Volume Ill
• GMDSS Manual

Nautical charts and publications:

 Adequate charts for the intended voyage - up to date


 Chart catalog - up to date
 Flag State Marine Notices and Guidance Notes
 Admiralty Tide Tables
 Admiralty List Of Radio Signals Volumes I to VI Global Maritime Distress and Safety System
{GMDSS) / NGA Radio Aids
 Tidal stream atlases

Other publications:

 IMO Code on Alerts and Indications


 ICS Guide to Helicopter I Ship operations
 Guidelines for the Safe Packing and Handling of Cargo to and from Offshore Locations
 Cargo Securing Manual
 UKOOA Guidelines for the Management of Helideck Operations
 CAP 437 Offshore Helideck Landing Area Guidance on Standards
 IATA Regulations
 ICAO Heliport Manual
 ICAO Convention on International Civil Aviation - Annex 14 Vol II (Heliports and Annex 6 Part Ill
{International Operations - Helicopters)
 IMO Resolution A.855(20) Standards for On-board Helicopter Facilities

FINDINGS RECOMMENDATION PRIORITY


Mandatory publications and charts not found I Acquire missing publications and charts
incomplete MEDIUM

VOLUME 7 1
6