0630-50.00.005.01-VOOW-MAN-Deck Equipment Operation Manual

Document number: 0630-50.00.005.01 Revision 1.
6
NEXUS – Deck Equipment Operations Manual Page 1 of 100
DECK EQUIPMENT
OPERATIONS MANUAL
NEXUS
[0630-50.00.005.01]
Function Initials Date Signature

Prepared by Superintendent HQN 04-12-2017
Verified by Production & Automation DHO 04-07-2017
Approved by Operations Manager OWP AOD 04-07-2017
Authorized by Vessel Master Nexus -
Document owner Vessel
0630-50.00.005.01 - DECK EQUIPMENT - OPERATION MANUAL

Document number: 0630-50.00.005.01 Revision 1.6
Revision record
Revision Description Date
1.6 Updated quadrant handling screens. March 2019
1.5 Added departure angle alarm September 2018
1.3 Updated VOMS format December 2017
1.2 Updates to VODAS November 2017
1.1 Updates to Survey October 2017
1.0 Final first revision February 2016
0 Draft November 2015
External referenced documents

Ref no. Document Name Version Date
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/3/
/4/
Supporting documents
Ref no. Document Number Document Name
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/6/
/7/
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/9/
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Distribution list
Vessel Nexus (Master, Chief Engineer, Survey)
Operations Manager OWP
Plant manager SMD
Production and Automation department (David Hordijk)
Cable Unit
Table of contents
Abbreviations ........................................................................................................................................... 5
1 Scope ............................................................................................................................................... 6
1.1 Introduction ................................................................................................................................. 6
1.2 Operations and Procedures ....................................................................................................... 7
1.3 Objectives ................................................................................................................................... 8
2 Vessel Description............................................................................ Error! Bookmark not defined.
3 Cable Routing, Buffering and Automation System ........................................................................... 9
4 Equipment ...................................................................................................................................... 10
4.1 Tensioners ................................................................................................................................ 10
4.1.1 Track Drive....................................................................................................................... 12
4.1.2 Hydraulic Power Unit ....................................................................................................... 12
4.1.3 Clamp System and Automatic Clamping Control (ACC) ................................................. 12
4.1.4 Frame Opening System ................................................................................................... 13
4.1.5 Absorption of Cable Diameter Variations ........................................................................ 13
4.1.6 Track Shoe Lining and clamping load geometry ............................................................. 13
4.1.7 Tension Sensing System ................................................................................................. 15
4.1.8 Guide Rollers ................................................................................................................... 15
4.1.9 Remote or Local Operation .............................................................................................. 16
4.1.10 Wireless Control Unit (Belly Pack) ................................................................................... 16
4.1.11 Emergency Stop Circuit ................................................................................................... 16
4.2 Wheel Pair Tensioner ............................................................................................................... 17
4.3 Quadrant, quadrant which, quadrant handler and side winches .............................................. 18
4.3.1 Quadrant .......................................................................................................................... 18
4.3.2 General ............................................................................................................................ 18
4.3.3 Hydraulic Power Unit ....................................................................................................... 19
4.3.4 Quadrant Winch ............................................................................................................... 19
4.3.5 Quadrant Handler and JIB ............................................................................................... 19
4.3.6 Side Winches ................................................................................................................... 20
4.4 Carousel and Loading Tower ................................................................................................... 21
4.4.1 Carousel Basket............................................................................................................... 22
4.4.2 Roller Assemblies and Roller Control Frame .................................................................. 23
4.4.3 Central Bearing and Central Bearing Housing ................................................................ 24
4.4.4 Basket Chain and Mount ................................................................................................. 24
4.4.5 Drive Modules .................................................................................................................. 24
4.4.6 Loader System ................................................................................................................. 25
4.4.7 HPU and Drive Suite ........................................................................................................ 27
4.4.8 Carousel Holding Brakes and Bracing ............................................................................. 27
4.5 DAMS ....................................................................................................................................... 28
4.6 Capstans .................................................................................................................................. 28
4.7 Remote Control Locations and Control Desks ......................................................................... 29
4.8 E-STOP CIRCUIT ..................................................................................................................... 30
5 VODAS Control System ................................................................................................................. 31
5.1 VODAS architecture ................................................................................................................. 31
5.2 GENERAL Menu ...................................................................................................................... 32
5.2.1 Alarms .............................................................................................................................. 32
5.3 SYSTEM Menu ......................................................................................................................... 33
5.3.1 CAROUSEL ..................................................................................................................... 33
5.3.2 TENSIONERS.................................................................................................................. 39
5.3.3 QUADRANT ..................................................................................................................... 44
5.3.4 WHEEL PAIR TENSIONER ............................................................................................. 47
5.3.5 DAMS ............................................................................................................................... 48
5.3.6 UMBILICAL WINCH ......................................................................................................... 49

5.3.7 E-Stop .............................................................................................................................. 50
5.3.8 STANDARD PROCEDURE to start up the system ......................................................... 51
5.4 PROCESS MENU .................................................................................................................... 53
5.4.1 LAY / LOAD ..................................................................................................................... 53
5.4.2 QUADRANT OPERATIONS ............................................................................................ 61
5.4.3 SETPOINTS..................................................................................................................... 73
6 Survey ............................................................................................................................................ 74
6.1 Survey Equipment .................................................................................................................... 74
6.1.1 Overview survey equipment ............................................................................................ 74
6.2 Survey software ........................................................................................................................ 75
6.2.1 Data flow .......................................................................................................................... 75
6.2.2 Data output ...................................................................................................................... 76
6.2.3 Software operational modes ............................................................................................ 77
7 CABLE OPERATIONS ................................................................................................................... 83
7.1 Safety........................................................................................................................................ 83
7.2 Cable Loading .......................................................................................................................... 83
7.3 Cable Laying ............................................................................................................................. 86
7.3.1 1st end lay down on the sea bed ..................................................................................... 86
7.3.2 1st end pull in into an offshore receiving structure (e.g. OHVS, tower)........................... 87
7.3.3 In-line joint........................................................................................................................ 88
1st end beach pull with floaters [TBD]............................................................................................. 91
7.3.4 Cable laying – Automation and monitoring system ......................................................... 92
7.3.5 2nd end lay down on the seabed ..................................................................................... 92
7.3.6 2nd end pull in in into an offshore receiving structure ..................................................... 93
7.3.7 2nd end beach pull with floaters [TBD] ............................................................................. 98
7.4 Cable Repair [TBD] .................................................................................................................. 99
7.5 Cable decommissioning [TBD] ............................................................................................... 100
Abbreviations
Abbreviations
CDA Cable Departure Angle

CLV Cable Lay Vessel
CPS Cable Protection System
CT Constant Tension
DAMS Departure Angle Monitoring System
DP Dynamic Positioning
E-stops Emergency stops
HMI Human Machine Interface
HPU Hydraulic Power Unit
MBR Minimum Bend Radius
PS Portside
RFU Ready for Use
ROV Remote Operated Vehicle
SB Starboard
VODAS Van Oord Dredging Automation System
WPT Wheel Pair Tensioner
1 Scope
The “Nexus” Deck Equipment Operations Manual is written as a supplement to the Van Oord Marine
Operation Manual as these are in use by the Van Oord fleet. Construction supervisors should be
familiar with the content of this Manual.
This manual only applies to the deck equipment, as described in this manual.
1.1 Introduction
The purpose of this operation manual is to give a clear overview on the operation of the system during
cable installation works. This document contains descriptions of the cable laying equipment and the
automation system of the Nexus as well as detailed explanations of cable handling operations and
corresponding procedures and work instructions.
The following pieces of equipment are described in the documents:
Equipment Manufacturer
2 x 20 mT tensioners SAS
2mT Wheel Pair Tensioner HULST
Quadrant winch (20mT) and quadrant handler system DRAFTEC
5000 mT carousel ICH
Loading tower ICH
Departure Angle Measurement System (DAMS) PLIANT
Each piece of equipment listed above, having been developed by different manufacturers, is
individually managed by its own PLCs and drives. Therefore, to manage the interface between the
different pieces of equipment and to have a clear and unique interface to run the entire cable laying
system, a control software called VODAS has been created and implemented on board the Nexus by
Van Oord. Moreover, the VODAS system has been also developed to automate most of the
operations carried out during cable installation works.
1.2 Operations and Procedures

The following operations and corresponding procedures and work instructions are described in this
document:
Activity Description
Cable loading Product is loaded onto the vessel from a supplying party
Cable unloading Product is unloaded from the vessel to a receiving party
Cable lay Product is laid from the vessel onto the seabed
1st end pull 1st End of product is pulled into a receiving structure
1st end lay-down 1st End of product is laid down onto the seabed
2nd end pull 2nd End of product is pulled into a receiving structure (using the
quadrant)
2nd end lay-down 2nd End of product is laid down onto the seabed
In-line joint The 2nd end of a length of product is retrieved from the seabed and
joined to the 1st end of another length of product which is on the
vessel.
Omega Ω Joint The two cables to be jointed are on the seabed. One is retrieved
over the SB chute and the other over the PS chute. When the joint
is completed, the omega bight has to be laid down on the seabed
using the quadrant. The omega joint is used in case of cable repair
or for a post-laying joint of two length of product.
Shore approach The cable is pulled to shore while using floatation devices to keep
the product buoyant. Receiving party uses winch to pull the product.
Emergency abandonment Due to an emergency, the product is cut, sealed and over boarded.
Cable repair A cable laid on the seabed needs to be repaired. The operations
are carried out by cutting the cable on the seabed and removing the
damaged part, and then an in-line joint between the old section of
cable and a new one on board will be performed. Once the in-line
joint is over boarded, the new section will be laid and finally an
omega joint will be done between the old section of cable and the
new one just laid
Cable decommissioning Retrieval of old or scrap cable into the vessel

1.3 Objectives
The purpose of this Marine Operations Manual for the Nexus is to meet the following objectives:
• To provide marine operating guidelines for Nexus’s personnel and project staff.
• To identify personnel responsible for marine operations conducted on board of the Nexus.
• To comply with regulatory requirements where applicable.
• To provide a comprehensive overview of marine operations, for the benefit of clients and Van
Oord personnel.
• To provide the basis for induction and training of Nexus personnel.
• To provide an inductive document for all involved.
This manual is intended to form a quick reference guide for a range of operating conditions and day-
to-day operations and is not intended to be a comprehensive reference.
Equipment and system specific manuals (e.g. user operating manuals) are to be retained and
maintained on board. This manual is not intended to duplicate the information contained within these
manuals, but rather provide an overview reference for marine and safety systems.
In exceptional circumstances, it can be that additional arrangements or procedures are required. This
can be driven by local regulations and conditions or contract requirements. Such arrangements are
always additional and cannot be in contraction to this manual without a proper change procedure,
which is reviewed, recorded and authorized by the appropriate Van Oord Management. Above
mentioned changes should be brought to the attention of parties concerned.
2 Cable Routing, Buffering and Automation System

The Nexus cable laying system has been designed to implement the use of a quadrant as a moving
buffer on deck. During cable laying and loading operations, the quadrant can move longitudinally on
two rails to actively compensate for any acceleration or deceleration in the laying equipment. The
main function of the buffering system is to keep steady the catenary parameters, particularly in case of
fast stops or sharp speed variations, without over-stressing the carousel. In fact, due to its inertia, the
carousel reacts lowlier than the tensioners to rapid speed changes, or stops.
The quadrant is connected to a constant tension winch, whose paid out length and tension, during
laying and loading operations, are continuously monitored and adjusted in accordance with given set
points (the same winch is also used for over boarding the quadrant).
During regular laying operations, the cable is picked up from the carousel through the loading arm,
where a constant tension 2 pair wheel tensioner is installed. In sequence, the cable is pulled towards
the stern, on the highway, by the port side tensioner and then pulled through the quadrant by the
starboard side tensioner. The cable finally leaves the vessel through the starboard chute where a
laser system, called DAMS, monitors the cable departure angle. The two chutes, as well as the
quadrant and loading tower, have bending radius of 5m (x, y, z planes).
The entire process can be remotely operated through VODAS, by just one operator, either from the
control cabin on deck or from the control desk on the bridge next to the DP console. It can be
operated in a fully automated mode, as well as in several semi-automated modes or manually. When
the system runs fully automatic, the speed of the SB tensioners is controlled by the DAMS so that the
cable departure angle is constantly kept at the chosen value. In sequence, the carousel follows the SB
tensioner to maintain the quadrant around the neutral position and, finally, the PS tensioner follows
the carousel. The wheel pair tensioner and the quadrant winch stay in CT at all the time.
Figure 1 Cable routing and buffering system. Home, neutral and aft position of the quadrant are shown.
3 Equipment
In the following pages, the deck cable lay equipment used during cable installation works are
described.
# Description
1 Tensioner PS
2 Tensioner SB
3 Wheel pair tension
4 Side winch PS
5 Side winch SB
6 Capstan PS
7 Capstan SB #19
8 Quadrant winch
9 Quadrant
10 Quadrant trolley
11 Quadrant rails #3
12 Quadrant handler #6
13 Chute #7
#8
14 Jointing house
15 Cutting station
#18
16 Roller boxes
17 CPS
18 Loading tower #23
19 Carousel
20 Deck crane
#11
21 DAMS
#10
22 Capstan SB aft
23 Capstan SB FWD #14
#9
#17
#20
#15 #5
#16 #2
#1
#4 #22
#12 #13
#21
Figure 2 NEXUS schematic overview deck lay-out

3.1 Tensioners
Figure 3 3D drawing of the SAS tensioner.
The tensioner is an open skid type, consisting of two tracks clamping the cable in the vertical plane.
The lower track is fixed on the base frame and the upper track in the tiltable frame that can be moved
away to ease (un)loading of the product.
The lower and upper tracks are connected to each other by hydraulic cylinders, which are used to
apply clamping force. In case of a temporary hydraulic system failure or main power blackout, the
clamping force is ensured by fail safe brakes and nitrogen accumulators fitted on the clamping
cylinders. The hydraulic power is generated by a power pack, installed on the frame.
The bottom track is a double chain arrangement, for increased stability during clamping of larger
products.
Electric motors with gearboxes drive the tracks. Each motor has an integrated fail safe (spring
applied) brake.
The base frame is mounted on a four corner supports, with the two corner supports on the idler side
with load cells to measure the cable in-line tension in both directions.
The base frame, at each end of the tracks, has mounting provisions for guide rollers to guide the
products into the tracks.
An audible alarm and flashing light indicate the start of an operation.
The two tensioners on deck are mirrored images of each other, further specifications are identical.
Description Value
Maximum dynamic load 20 [t]
Maximum static load 25 [t]
Maximum speed (pay in) 1.000 [m/hour]
Maximum speed (pay out) 1.000 [m/hour]
Design Friction coefficient 0,07
Cable diameter range 50-648 [mm]
Clamping force range 42.5-215 [kN/m]
Circular clearance (upper track vertical) 700 [mm]
Circular clearance (upper track tilted) 1.700 [mm]
Type of drive AC Electric
Track shoe models V-type, 160° included
Track shoe material PU
Type of local controls WCU, one unit for each tensioner
Length (excluding guider rollers) 6.039 [mm]
Contact length1 2.890 [mm]
Width 2.500 [mm]
Width with tilted upper track 3.700 [mm]
Height 3.7000 [mm]
Hydraulic Power Unit Installed on machine
Table 1 Tensioner specifications
3.1.1 Track Drive

Each track of the tensioner is driven by an electric motor (AC) via a gearbox. The speed and control of
the motors is managed by Variable Frequency Drives (VFD) in the drive cabinet. Each motor that
drives the track chain is equipped with an electrical disk brake located on the motor shaft. The brake
is designed to hold the load when the drives are off and is only used for dynamic braking in case of
emergency. Each gearbox has a temperature sensor to monitor the oil temperature.
3.1.2 Hydraulic Power Unit

The Hydraulic Power Unit is integrated on the tensioner frame and starts automatically when a
hydraulic function is started (e.g. clamping). The HPU only has one main pump, no auxiliary. The oil
reservoir is equipped with the necessary sensors to maintain the oil at optimum working condition and
prevent rapid oil degrading.
3.1.3 Clamp System and Automatic Clamping Control (ACC)

The tracks are clamped onto the cable by means of hydraulic cylinders with hydraulic accumulators
working as a flexible clamping system. This system operates as an automatic fail-safe clamping
system, including during a temporary hydraulic system failure or blackout. When the close
command of the tensioner is activated by the operator, the upper track moves down towards the
cable, until the system detects the product. At this point the system switches over from position
control to force control and slowly the clamping force is increased towards the clamping set point.
As soon as the clamping set point is reached the Automatic Clamping Control (ACC) becomes
active. To prevent continuous pressure adjustments, the ACC automatically keeps the actual
clamping force between two thresholds. The lower threshold is the clamping set point and the
higher threshold is the clamping set point plus 10%.
1The contact length mentioned is the length measured between the centres of the first and last track roller
supporting the chain where it is in contact with the product.
Figure 4 Tensioner assembly and clamping cylinders (yellow)
3.1.4 Frame Opening System

The frame can be tilted to ease the (un)loading of products and to allow the passage of large items
that require the assistance of the crane (e.g. joints, CPS). The frame opens by means of two hydraulic
cylinders. However, the opening mechanism creates a weak point in the frame, which requires
strengthening when a product is clamped. This is achieved by means of two hydraulic operated
locking pins.
Therefore, before tilting the frame, the two locking pins have to be unlocked and the upper track must
be opened to its highest position.
Figure 5 Tensioner fully tilted. Max allowable diameter 1700 mm
3.1.5 Absorption of Cable Diameter Variations

Overall cable diameter variations are absorbed by reaction of the clamping cylinders with
accumulators. This function allows the use of a fore runner rope of similar diameter to pull the cable
through the tensioner.
3.1.6 Track Shoe Lining and clamping load geometry

The track shoes are mounted directly on the chain and are easy to replace, making several setups
possible for different product sizes and/or materials.
The bottom track of the tensioner is a double chain arrangement, for increased product stability
during clamping of large products, the top track is a single chain arrangement as shown in the
following cross-tie pad assemblies. The angle of the pads installed on both tracks is 160°.
Figure 6 Cross-tie pad assembly of the bottom track
Figure 7 Cross-tie pad assembly of the top track
Figure 8 Particulars of the track shoes.

3.1.7 Tension Sensing System

The actual tension of the tensioner is measured with two load pins. Each load pin contains two load
cell bridges (A+B) for redundancy purposes. Two load cell bridges (one from each load pin) are
connected in parallel to an individual amplifier. When both sensors are healthy, only one of the
sensors is used. If the selected load cell bridge fails then the other bridge can be selected. If the
difference between the two bridges is too large, an alarm is generated. The tension is measured in
both directions.
3.1.8 Guide Rollers

The tensioner frame has mounting provisions on the drive and idle side to mount guide rollers onto the
frame. They are provided to support the product and prevent it from running out of the tracks. A
control box to operate a set of guide rollers is mounted on each side of the tensioner.
Vertical rollers
The vertical rollers are individually adjustable, by means of an electric motor with spindle. Each roller
is capable of withstanding 3 ton of side or longitudinal load, not being simultaneous in both directions
nor on both rollers.
Figure 9 Vertical rollers Figure 10 horizontal roller (diabolo)
Horizontal roller
The horizontal roller is of diabolo type (V-angle 140 [°]). It can be vertically adjusted with a range of
400mm, by means of electric motor and spindle. In its lowest position, the V button is 1290 from deck.
The maximum vertical load downwards on this roller is approximately 3 ton.
Figure 11 Particulars of the tensioner rollers.

3.1.9 Remote or Local Operation

The tensioners can be controlled either from VODAS screens (control cabin or bridge), from the
remote-control consoles in the drive container (PS aft) or using a Wireless Control Unit (belly pack). In
all the standard cable handling procedures of the Nexus, the tensioners, as the rest of the equipment,
are mainly controlled through VODAS. The belly packs are only used to open and close the frames;
the remote-control consoles in the drive container are used only as backup or for maintenance.
3.1.10 Wireless Control Unit (Belly Pack)

Each tensioner can be individually controlled by a dedicated Wireless Control Unit that houses
controls and indications for operating the equipment locally. A removable plug contains a chip which is
coded and guarantees the communicating with the correct receiver.
The (un)locking and opening of the frame can only be carried out using the wireless control units.
Figure 12 Tensioner Wireless Control Unit.
3.1.11 Emergency Stop Circuit

The emergency stop circuit of the tensioners is interfaced with the VODAS control system that
connects the safety circuits of all the cable laying equipment and E stop buttons on deck.
For each tensioner, the E-stop buttons are located on the distribution cabinet, on the remote-control
console and on the belly pack. To activate the emergency, stop any E-stop button can be pressed.
This immediately commences a controlled fast stop. After a defined delay, all controls and actuators
are disabled. That means that even when the equipment has not reached a complete stop, the brakes
will apply directly after this delay.
To reset the emergency stop, all pressed E-stop buttons must be retracted.
3.2 Wheel Pair Tensioner

A 2 Tons, 2 pair wheel tensioner is located on top of the loading tower. The WPT is driven by an
electric hydraulic power pack assembled with a variable displacement closed loop hydraulic pump and
an open loop boost pump. This arrangement ensures a step-less control of the speed in manual mode
as well as the option, through a selector switch, to operate the wheel pair tensioner in constant
tension mode (CT).
To detect wheel slip, each wheel is equipped with an encoder. If an encoder is broken, this encoder
can be deselected on the VODAS screen. If one of the wheels in slipping, an alarm in the VODAS
system will be generated to notify the operator.
The WPT can be operated remotely from the VODAS screens. When required, each of the two pair of
wheels can be opened, closed, braked or operated independently.
In case of contingency or maintenance, the WPT can be controlled locally using the control cabinet
located on the first level of the loading tower.
The emergency stop circuit of the wheel pair tensioner is interfaced with the VODAS control system
that connects the safety circuits of all the cable laying equipment and E stop buttons on deck. On the
wheel pair tensioner and on the control cabinet there is an emergency stop button, which can be used
to stop the electric motor of the HPU and, consequently, when remotely operated from VODAS, to
stop all the rest of the cable laying equipment.
Figure 13 WPT outside body Figure 14 Inside WPT showing wheels and rollers
3.3 Quadrant, quadrant which, quadrant handler and side winches
3.3.1 Quadrant
The quadrant is located on the vessel centreline and is mounted on two trolleys that moves on two
rails. During laying or loading operations its longitudinal position is controlled by the quadrant winch,
whose paid out length and tension is monitored and adjusted by VODAS in accordance with given set
points.
It is used for:
- guiding the cable along the cable highway, from the SB tensioner to the PS tensioner
- as a buffering system on deck to actively compensate variations in cable laying parameters
- for executing 2nd end pull ins and Ω-joints.
The bending radius of the quadrant is 5 m and the maximum product diameter that can be
accommodated is 450 mm.
Figure 15 Overview of the deck. Quadrant in neutral position and quadrant handler down
3.3.2 General
The quadrant handling system is made up of the following equipment:
- Hydraulic power unit;
- Quadrant Winch;
- Quadrant Handler (Clamps + Locking Pins);
- 2 Side winches;
- JIB.
The quadrant winch, the quadrant handler, jib and side winches can be controlled from different
locations:
- Local control panel on the PS aft deck (for every winch and cylinder by means of joysticks and
push buttons)
- Local control panel at the quadrant winch (for quadrant winch only by joystick)
- Remote control through VODAS mimics screens and the dedicated joysticks in the control
cabin or bridge operator desk
3.3.3 Hydraulic Power Unit

The hydraulic power unit for the quadrant handling system is installed in the HPU 20ft container which
is located on deck on the PS aft. There are four pumps and three electro motors:
- Motor #1 / Pump #1 are used for the quadrant winch
- Motor #2 / Pump #2 and Pump #3 are used for the side winches, quadrant handler (including
locking pins, clamps and jib) and to swing the DAMS in and out
- Motor 3 / Pump #4 are used to circulate the hydraulic oil until the temperature in the tank is at
required level
Each motor for each pump is started by soft starters that are in an electrical cabinet in the same HPU
container. The starting and stopping of the hydraulic pumps is controlled by a PLC that is also located
in the container.
Each hydraulic pump can be individually started from:

- Local control panel at the PS aft deck
- Local control panel at the quadrant winch (quadrant winch only)
- Remote control, from VODAS, in the control cabin or bridge operator desk
Note: If the hydraulic oil temperature is too low, the system needs to be heated up by starting and
circulating the oil with the hydraulic pump. This is necessary for the RFU (ready for use) condition of
the quadrant winch. The heating process starts automatically, if needed, when the RFU condition is
requested from any remote-control locations or local control panels. Pump #4 will start and circulate
the hydraulic oil until the temperature in the tank is 30 degrees and the oil temperature at the quadrant
winch is 20 degrees. During operation, the temperature difference between the oil in the tank and the
oil at the quadrant winch should stay within 15 degrees.
3.3.4 Quadrant Winch

The quadrant winch is a hydraulic direct drive 20T operated winch. This winch is located on the PS of
the vessel and its wire is permanently connected to the quadrant through wire sheaves.
The quadrant winch can be operated using the dedicated joysticks, either from the local control panels
on deck or from the control desk in the control cabin or bridge. The joystick provides the speed set
point of the winch.
When the quadrant is at home position (most forward position) the wire length of the quadrant winch is
calibrated automatically.
During cable loading and laying, when the cable is clamped in the two tensioners, the quadrant winch
must be operated in CT control. The remote manual control of the quadrant winch is not possible if the
two tensioners are closed.
During upending or down ending, the quadrant winch is operated in position control mode. In order to
have sufficient slack during the movement of the quadrant handler, the length of the wire is defined by
means of a look-up table as a function of the quadrant handler angle.
3.3.5 Quadrant Handler and JIB

The quadrant handler is located at the aft deck of the vessel near the chutes and it is used to tilt the
quadrant from horizontal to vertical position. To secure the quadrant during the upending and down
ending and prevent any uncontrolled movement, there are two retractable locking pins and two
clamps on the handler that can be operated either from the local control panel at the PS aft deck or
through VODAS.
Figure 16 Quadrant on the handler during upending Locking pins out, clamps closed and jib in “centre” position
(export cable 2nd end pull in)
The jib, which is the moving part at the top of the quadrant handler, where the sheave for the quadrant
wire is located, can be moved by a cylinder to keep the quadrant in line with the handler, during
upending and lowering, and in a straight line with the chutes during the lowering and lifting. The stroke
of the jib can be adjusted from the pushbuttons on the local control panel on the PS aft deck or from
the VODAS mimics screen.
3.3.6 Side Winches

The winches are designed to stabilize the quadrant during the lowering and to tip the quadrant when it
is at the required water depth. The wires from the side winches are routed through several sheaves to
the stern and then to the side of the chutes (Figure 17Error! Reference source not found.). They
have to be connected manually to the quadrant before the upending.
Figure 17 Quadrant on the handler ready for upending. Side winches (red lines – note the routing) connected to
the quadrant.
The PS and SB side winch are hydraulic direct driven winches and the system is developed for two
types of control:
- Speed control: When this option is selected, the speed can be controlled using the joysticks
(either on the SB aft local control panel or on the remote-control desks). This option is only
applied for connecting and disconnecting the side winch wires to the quadrant (manually).
- CT control: CT control is applied during lowering/lifting the quadrant to or from the seabed.
The CT prevents any uncontrolled rotation of the quadrant.
The CT mode can only be operated through VODAS mimics in the control cabin or bridge
operator desk.

The emergency stop circuit of the quadrant handling system is also interfaced with the VODAS control
system that connects the safety circuits of all the cable laying equipment and E stop buttons on deck.
E-stop buttons are in the HPU container and on the two control consoles on deck.
3.4 Carousel and Loading Tower

The carousel consists of several major components:
- The Basket, including the drive chain, tracks and main bearing Table 2
- The Access, including the gangway, core access and hatches
- The Grillage, including the hydraulic suspension system and drive systems
- The Loader System
- The HPU
- The Drive Suite
Load capacity 5,000 tons

Storage volume m³ 2,994 [m³]
Inner diameter 6.0 [m]
Height 6.25 [m]
Storage height for cables 5.5 [m]
Outer diameter 26 [m]
Nominal speed (turning) 1000 [m/ hour]
Drive system 3 x 185 kW AC motors
Emergency stop (full speed to complete stop) <7 seconds
Supporting rollers 63 pcs
Table 2 Carousel specifications
The carousel is in general operated remotely through VODAS. For special operations or maintenance,
the carousel can also be operated locally from the HMI in the drive container, where a small number
of hardwired controls are available to allow the operator to run the drives in jog mode.
3.4.1 Carousel Basket

The basket sits on the grillage, supported by the rollers on 3 tracks that are fastened to the underside
of the basket. The basket is designed to hold 5000t of product in a series of concentric wraps and
many layers to a height of 6.25m from the floor of the basket.
The walls of the basket are constructed using steel plates over a circular framework. The floor is
fabricated in a similar fashion with large skin plates welded to a framework of rings and spokes.
When needed three concentric dividers can be mounted inside the carousel to make up four storage
rings. The most inner divider is installed at 6.65m from the centre of the basket, the second ring at
9.05m, the third, namely the most outer one, is at 11.95 m. The thickness of the dividers is 0.3 m.
Access is provided into the basket via a retractable aluminium gangway mounted on a stationary
platform connected to the vessel structure. The gangway pivots between 0 and 55 degrees to allow
safe access to the interior of the basket when the basket is both empty and full loaded.
The composite carousel bearing is housed in the core and runs against the stainless-steel kingpost on
the grillage.
Figure 18 Divider rings in the carousel
Figure 19 Carousel system Figure 20 Carousel grillage assembly

Figure 21 Carousel grillage assembly
3.4.2 Roller Assemblies and Roller Control Frame

The carousel table is supported by an array of rollers mounted on a grillage. The roller units are
supported by means of a hydraulic cylinder. There are 63 units installed on the grillage rings. Each
ring has its own specific roller assemblies. The 63 roller pairs are split into 3 sections, and each
section contains 3 roller groups with 7 rollers in each group.
Each section is fitted with a triple rod less cylinder that acts as an accumulator to evenly distribute
pressure about each group. The triple rod less cylinder shares the hydraulic pressure between each
roller group and balances each group in that section to ensure that the load is spread evenly on the
rollers. This means that if the pressure is lost on one roller group, the load will be evenly spread on
the other two. A roller control frame is mounted in each of the 3 sections and provides local hydraulic
control for each roller group. The three sections are labelled (PORT, STBD and AFT), and each
section contains 3 roller groups labelled (A, B, C, D, E, F, G, H and I).
Figure 22 Grillage roller assembly Figure 23 Roller control panel with rod-less cylinder
3.4.3 Central Bearing and Central Bearing Housing

The carousel central bearing is locked rotationally to the core of the basket via spigot pins and it runs
against the King Pin built into the grillage. The bearing is made up of 15 different composite
segments/pads bolted to the frame bearing housing. The housing has several inspection holes in the
upper plate to inspect the condition of the bearing.
The central bearing housing is designed so that it can be removed and serviced, without the basket or
grillage being removed from the deck, by lifting it through the core of the carousel. Due to the addition
of access platforms inside the carousel core, these will need to be removed prior to the
aforementioned activity.
Figure 24 Central housing mounted on King Pin
3.4.4 Basket Chain and Mount

The basket chain is positioned around the circumference of the base of the basket. The sprockets
mounted on the drive modules engage with the chain to drive the basket round on the roller rings and
tracks.
The chain is connected to chain mounts via a clevis, the chain mounts are bolted to mounting plates
on the basket. The chain mounts are shimmed out from the brackets in order to maintain the correct
tension, roundness and concentricity of the chain.
3.4.5 Drive Modules

Three drive modules are positioned on the circumference of the basket in order to power its
movement.
Each drive module consists of an independent AC drive, flexible coupling, gearbox, gearbox cooler
and sprocket. The system can operate with one drive in a failed state thus providing redundancy, but if
another drive fails the system will come to a normal stop.
Figure 25 Carousel drive module drawing Figure 26 Driving module
3.4.6 Loader System

The loading tower is positioned on the SB of the vessel, aft of the carousel. It guides the cable from
the vessel main deck level into the carousel while ensuring a minimum MBR of 5 m. The product is
guided in a series of roller blocks that run along the loader system. These roller blocks restrain and
protect the product. Access is provided for every roller block for maintenance and to assist the
passage of cable ends during loading and laying. The WPT on top of the loading arm can be easily
removed from its position (fast hydraulic connections) and all the roller boxes can be fully opened
when needed.
Figure 27 Loader system overview

Figure 28 Roller block
The loader arm is hydraulically actuated; it can pivot through 42° port/starboard relative to the loader
tower. This allows the product to be loaded or laid correctly. The angle of the loader arm can be driven
automatically from the control system, or manually using the joystick on the control desks (control
cabin / bridge).
There are product position monitoring sensor levers (limit switches) mounted on the exit of the loader
arm that allow the system to detect if the cable is in the correct position and if it is tight or slack.
Both sets of levers pivot on a frame welded to the end of the loader arm, the tension sensors can be
adjusted in the forward and aft direction to account for varied product diameters and bend stiffness. A
set of springs on each lever arm returns the levers to the closed position around the cable. Each lever
is fitted with a polyethylene wear pad to ensure no damage to the product during a contact. All levers
are fitted with two proximity sensors for redundancy.
For transit and seafastening, when the loader arm is in its innermost position, it can be locked to the
loader tower using a locking pin that can be lowered or rised locally, by means of a screw mecanism.
There is no sensor detecting the position of the locking pin.
Figure 29 Loader arm overview Figure 30 Product position and tension sensors
3.4.7 HPU and Drive Suite

A single containerised (10’ ISO) HPU is provided to supply hydraulic fluid for both the loader arm and
grillage hydraulic systems. The HPU is self-contained and can be operated remotely from the either
control stations or locally from the HPU Control Panel. A small dedicated PLC is used within the HPU
to perform all control and monitoring functions.
A single containerised (20’ ISO) Drive Suite is provided to supply electrical power for the drives,
system lighting, sounders, beacons and control systems. Local HMI is mounted within.
Both containers are located forwards the carousel.
3.4.8 Carousel Holding Brakes and Bracing

The carousel is fitted with holding brakes. The brakes are failsafe, meaning that they must be
energised to be released. The brakes are not designed to stop the carousel under normal operating
conditions. It is the electric motors that are used for braking, with the excess energy produced
dumped into the air-cooled brake resistors. The brakes are normally only applied when the equipment
has come to a halt. However, during a power supply failure or blackout condition the brakes will be
applied immediately to stop the system safely.
The carousel brakes are not designed to hold the equipment during maintenance and transits. The
system should be braced and electrically isolated (turning off the breakers of the drives), when
personnel is required to work close or under the carousel and / or sea-fastenings have to be installed
for transit. The brace function is provided to take up the slack in the gearboxes and sprockets. It can
be initiated only locally from the HMI in the drive container and works on one drive at a time. When the
sequence starts, the system puts the selected drive into “torque with speed override” mode, releases
the brake and then runs the drive for a short time at low speed to take up the slack.

The E-Stop system consists of a dedicated safety programmable controller that monitors the status of
all safety inputs and controls the system into a safe stopped status in the event of any safety input
becoming active.
The carousel E-Stop push buttons are placed in areas where personnel activity is possible, namely
main drive panel suite, HPU local control panel, loader arm, around the grillage and basket access
gangway.
Since the emergency circuit of the carousel is also interfaced with the Nexus safety circuit that
connects all the cable laying equipment together, on activation of any of the E-Stops all main PLC
outputs and HPUs are immediately stopped. To restart the system, the emergency stop relay must
first be reset. When the carousel is operated locally from the drive container, the emergency circuit of
the carousel can be isolated form the rest of the equipment using a key switch in the front panel.
When the key switch is on OFF position, the system only looks to the E-Stops related to the carousel
and loading tower.
3.5 DAMS
The Departure Angle Measurement System, is developed to measure the angle of a cable on the
chute entering the water using LIDAR (light radar) technology. This piece of equipment is swung into
position above the SB chute with a hydraulic cylinder and it can precisely measures:
- the vertical angle (between the z-axis of the ship and the cable), ranging from +10° to +60°
(Vertical is 0°)
- the horizontal angle (between the x-axis and the projected cable in the horizontal plane of the
ship) ranging from -90° to +90°. Counter clockwise is positive.
There are three Sick LMS LIDAR devices that work by emitting a pulsed laser beam and measuring
reflections, similar to radar systems. These three LMS devices are connected to a PLC and interfaced
with VODAS.
By using object detection and filtering techniques, a 3D orientation of a cable is generated, from which
the two angles are derived. The values of these angles are constantly sent to VODAS and can be
used for the control processes of cable laying. In case of miss-calibration or poor-quality readings of
the lasers, an alarm is shown on the VODAS mimics.
The DAM device is equipped with two active thermoelectric cooling/heating units. This ensures safe
operating temperature ranges and avoids condensation.
Figure 31 Illustration of the LMS scanners measuring rays Red = LMS1, Green = LMS2, Blue = LMS3
3.6 Capstans
There are four identical 50 KN capstans on deck: two are aligned
with the SB and PS cable highways, one is located at the SB aft,
close the SB chute, and one is located on the SB side, close to the
foundation of the loading tower.
To accurately control the speed of the capstans and safely use

them together with the other cable laying equipment (e.g. to pull a
cable through the system or around the quadrant), the electric
motor of each of them is driven by a variable frequency drive.
The capstans can only be operated locally.
Figure 32 Capstan
3.7 Remote Control Locations and Control Desks

Each piece of equipment and every cable handling operation can be controlled by just one operator
from either one of two remote control locations, namely the control cabin and bridge operator desk.
Each control locations is equipped with two touchscreens used for controlling the equipment through
VODAS. Additionally, on the left screen, by pressing a button on the control desk, it is also possible to
visualize survey screens such as navigation, echoscope, cable laying management system etc.
On the control desks, which are identical in the two different control locations, all the control joysticks
and dials are available. On the right hand side there is a dial to control the PS tensioner speed, and
the joysticks for side winches, quadrant winch and quadrant handler. On the left hand side there is a
joystick to control the position of the loader arm and three dials for SB tensioner, carousel and wheel
pair tensioner speeds.
On each control desk there is a control switch (BRIDGE – CONTROL) to select the location where the
control is taken over from. These switches only enable/disable the hardwired control on the desk
(joysticks and dials), the mimic screens are always operative in both locations. Both switches must be
kept in the same position.
Figure 33 Control Desk

The control cabin is located on the PS side, aft the carousel, on an elevated structure that allows the
operator to have a clear view of the entire process. The operator can see inside the carousel, monitor
the cable catenary at the loading arm and he has an open visual of the deck, tensioners and quadrant
movement.
The bridge operator console is located on the bridge, on the right side of the DP control station, and
can be used when a direct communication between DPO, survey and cable operator is required.
Several screens showing selectable CTV cameras are also available in both locations.
3.8 E-STOP CIRCUIT

As stated previously, the safety circuits of the cable laying equipment and the E-stop buttons on deck
are inter connected and interfaced in the VODAS control system. When the system is operated
remotely from VODAS, the activation of any of the E-Stops button will immediately stop all main PLC
outputs and HPUs of the cable laying equipment. The positions off all E-stop buttons on deck are
shown in Figure 34. To restart the system, the emergency stop relay must first be reset.
During cable laying, the E-Stop circuit can be linked to the DP system of the vessel. If the conditions
listed below are met, any E-Stop triggers a “stop on track” on the DP system, namely the Nexus stops
automatically on track when any E – Stop is activated. The conditions are:
- DP is set to track mode

- e-stop function enabled on both the DP and VODAS
- the SB tensioner laying speed is higher than 4 m/min
There are other conditions that can trig a “stop on track” request to the DP but these will be discussed
in DP automatic ‘Stop On Track’ paragraph.
Figure 34 E-stop button overview

4 VODAS Control System

As already mentioned, VODAS is a controlling software that manages the intercommunication and the
remote control of all the equipment on deck. By mimic screens, VODAS gives a clear and unique
interface to allow one single operator to run the entire cable laying system. It has also been developed
to automate most of the operations carried out during cable installation works.
In the following section, a detailed overview of the system and a description of each page of the
system is given.
4.1 VODAS architecture

The main menu can be opened at any time by pressing the Van Oord icon in the left bottom corner
bar of the VODAS mimic screen.
As shown in the VODAS architecture diagram, the main menu is divided in four sub-menus
(GENERAL, VODAS, SYSTEM, PROCESS) that give access to all the pages of the system.
GENERAL Alarms Specs Monitor Time
Input
VODAS Calc Field Diagnose
Output
Wheel Pair Umbilical

SYSTEM Carousel Tensioners Quadrant DAMS E Stop
Tensioner Winch
x x x x x x x
PS Winch
Overview Overview Overview Overview Emergency
Tensioner Handler
SB Side
Suspensions
Tensioner Winches
Loader Arm Clamping Hydraulic
Hydraulic Hydraulic
Stops Frame
Overrides
Quadrant
PROCESS Lay / Load Set Point
Operations
Figure 35 VODAS Menu – System architecture

In the following paragraph, a description of each VODAS page shown in this diagram will be given and
it will be explained how to operate each piece of equipment as well as to control cable operations and
automation.
The crossed out grey buttons in the diagram, namely GENERAL -> Specs / Monitor / Time and
VODAS -> Input Output / Calc / Field / Diagnose, will not be discussed in this manual since are only
used for information, I/O data flow monitoring and software diagnosing.
4.2 GENERAL Menu
4.2.1 Alarms
There are more than 600 alarms set in the system regarding equipment functionality, communications
and operations. They have been divided in three alarm types/levels (information, alarm and
meltdown), depending on their impact on equipment, safety of personnel and product cable during the
ongoing operation. Alarms have been organized in seventeen groups, shown in the first column of the
Alarms page, such as Tensioner SB, Tensioner PS, Wheel Pair, Carousel, Quadrant system, I/O,
DAMS etc.
At the opening of the Alarms page, the Active alarms, with all the relevant details, are shown. On the
bottom of the page there are two buttons to acknowledge an alarm selection or the entire page.
Selecting the tab History at the top of the page it is also possible to visualize the alarm history.
On “alarm” and “meltdown” alarm types a beeper is triggered and it should be acknowledged by the
operator by pressing a push button on the control desk.
Information alarm types do not have a direct impact on the ongoing operation and just inform
operators and engineers about the status of each piece of equipment on deck, malfunctioning and
need of maintenance.
On the top of any VODAS page, to inform the operator about the status of the system, the latest
activated alarm or warning is displayed in a red bar. By pressing the red bar from any page, the alarm
page can be opened directly.
Figure 36 Alarms page

4.3 SYSTEM Menu

This menu contains all the relevant pages to remotely control and monitor the functioning of deck
equipment. The following pages are mainly used to start up and shut down the system (drives,
hydraulics etc.), give or take control from local control locations, check equipment status and input
machineries set points and setting.
4.3.1 CAROUSEL
Overview
By opening the carousel overview page, a schematic of the layout of the carousel system is
visualized, including the relevant data of drives, motors and gear boxes. In the upper part of the page
there are two control buttons to switch the drives of the carousel ON and OFF. This can be done if the
start conditions, shown on the right, are met.
As previously said, the carousel can also be operated from the drive container, mainly for
maintenance purpose or other specific tasks that will be discussed later. To take the control back in
VODAS, the Remote request button should be pressed on the mimic screen. When this button is light
grey and is not functioning, it means that the system is being locally operated from the HMI in the
container or the control handover is inhibited.
Figure 37 Carousel - Overview page

Suspension
In the top left part of the suspension page, the rodless cylinder positions are shown for each section
(PORT, STBD and AFT) and roller groups (A,B,C,D,E,F,G,H,I,). During operation, the rodless cylinder
positions should be in the range of about 67%.
In the bottom left part of the page, the roller cylinder heights are shown, two rollers for each section.
The height set point is 55 mm, indicated by a purple line on the indicator. Red lines at 5mm and 95
mm represent the maximum and minimum limits of the cylinder height. When the roller cylinders are
lower than 5 mm or higher than 95 mm, the carousel will automatically stop. The blue lines show the
range of the cylinder height, determined by taking the lowest and highest value during the rotation of
the carousel. It can be reset by pressing the Reset Range button.
On the right part of the suspension page, the command buttons to raise and lower each section of the
carousel suspension are shown. For example, to raise the carousel from the lowest position up to the
height set point of 55 mm, the Raise Basket buttons for the Port, Starboard and Aft section have to be
pressed. During this operation, the roller heights have to be monitored in order to make sure that the
average roller height for each section is close to the others, and if not, each section can be
independently controlled or stopped.
Once the carousel suspensions are at the desired height, the Autoset Position buttons have to be
pressed in order to equalize the rodless cylinder positions and pressures. During cable operation, this
page has to be checked from time to time to ensure the correct functioning of the suspension system.
Figure 38 Carousel - Suspension page

Loader Arm
The loader arm is driven by the same HPU of the carousel. In the loader arm page, the inner and
outer carousel radius can be set in order to limit, if needed, the loader arm movement within a given
range. If there is no operational restriction, the loader arm can swing between 3 m, that is the inner
core radius, and 13 m, the outer wall radius.
Figure 39 Carousel – Loader arm page

Hydraulic
On the hydraulic page, the HPU of the carousel and loader arm can be started and stopped. Start
conditions have to be green and the system remotely controlled as explained for the carousel
overview page.
Figure 40 Carousel – Hydraulic page

Stops
On the stop page the status of all the stop signals are shown. They are divided as Overrides Carousel
E-Stop System, Fast stop signals, and Forced stop signals.
Figure 41 Carousel – Stops page

Overrides
On the overrides page, there are ten buttons that can be used to override particular conditions that
otherwise would cause a forced or fast stop signals to the carousel.
These overrides can only be used by, or on request of, a qualified engineer or technician to
accomplish specific tasks or maintenance.
Figure 42 Carousel – Override page

4.3.2 TENSIONERS
PS Tensioner and SB Tensioner

PS and SB tensioner pages are identical. In the centre of the page a schematic of the layout of the
tensioner driving system is shown including relevant data of drives, motors and gear boxes. The
clearances between the tracks at the aft and forward positions are shown on top of the symbol of the
tensioner. On the right side, there are three buttons to operate the clamps. Once either the open or
close button is pressed, the hydraulic starts automatically and the tracks start moving. This operation
can be stopped anytime by pressing the stop button. If a cable is clamped, once the open button is
pressed, firstly the clamping force is released and then, if not stopped, the tracks will open until the
maximum. Similarly, once the close button is pressed, the tracks will close automatically on the
product until the clamping force reaches the set point, input in the Clamping page (see next
paragraph). Once the tracks are closed at the right clamping force, the close condition is met and the
close button turns green. Independently from the status of the tensioner drive, the system will
automatically maintain the clamping force about the set point. If the clamping force drops below a set
value, the hydraulic starts to restore the clamping force. It is worth noticing that in case of an
emergency stop of the equipment, the clamping force will be kept, but the close button has to be
pressed again to restore the close condition in VODAS (close button green) and the automatic
function from the clamping just described. The close condition of the tensioners is very important in
many automated processes and operations that will be discussed later.
On the top left of the page, the remote-control location can be selected: VODAS or belly pack. If the
belly pack is selected, the device should be switched ON and the control request has to be accepted
by pressing the reset button (on the back, left hand side). Similarly, when finished, the reset button
has to be pressed again, before switching OFF the belly pack, in order to be able to take the control
back in VODAS.
The command buttons to switch the tensioner drive ON and OFF and the staring condition are found
on the top centre page. The drive cannot be started if the tensioner speed dial on the control desk is
not at the zero position or the system is not in remote.
Level 1,2,3 alarm status is shown on the top right page. Alarms can be reset by pressing the Reset
Alarm button.
On the bottom right page, the tensioner speed, tension and clamping forces at clamping cylinders are
shown. For safety reason, if there is tension in the cable, either due to the catenary or to the buffer
system on deck, the open clamps command does not work.
Figure 43 PS tensioner page
Figure 44 SB tensioner page

Clamping
As explained in the previous section, on the “Clamping” page it is possible to change the clamping set
point of the two tensioners. For each tensioner, the clamping forces measured at the clamping
cylinder and, on the top of the tensioner symbol, the clearance between the two tracks are shown
Figure 45 Tensioner - Clamping page

Hydraulic
The “Hydraulic” page is only used to check status and alarms of the hydraulic of the tensioners. The
hydraulic starts automatically when there is a request to operate the clamp.
Figure 46 Tensioner - Hydraulic page

Frame
Similarly, to the previous page, this page it is only used to monitor the status of the frames and locking
pins of the two tensioners.
Figure 47 Tensioner - Frame page

4.3.3 QUADRANT
Winch / Handler
The left-hand side of the page is dedicated to the quadrant winch, the right-hand side to the quadrant
handler.
The hydraulic can be switched ON by pressing the RFU button. If the hydraulic oil temperature (shown
on the bottom part of the page) is too low, the hydraulic oil of the system needs to be heated by
starting and circulating the oil with the hydraulic pump #4. The RFU button in this case will start
blinking and pump # 4 will start to circulate the hydraulic oil until the temperature in the tank is at a
minimum of 30 degrees and the temperature at the quadrant winch is at a minimum 20 degrees.
During operations, the temperature difference between the oil in the tank and the oil at the quadrant
winch should be within 15 degrees. Once the right temperatures are reached, the RFU button will turn
green, pump #4 will stop and the dedicated pump will start (e.g. pump #1 if the RFU button for the
quadrant winch has been pressed and pumps #2 and #3 if the RFU button for the handler and/or side
winches has been pressed). If the hydraulic oil is already at the right temperature, by pressing the
RFU button the dedicated pump starts immediately. To turn OFF the hydraulic the RFU button has to
be pressed again and will turn from green to grey.
By pressing the Deck button, the control is handed over to the deck control panels, where the control
has to be accepted
From this page, once the RFU of the handler is met, it is also possible to control the locking pins,
clamps and jib of the quadrant handler. This is only for manual operations, maintenance or testing
since these items are normally controlled through the Quadrant Operation pages.
The start conditions and status are shown for both quadrant winch and handler.
Figure 48 Quadrant – Winch/Handler page

Side Winches
Similarly, to the “winch / handler” page, to start the two side winches, the RFU buttons have to be
pressed. If the hydraulic oil is already at the right temperature, pump #2 and #3 will start immediately,
otherwise pump #4 will start as previously described.
From this page, the Constant Tension (CT) can be activated by pressing the CT buttons. The CT set
point can be set for each individual winch (purple arrow) or combined so that pressing +/- 0.1t the CT
setpoints of both winches are increased or decreased by the same amount. This operation is usually
controlled through the Quadrant Operation pages.
By pressing the Deck button, the control of the side winches is transferred to the deck control panels
(PS aft only), where it has to be accepted.
Start conditions, pay out length and pull force are shown for both side winches.
Figure 49 Quadrant – Side winches page

Hydraulic
In the “Hydraulic” page the schematic of the hydraulic of the quadrant handling system and the
pressure values of the pumps are shown.
As explained previously, motor #1 and pump #1 are for the quadrant winch; motor #2 and pumps #2
and #3 are for the quadrant handler, side winches (and DAMS); motor #3 and pump #4 are for heating
up the hydraulic oil.
Figure 50 Quadrant – Hydraulic page

4.3.4 WHEEL PAIR TENSIONER
Overview
The wheel pair tensioner can be remotely controlled from this page. The HPU can be started and
stopped by pressing the Start HPU and Stop HPU buttons. Once the HPU is running, the clamps can
be opened or closed. If the Clamps ON or Clamps OFF button is pressed, the two pair of wheels will
close or open simultaneously. It is also possible to open/close only one pair of wheels at the time by
pressing the buttons Cylinder fwd In / Out and Cylinder aft In / Out. Cylinder aft operates the aft pair
and cylinder fwd the forward pair. Brakes are automatically applied when not in CT mode and the
requested velocity is zero. The brakes are also automatically released when the operator restarts
operating the machine.
The CT mode can be selected by pressing the CT buttons. The CT set points can be input in the
system by pressing the purple arrows. During loading, the wheel pair tensioner has to pull the cable
from the PS tensioner all the way up to the top of the loader arm, during the laying only from the
carousel. For this reason, there are two set points for the CT, one for the loading and one for the
laying. The wheel pair tensioner automatically switches between these CT values every time the cable
moves in one direction or the other.
The clamp force set point can also be input in this part. Speed, CT force and Clamp forces are shown
in the bar chart in the centre of the page.
Below the settings, the speed indication and the status of each wheel is depicted. By enabling the
wheel speed measurement of each wheel, VODAS can detect and alarm the operator if any of the
wheel is slipping. The slip detection system works for speeds above 1,5 m/min (= 1 rpm) and it gives
a visible and audible alarm when the speed of one of the wheel is larger than two times the average of
the other wheels.
Status and alarms are shown on the right of the page.
Figure 51 Wheel pair - Overview page

4.3.5 DAMS
Overview
All the relevant information to monitor the correct functioning of the DAMS are given in this page. The
measurement quality of the three laser devices (LMS) and their combined reliability are shown.
Besides, the pollution level of the glass in front of LMS1 and LMS2 is indicted. It is advised to clean it
when the pollution level is above 10 %.
Figure 52 DAMS - Overview page

4.3.6 UMBILICAL WINCH
Overview
The “umbilical winch overview” page is for information only since the umbilical winch can only be
operated locally from the control panel located on the winch itself. However, the status, settings and
alarms are integrated in the system and shown on this page. Also, an override button is available if
due to any case the winch cannot be operated and this is preventing other systems from starting up.
This option should always be used carefully.
Figure 53 Umbilical winch - Overview page

4.3.7 E-Stop
Emergency
The “E-stops” page shows the status of all the emergency stops of the system. If any of these is
active, none of the previous mentioned operations can be carried out. In order to be able to start the
operations the emergency stops have to be reset (locally if needed) and by pressing the E-Stop reset
button on the VODAS screen.
Figure 54 E-Stop page

4.3.8 STANDARD PROCEDURE to start up the system

To summarize what has been described so far and before moving to the process control during
operations, the standard procedure to start the system through VODAS and via the System menu is
schematically described below:
1. E Stop -> reset emergency stops by pressing E-Stop reset button
2. Carousel -> Overview -> If not in remote control yet, press the Remote request button
-> Check start conditions
-> Press Drive ON button
-> Hydraulic -> Check start condition

-> Start the hydraulic by pressing the Start button
-> Suspension -> Check carousel suspension and, in case, adjust the position
-> Loader Arm -> Check set points
-> Overrides -> Check overrides (none has to be active)
3. Wheel Pair -> Overview -> Start HPU

-> Check settings
-> Depending on the operation, close / open the clamps
4. Tensioners -> Clamping -> Check / input set points for the clamping force
-> Tensioner PS -> Remote control has to be in VODAS

-> Reset alarms
-> Switch on the drive by pressing the Drive ON button
-> Tensioner SB -> Remote control has to be in VODAS

-> Reset alarms
-> Switch on the drive by pressing the Drive ON button
-> Hydraulic -> Check the status of PS and SB tensioners
-> Frame -> Check the status of PS and SB tensioners
5. Quadrant -> Quad. Winch -> Check start conditions

-> Switch on the hydraulic by pressing the RFU button
-> Check status and wait for HPU/winch heating up (if required)
-> Handler -> (if needed) Switch on the hydraulic by pressing the RFU button
-> Side winches -> (if needed) Switch on the hydraulic by pressing the RFU buttons
-> Hydraulic -> Check the status/pressures of the pumps

6. DAMS -> Switch on the hydraulic of quadrant handler by pressing the RFU button
-> Handover the control to deck by pressing the Deck buttons in the quadrant
handler page
-> Accept the control from the SB aft control console (Barbeque)
-> Operate the DAMS (swing it IN or OUT)
-> Take the control back to VODAS by pressing the Deck buttons in the quadrant
handler page
-> Switch off the hydraulic of quadrant handler by pressing again the RFU button (if
not needed)
7. Survey winch -> Overview -> Start the winch locally

-> Enable CT locally
4.4 PROCESS MENU
4.4.1 LAY / LOAD

Once the equipment has been started, any cable operation and automatic function is controlled
through the LAY / LOAD page. Prior to start operating any machinery, this page should be shown on
one of the two mimic screens since it displays all the relevant information needed to control the entire
process. It can be opened any time by pressing the home icon in the left bottom corner bar of any
page.
Figure 55 LAY/LOAD page

On the top of the page a schematic of the complete cable laying system is given. The cable is
represented as a continuous line going from the carousel and loader arm through the wheel pair
tensioner, PS tensioner, quadrant and SB tensioner to the chute.
In the centre of the page two graphs are shown: the left one shows the trends of vessel and SB
tensioner speeds, the right one the trend of the cable departure angle about the set point. In the
centre, the total pay-out length, the pay-out length in the last hour and the average speed are
displayed. On the bottom of the page, all the main parameters to control the deck equipment and
automated processes during cable laying or loading are shown. From left to right on the bottom of the
page is displayed:
- Carousel speed (+ laying , - loading)
- Loading tower position
- PS tensioner speed (+ laying , - loading)
- Quadrant position and tension
- SB tensioner speed (+ laying , - loading)
- Catenary angles
On top of these items there are the Auto buttons to enable the auto modes of each piece of deck
equipment as explained in the following pages. Set points for the cable departure angle, quadrant
position and quadrant CT value can be set in this page by pressing the corresponding purple arrows.
When no auto function is enabled, and drives and HPUs are running, every piece of machinery can be
manually controlled using the hardwired dials and joysticks on the control desk. In this case the page
is only used to display and monitor the above-mentioned parameters. However, running the
equipment in manual mode is never the preferred option and it has to be minimized. Sometimes, for
specific operations that will be discussed later in this document, it is required to manually operate
more than one piece of machinery at the same time. This requires skilled operators, specifically
trained, with a full understanding of the system. The general rule is that when the conditions to use an
automatic function or CT mode are met, the auto function or the CT mode must be used. Every time a
product is running around the quadrant and is clamped in the two tensioners, the quadrant winch must
be kept in CT mode to avoid excessive tension/slack in the product during operation.
Note: when both tensioners are closed (the “closed condition” is met when the Close buttons turn
green in the tensioner screens) and a cable is in the system, for safety reason the quadrant cannot be
manually controlled with the joystick on the control desk. The quadrant in this case can only be moved
using the CT function (and pay in or out with tensioners) or, if needed, it can be locally operated from
either deck control consoles.
Auto Modes
Assuming a cable is already fed in the system, from the carousel through loading tower, wheel pair,
PS tensioner, quadrant and SB tensioner and each piece of the equipment is healthy and running.
The wheel pair tensioner, as soon as the cable is clamped in the PS tensioner, can be kept in CT
always. For the rest of the equipment, there is a precise sequence to follow to start up the auto
modes, as described below:
- Quadrant winch CT
Figure 56 PS CT switch
The first automatic function that can be enabled is the CT of the quadrant winch. By pressing the CT
button (centre of the page above quadrant position and tension data), a new window will pop up
showing a description of the function and the conditions required to enable it. If all the conditions are
met (green lights), the CT can be activated by pressing again the CT button on the popup window.
The CT button on the Lay/Load page will turn green and the quadrant winch will start building up the
tension until the tension set point is reached.
When only the quadrant winch is in CT, the tensioners and the carousel can be manually operated if
needed. In this case the quadrant will only look at the tension set point and not to the position set
point. The quadrant can be moved by paying in or out with either tensioners.
As shown in the conditions box, the two tensioners have to be closed, the survey winch have to be in
CT or if not connected overruled and the quadrant winch ready for use. If these conditions are lost, or
an E-Stop is activated, the CT function will be automatically switched OFF.
- PS tensioner
Figure 57 PS tensioner auto-control
Once the quadrant is in CT, the auto control of the PS tensioner can be enabled. By pressing the Auto
button on the PS tensioner, a new window again will pop up showing a description of the function and
the conditions required to enable it (this happens every time an Auto button is pressed). When
enabling this auto-control the PS tensioner will automatically follow the carousel.
At this stage, the SB tensioner and the carousel are still in manual control (e.g. paying out with the dial
of the carousel, the PS tensioner will follow and the quadrant, in CT, will start moving forward).
NOTE: the PS tensioner control follows the carousel but if the catenary in the carousel needs to be
adjusted, the speed of the PS tensioner can be offset using the dial while still operating in auto
- Carousel
Figure 58 Carousel auto-control
Once the quadrant is in CT and the PS tensioner is in auto, the auto control of the carousel can also
be enabled following the same procedure previously described. Enabling the carousel auto control,
the carousel will automatic keep the quadrant at the set point position. This has as consequence that
the quadrant will stay in CT but its position will be controlled by the carousel.
Having the quadrant in CT, the PS tensioner and the carousel in auto, the operator can control the
entire laying or loading process by manually operating the SB tensioner only. This set up is very
useful in many circumstances.
- SB tensioner
Figure 59 SB tensioner auto-control
Once the quadrant is in CT and the auto functions of PS tensioner and carousel are active, the auto
function of the SB tensioner can also be enabled if the DAMS is healthy and in position. The SB
tensioner, in auto mode, will adjust its speed to keep the cable departure angle at the chosen value
(catenary set point). To improve the accuracy over the catenary control and to reduce the reaction
time of the SB tensioner after speed alterations, the vessel speed can also be used as a secondary
controlling input of the SB tensioner in auto mode. This option can be enabled or disabled in the
Setpoints page (PROCESS -> Set point)
To summarize, the fully automatic mode can be activated following this sequence:
CT quadrant -> PS tensioner in auto -> Carousel in auto -> SB tensioner in auto
When the system runs in the fully automated mode, the DAMS controls the speed of the SB
tensioners to keep the set CDA, the carousel follows it keeping the quadrant at the set position (winch
is usually half way of the buffering stroke, ca 7 m) and the PS tensioner follows the carousel. The
wheel pair and quadrant winch stay in CT at all the time. In auto mode, none of the manual control
works, apart from the PS tensioner. The reason why it is possible to manually give an offset to the PS
tensioner speed, as well as the position of the loader arm and its automatic mode, will be discussed in
the following pages.
Before activating the auto functions, all the relevant set points should be correctly inserted. They can
be changed at all the time but it should be done in small steps.
To switch off the automatic functions, there are two options: either following the same sequence just
mentioned but in the reverse order or pressing the Auto controls button in the bottom right corner of
any VODAS page. With this command, all the auto functions can be turned off at once, only the CTs
of the quadrant and wheel pair stay on.
Figure 60 Turn off all auto functions

NOTE: When turning off an auto function, the control goes directly back to manual. Consequently, the
system looks at the position of the speed dials on the control desk and operates the equipment
accordingly. It is therefore a good practice to put the dials always back in the ZERO position when not
in use or when the auto function has been enabled. To aid the operator, an alarm is in place to notify
the operator if an automatic function is switched off and the corresponding dial is not in zero.
Carousel Speed Calculation and Loading Tower Automation

Before introducing the auto function of the loading tower, it has to be explained how the carousel
speed is calculated. Its rotational (angular) speed is measured, but the line (tangential) speed
depends on the radial position of the touchdown in the carousel. Clearly, during laying or loading
operations, the line speed of the cable leaving or entering the carousel has to match the line speed of
the tensioners.
For example, if the laying speed is 10m/min and the radial position of the touchdown of the cable in
the carousel is 5m, the required rotational speed to control the carousel is 2 rad/min which is about
0.3rpm.
It is clear from this example that, in order to avoid excessive slack or tension in the cable catenary in
the carousel during automatic process, the estimation of the radial position of the touchdown is
extremely important. The solution to this problem is that the carousel calculates its rotational speed
based on the radial position of the loading tower, assuming that the touchdown point is exactly below
it. In reference to the example just given, if the radial touchdown position is 5 m, the loading tower
also has to be at 5m. In this case, to get a laying speed of 10 m/min, the rotational speed of the
carousel is calculated to be 2 rad/min (0.3rpm).
Assuming again that the laying speed is 10m/min and the loading tower position is at 5m but the
touchdown in is actually at 5.5 m. The rotational speed of the carousel is calculated using the loading
tower position, resulting, shown above, in a rotational speed of 2 rad/min (0.3rpm). The line speed of
the cable leaving the carousel, however, is given by the actual position of the touchdown point
multiplied by the rotational speed of the carousel, which results in a line speed of 5.5 *2 = 11 m/min.
Therefore, the carousel is running a 1m/min faster than the required laying speed. In this situation, the
operator has two options: moving the loading tower to the right position and/or compensate with the
PS tensioner using the speed dial on the control desk. When the system runs in fully automatic mode,
it is possible to give an offset to the speed of the PS tensioner in order for the tensioner to run faster
or slower than the carousel to temporarily adjust the catenary in the carousel. The quadrant will move
accordingly to accommodate the extra cable that has been pulled in or out from the carousel. The
speed offset is shown at the bottom of the PS tensioner speed bar.
The position of the loading tower, which is also shown on the Lay / Load page together with other
equipment, can be adjusted always with the joystick on the control desk. Practically, at a constant
laying or loading speed:
- moving IN the loading tower the rotational speed of the carousel is increased
- moving OUT the loading tower the rotational speed of the carousel is decreased
The loading tower has also an auto function and can be activated any time by pressing its Auto
button. In auto mode, the loading tower automatically moves with one cable diameter each carousel
rotation. The required direction of the movement can be set by pressing the arrows (UP-out and
DOWN-in).
Figure 61 Loading arm auto-control

In some cases, the loading tower cannot be kept exactly above the touchdown point (e.g. during cable
loading in the innermost divider rings). In these circumstances, to avoid miscalculations in the
carousel speed, instead of using the loading tower as a position source, it is possible to give the
system the actual (estimated) touchdown position. This option can be enabled by pressing the use
button and adjusting the cable position in the input field (purple arrow). The actual position of the
touchdown cannot be measured but it is constantly calculated by VODAS averaging the carousel
speed and the corrections carried out with the PS tensioner, if any required. This value is shown just
above the cable position input field and it gives the operator a clear indication on how the system is
functioning. If further corrections are needed, the PS tensioner can still be used to give a speed offset,
as previously described, but that also means the cable position should be adjusted. Moving the
touchdown position inwards (reducing the cable position input), the rotational speed of the carousel
increases, moving the touchdown position outwards, the rotational speed of the carousel decreases.
By selecting one of the two arrows around the use button, the direction of cable spooling can be set in
order to automatically move the cable position value with one cable diameter each carousel rotation.
The loading tower can be manually operated, when needed, but it has no impact on the carousel
rotational speed when the cable position is used. In order to avoid an excessive difference between
the position of the loading tower and actual position of touchdown in the carousel, the cable position
that can be set in the input field is limited by a band of 2 meter around the tower position.
Limit switches
As previously described, there are two limit switches mounted on the aft and forward exit of the loader
arm that monitors the catenary in the carousel and reducing the chance of damaging the cable in case
of excessive tension or slack. As soon as either the tight or slack sensor is trigged, the carousel
immediately stops turning and its drives are switched off. If the system is running fully automatically,
the drive of the PS tensioner is switched off as well. The auto functions of the carousel and PS
tensioner are disabled but the quadrant stays in CT and the SB tensioner keeps following the DAMS
in auto control. In this way, the quadrant can be used as a buffer and there is sufficient time to stop
the vessel in a controlled manner.
Once the vessel has come to a controlled stop, the catenary in the carousel can be adjusted by
starting the PS tensioner and pay in / pay out cable into / from the carousel. When the limit switch has
been returned to the working position, the carousel drives can be started and cable loading or laying
can be resumed.
DP automatic ‘Stop On Track’

As previously mentioned, VODAS is interfaced to the DP system of the Nexus. During laying, VODAS
can trigger a ‘stop on track’ request to the DP as soon as the conditions that ensure the automatic
control of the catenary parameters as well as the correct functioning of buffering system are lost. This
option can be activated by enabling the stop on track function on both DP and VODAS system ( MAIN
MENU -> PROCESS -> Setpoints) and it is effective when the SB tensioner is running at speeds over
4m/min.
As shown in the flow chart, once the stop on track function is enabled and the SB tensioner speed is
higher that 4 m/min, there are four conditions that trigger the stop on track request: the loss of the CT
of the quadrant, a fault in the SB tensioner or DAMS and any E-Stop on deck.
Figure 62 Stop on track triggering conditions

4.4.2 QUADRANT OPERATIONS

The control for the quadrant handling system has been developed to optimize the process, ensuring
safe operations and minimizing the chances of operational errors during 2 nd pull in.
The whole quadrant handling process has been split in VODAS in 10 steps, called modes, each one
of them covering a specific task, namely:
1. Shifting quadrant to quadrant handler
2. Preparation for quadrant upending
3. Quadrant upending
4. Unlock quadrant from quadrant handler
5. Quadrant lowering
6. Quadrant tipping
7. Quadrant retrieval
8. Quadrant lock on quadrant handler
9. Quadrant down ending
10. Shifting quadrant to fore ship
Figure 63 QUADRANT OPS (modes) page
The philosophy behind this structure is that, when the modes procedure is enabled, VODAS activates
or deactivates the manual controls of the equipment depending on the specific tasks to be carried out.
On the main Quadrant Ops page, the ten buttons are shown, one for each mode. By pressing one of
these, a window will pop up showing a description of the operation, a set of starting conditions and a
step by step procedure to follow. Each mode has to be enabled at the beginning and then disabled
before moving to the next one.
Before starting the quadrant handling procedure, the modes procedure must be enabled by pressing
the Enable modes button on the top left part of the screen. At this point, none of the deck machinery
can be manually operated without going through each mode and following the procedure. If any
manual control is needed, for any unforeseen reason, the modes procedure must be disabled by
pressing again the Enable modes button.
Each mode has a set of starting conditions, with feedbacks from several hardwired proximity sensors
that are trigged when the quadrant is at home or handler position, when the clamps are open or
closed and locking pins in or out. If a sensor is defective or broken, and it is therefore not possible to
carry on the quadrant handling procedure, it can be overruled by opening the Sensor inhibit page
(button on the top right part of the screen). These options have to be used only when necessary and
after having assessed the actual state or position of the item.
Figure 64 Sensor inhibit page

NOTE: once a mode is enabled, the system does not look into the starting conditions anymore but
only to the conditions stated in the procedure steps. It is handy to keep the mode page on one monitor
and to use the other to do corresponding operations.
Mode #1. Quadrant to handler

The 10-step procedure starts when the quadrant is in front of the two tensioners. Once the starting
conditions are met and both tensioners are opened, the mode #1 can be enabled and the joystick on
the control desk can be used to pay-out the quadrant winch until the quadrant is at the handler resting
on the locking pins. At this point the clamps can be closed and the operator can continue paying out
the quadrant winch until the winch automatically stops because there is sufficient slack for the
upending.
On completion of a task, the button or the condition box turns green and it is possible to move to the
next one. When the procedure is finished, the mode has to be disabled, in this case by pressing the
Disable Quadrant movement button.
NOTE: Before opening the SB tensioner, in order to avoid uncontrolled movement of the cable, the
tension and the torque, shown on the right side of this page, have to be checked.
Figure 65 Mode #1 page

Mode #2. Prepare upending quadrant

In mode #2 the side winches are connected to the quadrant. Once the mode is enabled, the side
winches can be operated using the joysticks on the control desk. After connecting the slack off the
side-winches can be removed and CT mode can be enabled. For the upending, the jib has to be set to
the centre position (77% of the cylinder stroke) by pressing the Centre button.

Mode #3. Upending quadrant handler

Once mode #3 is enabled, the quadrant can be upended controlling the handler with the joystick on
the control desk. During upending the CT setpoints can be adjusted to ensure to slack in the side
wires. If necessary the setpoints of the CT winches can be used in combined mode to simplify their
control.

Mode #4. Unlock quadrant

In mode #4 the quadrant is unlocked from the handler and prepared for the lowering. Once the mode
is enabled, in order to safely open the clamps, some tension has to be applied to the quadrant wire by
operating the winch until approximately 2 tons is achieved. Than the quadrant has to be lifted away
from the locking pins so that they can be retracted. Finally, after having lowered the quadrant half a
meter, the jib can be set to the “out” position and the unlock mode can be disabled. The pay-out
length of the quadrant winch is zeroed when the locking pins are retracted.

Mode #5. Lowering quadrant

Once mode #5 is enabled, the quadrant can be manually lowered until the desired water depth is
reached. In the centre of the page, all the relevant data to monitor the lowering of the quadrant during
the 2nd end pull in are displayed. The CT of the side winches can be adjusted to control the quadrant
during lowering. When the quadrant has reached the desired water depth, this mode can be disabled.

Mode #6. Tipping the quadrant

By enabling mode #6, the quadrant can be tipped and the cable bight released on the seabed. The
first step is to switch off the CT of the side winches. This automatically sets them on brake. Then,
paying out with the quadrant winch, the quadrant starts tipping forward. When the quadrant is almost
horizontal, it can be further tipped by paying in manually with both side winches together. Once the
cable has been released, the quadrant has to be tipped back to the vertical position and, before
disabling the mode, the CT of the side winches has to be activated again for the recovery.

Mode #7. Retrieve quadrant

By enabling mode #7, the quadrant can be retrieved to the handler. When the pay-out length of the
quadrant winch is 0.5 m, the operation can stop and the mode can be disabled. The CT of the side
winches may require adjustment when the quadrant is in the splash zone or out of the water.

Mode #8. Lock quadrant to handler

In mode #8 the quadrant is locked to the handler and prepared for down ending. Once the jib has
been moved back to the centre position, the quadrant should be lifted until the pay-out length is 0 m,
in order for the locking pins to be moved out. At this point, the quadrant must be lowered until it
correctly rests on both locking pins and the clamps can be closed. Before disabling the mode, slack
has to be given to the quadrant winch.

Mode #9. Down end quadrant

In mode #9, the quadrant can be down ended by controlling the handler with the joystick. During down
ending the side winches are operated with a low CT setpoint. The quadrant winch will automatically
follow the movement of the handler. Once the handler is completely down the CT on the side winches
can be disabled and must be given slack.

Mode #10. Finalize handling

In the last mode of the procedure, the quadrant is released from the handler and the system can be
prepared for the next operation. Once the mode is enabled, the side winches can be disconnected
and the jib lowered down.
Just before pulling the quadrant forward, the clamps have to be opened.

4.4.3 SETPOINTS
All the relevant parameters, set points and settings that control the deck equipment and cable
operations are collected in the set point page. From this page, it is possible to:
- zero or change the value of the meter counters of PS and SB tensioner
- input cable diameter (used by the auto function of the loading tower)
- input quadrant and side winches wire length
- enable the VODAS – DP interface for the automatic “stop on track” function
- enable the use of the vessel speed as a secondary controlling input (besides the DAMS) for
the SB tensioner
- enable the auto switch of CT for laying and loading and corresponding set points, for the
wheel pair tensioner and set its clamp force
- enable alarm on exceeding a maximum vertical departure angle.
- define the set points of the jib position
- select data source for speed and heading, trim and list, motion reference unit
Figure 4-75 SETPOINT page

5 Survey
This chapter provides an overview of survey hardware, data flow and software setup of the survey
systems on board the Nexus. The main function of the survey system is to provide the following
services and support:
• Provide navigation and positioning of the vessel
• Provide navigation and positioning of the ROV
• Provide positioning, monitoring and visualisation of the cable lay operations
o Cable departure and catenary calculations
o Cable touchdown monitoring
o Quadrant lowering monitoring
• Provide bathymetric survey support
Hardware and software are installed and integrated into each other to provide above services. In
below sections the system setup, hardware, software and data flow will be made clear in more detail.
5.1 Survey Equipment

The survey hardware systems used in the survey software can be separated into four groups. The
hardware consists out of dedicated survey equipment and software, as well as measurement data that
are provided by the vessel and VODAS cable laying system. Several survey hardware systems on
board are shared with the vessel and DP system and managed by the survey department. The below
block scheme shows the system integrations.
Figure 76 Equipment integration
5.1.1 Overview survey equipment

An overview of the survey equipment is provided.
1. Dedicated survey hardware:
o Global Positioning Systems
o Inertial Navigation System
o Coda Octopus Echoscope 3D Sonar on a Coda Pan-Tilt system (if required on
project)
o Acoustic Doppler Current Profiler
o Multibeam Echoscounder
o Valeport SVP and SVS sensors
o Firetide and SeaMesh Wi-Fi data communication systems (if required on project)
o ADL radio data communication system (if required on project)
o Teledyne Blueview Imaging sonars
o Tritech Altimeters
2. DP measurement hardware (managed, checked and used by survey):

o Global Positioning Systems
o Motion Reference Systems
o Fibre optic Gyro’s and heading systems
o Kongsberg HiPAP 501 high precision SSBL
o Kongsberg SpotTrack
3. VODAS data input of cable lay system hardware used in survey software:
o Departure Angle Measurement System
o Quadrant winch measurement data
o Tensioners measurement data
o Crane measurement data
4. Vessel systems used in survey software:

o Single beam echosounders
o Wind measurement sensor
o AIS
5.2 Survey software

The main survey software used on board is the Teledyne PDS2000 Cable Lay suite. The Coda
Echoscope USE software is used for underwater visualisation and monitoring of the cable and the
quadrant when an echoscope is in use.
5.2.1 Data flow

To provide a general understanding of the systems, a basic data flow diagram is shown below.
Figure 77 Data flow

5.2.2 Data output

For cable laying, specifically PDS2000 in combination with the quadrant, echoscope, the ROV and the
SpotTrack is able to calculate and display the information shown in the following diagram.
Figure 78 Typical data output diagram

The quadrant, the ROV and the SpotTrack are mainly used during pull-in operations (Chapter 1.5.1).
The essential parts of all cable related operations are the PDS2000 software in combination with a
touchdown monitoring system such as the echoscope or an ROV. The echoscope visualizes the
catenary, touchdown point (TDP), quadrant operations, pull-in operations and confirms the cable
calculations of PDS2000.
5.2.3 Software operational modes

There are 2 cable laying operations:
1. Export cable operations (figure 4)
2. Infield cable operations (figure 5)
The 2 diagrams below show the general step of these 2 different operations.
Figure 5-79 Export cable
Figure 80 Infield cable
Cable loading
Prior to loading, each counter on the tensioners is set to zero when the cable end is at the zero point
of each tensioner. When loading starts the cable runs from the starboard tensioner via the quadrant to
the portside tensioner and ends in the carousel. The loading is recorded in PDS2000 in order to log
how much cable is loaded.
Cable laying
Visualisation of all the sensors is the main purpose of PDS2000. The visualisation is done graphically
and numerically. The laying process is closely monitored to validate that the cable is laid on the
planned route. The combination of PDS2000 and the ROV or Echoscope is essential for positioning
and monitoring the cable lay operation. PDS2000 displays the position of both the vessel and the
cable by taking into account the local circumstances as depth, current, specifications of the cable and
departure angle (figure 6). The TDP of the cable is calculated in real time taking the local
circumstances into account.
Figure 81 PDS2000 Laying cable

The calculated TDP is verified by the TDP observed by the ROV position or echoscope (figure 7). If
necessary the heading or offset of the vessel is adjusted to get the TDP on the planned cable route.
The route is pre-designed in the office and loaded into PDS2000. From PDS2000 it is exported to the
DP system. Objects and UXOs are avoided in the route. During large heading changes to avoid these
objects the speed of the vessel is reduced. Cable speed and cable departure angle are monitored
constantly and the buffer system allows easy adjustment of cable speed in order to keep these
constant during these changes. The cable speed must follow the vessel speed as closely as possible
and the departure angle and bottom tension must remain stable. All cable operations are recorded in
PDS2000.
Figure 82 Echoscope catenary and TDP

After laying operations are finished the Nexus or survey support vessel can do an as laid survey.
Cable jointing and joint overboarding

An export cable is - in most cases - too long to lay within one cable load. The export cable is laid in
sections based on loading capacity of the vessel, cable design parameters and route and seabed
circumstances. The end of the cable is placed on the seabed and marked in PDS2000. After the
loading of a cable section, the end of the stored cable is recovered from the seabed back on the ship.
After recovering a jointing crew will start jointing both cables to each other. Jointing will take several
days.
Both cables are marked to determine the total length that has been cut off from both cables, when the
jointing is finished. Overboarding of the joint is done with support of the crane. Once the joint is in the
water it can be monitored with the ROV or echoscope. The joint gives a very clear image on the
echoscope so the complete procedure of the lowering of the joint to the seabed can be closely
monitored
Figure 83 Joint overboarding
First and second end pull-in

During pull-in operations ROV support can be used. The position of the ROV is done by USBL and
visible in PDS2000. The ROV has various views that can be monitored. An assortment of cameras,
Sonar and radar can be used. If installed, the echoscope can also help with visualising the following:
• TDP of the cable
• Cable Protection System (CPS) guidance to the entry hole of the TP
• Engagement of the latches
• Visualisation of pulling out the omega when tipping of the quadrant is done at the
second end pull-in
• As laid survey
The example in shows the CPS getting into the entry hole with the latches still disengaged.
Figure 84 ROV views

On the TP, a tower team performs the cable pull-in into the TP. This is done with a winch. The force
and speed of the winch is received on the vessel and displayed in PDS or the control cabin
(depending on hardware). During first and second end pull-in, the SpotTrack will be activated. The
SpotTrack locks to the prism installed by the tower team and provides redundancy to the DP system.
In the case that all other positioning systems fail, the vessel will stay in position using the SpotTrack.
When the first end pull-in is done the vessel will start the main cable lay operation to the next tower.
On approach of the second tower, preparations are made to cut the cable. A cut calculation is made.
This is done by 2 different methods:
1. In PDS2000; based on the length of the route and the over length on both ends,
PDS2000 calculates the cut point.
2. By placing a marker on the cable when it passes the cutting station whilst
simultaneously zeroing the port side counter, and then measuring the location of this
mark when it is on the seabed. The mark can be measured on the seabed in several
different ways.
a. A HiPAP transponder can be attached to the mark and coordinates found by
using the HiPAP system.
b. A small buoy can be attached and coordinated with an Echoscope.
c. The ROV can sit on the mark to provide its coordinate.
3. Once the location of the mark is found on the seabed, the distance remaining to the
entry hole can be calculated. As we know the amount of cable paid out from the mark
(because the counter was zeroed), the cut point can be calculated.
Both values should be the same.

The vessel will divert from its original route and continue laying until the cut point is reached and then
the cable will be cut and sealed. When this is done the vessel will move back to the original route.
Preparations are made to overboard the cable using the quadrant.
The quadrant has several sensors which are all connected via an umbilical to the survey system. The
connected sensors are:
• 2 x Camera and light, to monitor the cable running off the quadrant
• 2 x Blueviews, to monitor the cable running off the quadrant and the height of the
quadrant in relation to the seabed
• 2 x Altimeters, to measure the height of the quadrant in relation to the seabed.
• 2 x USBL beacons, to monitor the position, behaviour and heading of the quadrant.
• 1 x Motion sensor / compass, to monitor the heading and behaviour of the quadrant.
• 1 x Octans fibre optic gyro and pitch roll sensor.
While the tower team is pulling the cable, the quadrant is lowered until the tipping position has been
reached. In combination with the ROV or echoscope the lowering of the quadrant is closely monitored
in PDS2000. Both catenaries of the cable can be seen on the Blueviews of the quadrant.
Figure 85 Lowering of the quadrant PDS2000

Figure 86 Lowering of the quadrant Blueviews
Figure 87 Tipping of the quadrant echoscope
Once the cable is on the seabed, the remaining omega in the cable can be pulled out. This can be
done with the support of the ROV. The ROV positions itself such that the complete omega is visible in
the blueview. The tower team will pull in steps until the desired shape/route of the cable is
established. In the following two figures, that are taking from the ROV video, the cable is shown
before pulling and after pulling.
Before pulling After pulling
Figure 88 Blueview ROV quadrant omega before and after situation

After the pulling is done, the ROV flies over the cable to check the cable’s final position of the second
end pull-in before recovering any beacon or buoy at the marker point.
6 CABLE OPERATIONS
6.1 Safety
All personnel involved in operations shall be aware of procedures and updated work instructions. A
toolbox meeting is held prior to the start of each operation to describe the operation and clarify step by
step the work instructions to be followed. After having identified all the possible hazards and risks that
may be encountered during the operation (Risk Assessment and Last-Minute Risk Assessment), all
the mitigation measurements that should be taken to work safely have to be discussed.
Relevant personal protective equipment (PPE) will be issued, accordingly to the risk assessment, prior
to the commencement of the work. PPE shall be worn always on site with exception of the dedicated
safe area(s) and welfare facilities.
Before starting any operation, the radio communication is checked between all the parts involved in
the operation and the correct functioning of the equipment is verified.
Two operators shall be available at all times and rotating within a 12 hour shift. One will be constantly
present at the control station and will concentrate exclusively on his task. The other operator will
handle all other routine and maintenance duties involved in these cable lay operations. Both operators
will normally change over in reasonable time to avoid the effects of fatigue.
During cable handling operation, a ‘’NO GO’’ area is present on deck. This zone covers the area in
which the quadrant is free to move.
Figure 89 NO GO zone on deck.
6.2 Cable Loading

This chapter describes a general procedure to load a cable from a supplier onto the Nexus. Detailed
work instructions are attached in appendix A for reference. Depending on product specs and load out
facility, some details may change.
Preparation for cable loading includes a full functional test and pre-load-out checks of the complete
loading system. A visual inspection of cable routing is performed regularly before and during the
loading operation.
Before starting the loading, a mooring rope (e.g. TIPTO®WINCHLINE, ø 80 mm) is fed into the
system. It can be clamped in the tensioners and wheel pair and it is used as forerunner to pull the
cable from the supplier, through the deck equipment and loading tower into the carousel.
In case a light cable is being loaded, the capstans, together with dyneema lines, can also be used to
feed the cable in the system and pull it into the carousel.
Generally, due to the stiffness of the cable, the most critical part is feeding the cable through the
loading arm. It is sometimes very useful to stop loading the cable from the supplier (stop the SB
tensioner) and use the buffer system (pay in/out only with the PS tensioner and quadrant in CT) to
have more control on the cable in the most critical points without asking the supplier for very small
cable movements.
When the cable is being fed into the system, the Nexus acts as master and the supplier adjusts the
catenary accordingly (slave). In this phase, apart from the CTs of the quadrant and wheel pair
tensioner that can be activated when needed, the equipment can only be operated manually since the
carousel is not turning. Only when the cable is connected to the carousel, the automatic functions can
be enabled.
If fibre optics should be tested end/or monitored during the laying, the cable can be pulled inside the
carousel core, using the capstan, and secured to a strong point. The fibres, when needed, can be
connected to the permanent FO testing equipment available in the core and tested/monitored from a
dedicated computer in the control cabin.
Cable length is measured by SB and PS tensioner, which are zeroed when the cable end is at their aft
vertical guiding rollers. The cable length is shown and recorded into VODAS and survey system.
Figure 90 Typical starting sequence of cable loading when a forerunner rope is pre-fed into the system (the
yellow line is the forerunner rope, the blue is the cable)
The system can run in fully automatic mode during loading operations using the DAMS to keep a
suitable catenary between the Nexus and the supplier. In this setup however, the catenary is adjusted
by the Nexus, which is then acting as slave. The supplier, which is in this case the master, has to
keep a constant pay out speed.
In automatic mode, the Nexus system accurately follows speed variations and stops. The operator
must monitor the catenary between the Nexus and the supplier at all times using cameras and DAMS
readings. He has also to make sure that the cable is being wound uniformly into the carousel, and
correct the automation of the loading arm and carousel when needed.
When the cable end reaches the SB tensioner, the hold back rope installed by the supplier is removed
and an aft runner rope (e.g. TIPTO®WINCHLINE, ø 80 mm) or hauling rope (dyneema rope) is
connected to the cable end to ensure sufficient back tension in the cable in last part of the loading into
the carousel.
6.3 Cable Laying

Generally, for any cable laying campaign, there can be four different starting conditions:
- 1st end lay down on the sea bed
- 1st end pull in into an offshore receiving structure (e.g. OHVS, tower) or HDD
- In-line joint
- 1st end beach pull with floaters [TBD]
Completed one of the above-mentioned operations, the cable laying along the designed route can
start.
At the end of the laying, there can be three possible scenarios to accomplish:
- 2nd end lay down on the seabed
- 2nd end pull in in into an offshore receiving structure
- 2 end beach pull with floaters [TBD]
A description of all the above-mentioned operations is given in the following paragraphs. Exhaustive
work instructions, detailing step by step procedures and tasks for the key personnel involved in the
operation, including VODAS settings and control instructions, are discussed and issued in a toolbox
talk with the crew prior of the starting of any operation.
6.3.1 1st end lay down on the sea bed

In this case, the cable laying operation starts with the deployment, in a controlled manner, of the
sealed cable end on the seabed. In order to recover the cable end at a later stage, as well as to
provide sufficient bottom tension on the cable at the beginning of the lying to comply with the MBR
requirement, a suitable clump weight, generally rigged as shown in the following picture, is connected
the cable end and firstly deployed on the seabed. The lengths of the ground wire and riser rope mainly
depend on the water depth and project specific tasks. The weight and shape of the clump weight has
to be carefully assessed on the basis of the bottom tension required to ensure that the bending radius
at the cable touch down comply with the MBR requirement of the product.
Figure 91 Typical rigging set up for cable end abandonment and recovering [Request to update drawing]
As explained in the survey chapter, all the relevant parameters to control the cable catenary are
monitored from the beginning of the laying. Once the clump weight has been deployed on the sea
bed, the laying operations can start moving the vessel forward, along the route, and paying out first
the ground wire and then the cable connected to it. The pay-out and vessel speeds are adjusted to
match the desired laying parameters ensuring the integrity of the cable.
The coordinates of the clump weight and cable end on the sea bed are recorded.
During the During the initial phase of the laying, it is advisable to keep the system in semi-auto mode
and manually control the speed of the SB tensioner to ensure that all the laying parameters are safely
met. When the cable is on the seabed and the system is steady, the full automatic control can be
enabled and the CDA adjusted in accordance to the project specific procedures.
6.3.2 1st end pull in into an offshore receiving structure (e.g. OHVS, tower)
When the 1st end of the cable has to be pulled into a platform or tower, the Nexus moves with the
stern at a calculated distance from the structure and keeps a steady position in DP, with the SB chute
on the cable route, until the pull in operation is completed.
To protect the cable in the transition zone between the seabed (trench or rock berm) and the j-tube or
the entry hole of the tower, a cable protection system (CPS) usually has to be installed. For the 1st end
pull in, the CPS is prepared on the SB roller way and the cable is pulled through it. When the cable
end is at the SB chute, a suitable pull in rigging or a pull head is installed on the cable. The SB
tensioner at this stage is fully opened and tilted to accommodate the CPS.
Once the preparations on deck are completed, a messenger line, which has been pre-installed in the
j-tube or in the tower before the beginning of the operation, is handed over to the vessel to haul on
board the pull line. After connecting the pull line to the pull head or Chinese finger, the pull in
operations can start. The pull in team on the receiving structure starts hauling on the winch and
simultaneously, from the Nexus, the cable is paid-out and the CPS over boarded.
Figure 92 Cable pulled through the CPS and pull line (purple) connected to the pull head or project specific
rigging
The laying parameters and the catenary shape are constantly monitored using the DAMS and the
echoscope. The paying out speed of the Nexus and the hauling speed of the receiving structure is
adjusted accordingly. Extra care is taken when the CPS is approaching the j tube or the entry hole of
the tower to make sure that it latches correctly. Generally, apart from specific cases where the rigging
set up for the pull in is different, as soon as the CPS is latched in, the weak link of the pull head is
broken and the pull in operation can continue until sufficient cable length has been pulled and the
hang off can be installed.
Figure 93 CPS overboarding and latching

Regarding the cable laying system of the Nexus, being the SB tensioner opened for the overboarding
of the CPS, the carousel and the PS tensioner can only be operated manually, with the quadrant
winch on brake. The wheel pair tensioner can stay in CT with the auto switch enabled. During this
operation, the operator has to pay extra attention to avoid any slack in the cable around the quadrant.
As soon as the CPS is over boarded, the SB tensioner can be closed and the CT of the quadrant
winch can be enabled. At this stage, depending on the conditions, the system can be ran in fully or
semi-automated automated mode (SB tensioner in manual).
6.3.3 In-line joint

When the installation campaign of the entire cable is subdivided in several sections (e.g. long export
cables), each length must be jointed together with the one previously laid and wet stored on the
seabed. This operation can either be done at the beginning of the laying with an in-line joint or at the
end, when both cable ends have been laid on the seabed, with a so-called omega joint.
When possible, the in-line joint is the most preferred option but the choice between the two
possibilities depends on project specific requirements and circumstances.
The in-line joint operations start by recovering the wet stored cable using the installed abandonment
rigging (such as the one shown in Figure 91). Depending on the cable weight and water depth, this
operation can be carried out either using the SB forward capstan or PS tensioner. In the first case, for
light cable and/or in shallow water, once the clump weight and the buoy (if any) of the deployment
rigging have been retrieved on board, the ground wire is connected to a dyneema rope and the
recovering of the cable is carried out using the SB capstan. The vessel will move astern, along the
route, to preserve the correct laying parameters (monitored by DAMS and echoscope). However,
when the weight of the cable and the water depth are significant (e.g. for export cable), the use of the
capstan is neither safe nor accurate to maintain the catenary parameters during the recovery of the
cable. In this circumstance, as soon as the ground wire is on board (usually the cable end is still on
the seabed at this stage), it is connected to a mooring rope (e.g. TIPTO®WINCHLINE, ø 80 mm)
which is clamped in the PS tensioner. In this way, the operator can safely control the cable recovering
operating the PS tensioner and monitoring the relevant parameters
As soon as the cable has been pulled through the open SB tensioner, it will be closed so that the
cable is securely clamped. When there is sufficient cable on board for the joint, a stopper is installed
on the SB chute for extra safety.
The cable end in the carousel is then pulled through the system to the jointing position and
overlapped, as required by the joint procedures, with the cable just recovered from the seabed.
Finally, the jointing container is lifted in place over the jointing position (Figure 94, Figure 95) and the
jointing can start. The two tensioners are kept closed (close buttons have to be green in the VODAS
tensioner pages) and the quadrant in home position on brakes. The Nexus stays in station keeping in
DP until the completion of the joint. The departure angle and catenary are continuously monitored
and, if needed, the position of the vessel is adjusted.
This sequence of actions described can vary, depending on the circumstances.
Figure 94 The cable (black line, left SB chute) has been recovered on board using the PS tensioner by
connecting the ground wire (blue line) to the mooring rope (yellow line) which is clamped in the PS tensioner. The
quadrant is at home position, on brake. At this stage, the SB tensioner can be closed
Figure 95 The jointing container (orange box) is in position and the joint is assembled inside it.
When the joint is completed, the jointing house is lifted from the jointing position and secured in its
sailing position on the SB side. At this stage, the joint is ready for overboarding. The rigging and the
procedures to follow for this operation may vary depending on the dimensions of the final joint
assembly, position of lifting points, extension of bend restrictors and limitations/technical specifications
of the joint. However, a general procedure can be described, considering that:
- One of the main advantages of the cable laying system of the Nexus, in comparison with other
traditional cable lay vessels, is that the cable can be always clamped in at least one tensioner.
Consequently, as explained for the overboarding of the CPS during the 1st end pull in, it is
possible to open the SB tensioner and control the laying with the PS tensioner (PS tensioner
in manual, carousel in manual, WPT in CT, quadrant winch on brake).
(On traditional cable lay vessels (carousel, loading tower, tensioner), when the tensioner is
open, the cable can only be controlled using stoppers and a winch or capstan)
Offshore joints are designed to hold the same amount of tension, in a straight-line configuration (e.g.
in the catenary), of the jointed cable. This is because the armouring wires are clamped on the joint
casing.
Having said that, when the joint is ready for the over boarding (see next page, Figure 96 Storyboard
over-boarding joint and the jointing house has been removed from the jointing position, the crane lifts
the joint casing and keeps it at the same height of the SB cable highway (step a) At this point, the
cable bight around the quadrant, between the two tensioners, has to be put under tension (paying in
manually with the PS tensioner and carousel only) so that the resultant force acting on the SB
tensioner is zero. The PS tensioner holds the in-line tension of the cable due to the catenary and the
crane supports the weight of the joint. From that position, the SB tensioner can be safely opened and
tilted to allow the passage of the joint. Thereafter, synchronizing the PS tensioner (pay out) with the
movement of the crane and adjusting continuously the position of the vessel to maintain the correct
catenary parameters, the joint is guided through the SB tensioner towards the SB chute (step b). The
most critical moment of the operation is when the joint casing is on the chute, since it is a rigid and the
length of the structure is longer than the chute. The structure that must rotate from the horizontal
position on deck to the angle of the catenary in the water (step c – d) This transition must be carried
out in a controlled manner, using a suitable rigging arrangement (project specific), in order to ensure
the integrity of the joint and equipment.
When the joint is in a safe position, sufficiently far from the chute, the crane can slowly lower the joint
down so that the weight of the joint is transferred on the catenary. When the lifting rigging is slack, it
can be released from the joint casing (step e – f) The SB tensioner can be closed as soon as the joint
assembly has gone through and the system can be set in semi-automatic mode (SB tensioner stays in
manual during the overboarding and laying of the joint on the seabed). Once the joint is in the
catenary and the lifting rigging has been recovered, the Nexus can continue laying until the joint is on
the seabed.
During the entire operation, the catenary parameters and the position of the joint in the water is
constantly monitored by the survey using DAMS readings and echoscope.
[a] [b]
[c] [d]
[e] [f]
[g]
Figure 96 Storyboard over-boarding joint
6.3.4 1st end beach pull with floaters [TBD]

Chapter to be determined.
6.3.5 Cable laying – Automation and monitoring system

On completion of one of the above described operations, the cable is laid on the seabed along the
designed route. During the laying, as explained in the survey chapter, several parameters are
simultaneously monitored to control the catenary shape of the cable and the laying progress, namely:
- Cable departure angle for the evaluation of the touch down point, touchdown radius, catenary
length and bottom tension on the cable
- In line tension at the SB tensioner
- Water depth
- Length of cable laid in comparison to the distance travelled by the vessel (cable loss)
- Vessel position, heading and speed along the design route
- Tension of the cable on deck, around the quadrant (controlled by the buffering system)
Moreover, using the echoscope, the actual position of the cable touchdown and shape of the catenary
is constantly verified.
Weather condition (current, waves, wind, etc.) will be constantly monitored and the possible impacts
on the laying operation will be considered and assessed.
During laying the system can be ran in auto mode using the DAMS to keep the chosen catenary
configuration. This means that, in fully automated mode, the cable paid out speed is mainly driven by
the measurement of the CDA. However, it is important to underline that the control of the laying is
based on the evaluation of the whole set of the above indicated parameters as the CDA cannot be
considered a standalone controlling parameter. The cable system operators receive clear instructions
from the cable laying superintendent in charge about the main parameters to control. Moreover, the
operators have to make sure that the automated functions work properly and correct the position of
the loading arm / carousel speed when needed.
6.3.6 2nd end lay down on the seabed

Similarly, to the 1stend lay down, in order to lay the 2nd cable end on the seabed in a controlled
manner as well as to recover the cable end at a later stage, a suitable abandonment rigging (such as
shown in has to be installed on the cable end and deployed on the seabed from the CLV.
The ground wire, which is connected to the 2 nd end when the cable is at the SB tensioner, has to be
used to lay the last part of the cable on the seabed. Similarly, to what already described for the
recovery of the cable for the in-line joint, depending on the cable weight and water depth, this
operation can be carried out either using the SB forward capstan or PS tensioner. In the first case, for
light cable and/or in shallow water, the ground wire is connected to a dyneema rope and the laying is
controlled using the SB capstan. The vessel moves along the route in order to preserve the correct
catenary parameters (monitored by DAMS and echoscope). However, when the weight of the cable
and the water depth are significant (e.g. for export cable or deep-water installations), the use of the
capstan is neither safe nor accurate for the laying. In this case therefore, the ground wire is connected
to a mooring rope (e.g. TIPTO®WINCHLINE, ø 80 mm), which is clamped in the PS tensioner, so that
the operator can safely control the laying operating the PS tensioner only (the SB is opened once the
cable has left). Several lengths of ground wire may need to be used, depending of the water depth:
when the connection between the mooring rope and the ground wire is at the SB chute, the first
ground wire is secured, one end of the second ground wire length is connected to it and the mooring
rope is connected to the other end. Then, after having applied some tension to the deployment rigging
with the PS tensioner, the stopper is removed and the laying can be resumed. Finally, when the last
end of the ground wire is at the SB chute, clump weight, raiser line and buoy are connected to it and
lowered to the seabed with a slip rope, moving the vessel accordingly.
Figure 97 Typical initial condition for the 2nd end lay down.
The cable (black line) is still clamped in the SB tensioner, the ground wire (blue line) is connected to it
and the mooring rope (yellow line) is connected to the other end of the ground wire and clamped into
the PS tensioner. The quadrant is on brake in home position. Firstly, some tension is applied to the
deployment rigging with the PS tensioner so that the SB tensioner can be open.
Figure 98 The first section of ground wire (blue line) is secured at the SB chute another ground wire
section (red line) is connected to it. The mooring rope (yellow line) it is connected to the 2 nd end of the
ground wire and clamped in the PS tensioner. And so on until the cable end is on the seabed.
6.3.7 2nd end pull in in into an offshore receiving structure

When the cable laying ends at an offshore structure such as platforms, OHVS or towers, a 2 nd end pull
in is performed.
Once the CLV Nexus is at a calculated distance from the structure, she starts altering her heading and
moves along a service route, which is a temporary route, perpendicular to the design cable route
(RPL), used in the initial phase of the 2 nd end pull in. The cable is laid along this temporary route until
the cutting point is reached. The cable is then cut at the cutting station (PS) and sealed; the pull in
rigging is prepared and installed.
Figure 99 The Nexus starts altering her heading and moving along the service route, laying cable until the cutting
point is reached.
Figure 100 Position of the cutting point. Quadrant at home position and winch on brake.
Once the cable has been cut and both ends sealed, the on-board section of the cable is pulled
towards the carousel (using the WPT in manual) because the aft bend of the cable highway has to be
free for the quadrant handler during the quadrant upending. Meanwhile, the vessel moves forwards on
the service route laying cable with the SB tensioner (in manual mode, quadrant on brake), until the
cable end reaches the PS aft edge of the quadrant. At this point, the PS cable highway is free and the
CPS can be lifted in place.
Figure 101 CPS lifted in place (green line), cable end at the PS AFT edge of quadrant, AFT bend free of cable
Once the CPS is secured on the PS cable highway, the Nexus starts moving astern along the service
line while keeping her heading perpendicular to the design route. Simultaneously, the cable is being
paid in with the SB tensioner (in manual mode), and it is pulled through the CPS towards the PS chute
using dyneema lines and a capstan.
When the cable end has reached the PS chute, the Nexus comes to a controlled stop. A pull head or
a project specific rigging arrangement is installed on the cable end. A messenger line, which has been
pre-installed in the j-tube or in the tower before the beginning of the operation is handed over to the
vessel to haul on board the pull line.
Figure 102 Cable pulled through the CPS and pull line (purple) connected to the pull head or project specific
rigging
After connecting the pull line to the rigging installed on the cable or to the pull head the pull in
operations can begin. The pull in team on the receiving structure starts hauling on the winch and
simultaneously the Nexus resumes her movement astern along the service route, recovering cable
with the SB tensioner (in manual) and paying out cable from the PS chute (pulled from the receiving
structure). Usually the PS tensioner can be kept open during the operation to allow the passage of the
CPS for the overboarding; the quadrant stays in home position on brakes. Depending on the project,
the CPS may be over boarded at the beginning of the pulling if it is connected to the pull head or after
a certain length of cable has been laid from the PS chute. In the case shown the CPS is secured on
the cable highway and the cable is laid through the CPS until a certain predetermined distance from
the cable end is reached before it is over boarded). Extra care is taken when the CPS is approaching
the j tube or the entry hole of the tower to make sure that it latches correctly. When the CPS is latched
in, the weak link, if any, can be broken and the pull in can continue.
The movement astern of the Nexus carries on until the chutes are back on the design route, then she
comes to a controlled stop and she will keep this position until the end of the operation. The SB
tensioner also stops as soon as the catenary parameters are ensured.
From this point, the quadrant can be slowly shifted towards the stern while the team on the receiving
structure keeps pulling in the cable. During the movement of the quadrant on deck, the SB tensioner
stays closed and stoped, the PS tensioner is open and quadrant is moved by manually controlling the
quadrant winch. When the quadrant is just in front of the tensioner, the operation is halted and the
VODAS modes (Quadrant Operations) can be enabled as previously described. The operation,
through the VODAS mode pages, is resumed by opening the SB tensioner, making sure that the
catenaries are well balanced and the resultant force on the SB tensioner is close to zero. After having
fully opened and tilted both tensioners, the quadrant is moved to the handler by paying out the
quadrant winch and simultaneously pulling the cable from the receiving structure.
When the quadrant is on the handler, the upending procedure as fully detailed through the VODAS
modes can be followed.
Figure 103 Quadrant upending sequence.

Top left: quadrant on the locking pins ready for upending, clamps closed, side winches (yellow lines) connected
Top right & Bottom left: quadrant is being upended, quadrant winch automatically follows the handler
Bottom right: clamps opened, pins retracted, jib out, side winches in CT, quadrant ready for lowering
The lowering speed of the quadrant and the pulling speed of the winch on the receiving structure has
to be synchronized in such a way that the cable integrity is not compromised and the cable bottom
tension kept as low as safely possible to comply with MBR requirements. The survey equipment
installed on the quadrant (cameras, Blueviews, motion sensors, compass) together with the
echoscope, give a full understanding and a clear picture of the dynamic system of the two catenaries
and the quadrant during the lowering, as described in the survey chapter.
Figure 104 Lowering of the quadrant from the Nexus

Depending on the circumstances and project specifications, the quadrant may be tipped before
completing the pull in operations or at the end, when sufficient cable length has been pulled into the
receiving structure. In the first case (typically done for infield cables) after the tipping, few more meters
are pulled in so that the cable bight left on the seabed is minimized (e.g. for trenching). In the second
case, the quadrant is tipped at the very end of the operation since it is not always possible to drag the
cable on the seabed to straighten out the bight.
However, as a general procedure, when the quadrant is sufficiently close to the seabed, the side
winches are braked and the quadrant is tipped by paying out with the quadrant winch.
When the pull in operations are completed, the hang off is installed by the pulling team.
NOTE 1- Depending on the cable length to be pulled in as well as on the distance of the service route
from the receiving structure and typology of CPS/rigging arrangement, the latching of the CPS in the
J-tube or entry hole can take place either during the shifting of the quadrant to the stern, during its
upending or during the lowering. Calculations must be carried out before the starting of the operation
to ensure the right sequence of events.
Note 2- As a contingency only, the upending of the quadrant can be carried out also from the local
control console at the PS aft. From this location, however is not possible to follow the VODAS mode
and everything has to be operated manually. The CT modes of the side winches cannot be enabled
from this location.
Note 3- In the operation just described, the service route is on the SB side of the design route and the
cable bight on board is formed by pulling the cable from the SB tensioner, around the quadrant
towards the PS chute. This is most the most preferred option. However, since the cable laying system
on deck symmetrical, it is equally possible to perform a 2 nd end pull in along a service route on PS
side, with the vessel heading turned by 180 degrees. This can be useful in some circumstances such
as unfavourable weather conditions or route engineering. To do that, after the cutting and sealing, the
cable has to be laid from the SB chute and picked up from the PS chute (by means of two dyneema
lines and two capstans). The bight is then formed on board buy pulling the cable from the PS
tensioner, around the quadrant towards the SB chute. The CPS is lifted on the SB roller highway and
the cable pulled through it by moving the vessel astern and paying in cable with the PS tensioner. The
operation carries on as previously described but mirrored.
6.3.8 2nd end beach pull with floaters [TBD]

6.4 Cable Repair [TBD]

6.5 Cable decommissioning [TBD]


0630-50.00.005.01-VOOW-MAN-Deck Equipment Operation Manual

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External referenced documents

5.3.6 UMBILICAL WINCH ......................................................................................................... 49

CDA Cable Departure Angle

The following pieces of equipment are described in the documents:

1.2 Operations and Procedures

Cable unloading Product is unloaded from the vessel to a receiving party

Cable decommissioning Retrieval of old or scrap cable into the vessel

2 Cable Routing, Buffering and Automation System

Figure 2 NEXUS schematic overview deck lay-out

Figure 3 3D drawing of the SAS tensioner.

An audible alarm and flashing light indicate the start of an operation.

Table 1 Tensioner specifications

3.1.1 Track Drive

3.1.2 Hydraulic Power Unit

3.1.3 Clamp System and Automatic Clamping Control (ACC)

Figure 4 Tensioner assembly and clamping cylinders (yellow)

3.1.4 Frame Opening System

Figure 5 Tensioner fully tilted. Max allowable diameter 1700 mm

3.1.5 Absorption of Cable Diameter Variations

3.1.6 Track Shoe Lining and clamping load geometry

Figure 6 Cross-tie pad assembly of the bottom track

Figure 7 Cross-tie pad assembly of the top track

Figure 8 Particulars of the track shoes.

3.1.7 Tension Sensing System

3.1.8 Guide Rollers

Figure 9 Vertical rollers Figure 10 horizontal roller (diabolo)

Figure 11 Particulars of the tensioner rollers.

3.1.9 Remote or Local Operation

3.1.10 Wireless Control Unit (Belly Pack)

Figure 12 Tensioner Wireless Control Unit.

3.1.11 Emergency Stop Circuit

3.2 Wheel Pair Tensioner

3.3 Quadrant, quadrant which, quadrant handler and side winches

3.3.3 Hydraulic Power Unit

Each hydraulic pump can be individually started from:

3.3.4 Quadrant Winch

3.3.5 Quadrant Handler and JIB

3.3.6 Side Winches

3.3.7 Emergency Stop Circuit

3.4 Carousel and Loading Tower

Load capacity 5,000 tons

3.4.1 Carousel Basket

Figure 18 Divider rings in the carousel

Figure 19 Carousel system Figure 20 Carousel grillage assembly

Figure 21 Carousel grillage assembly

3.4.2 Roller Assemblies and Roller Control Frame

3.4.3 Central Bearing and Central Bearing Housing

Figure 24 Central housing mounted on King Pin

3.4.4 Basket Chain and Mount

3.4.5 Drive Modules

Figure 25 Carousel drive module drawing Figure 26 Driving module

3.4.6 Loader System

Figure 27 Loader system overview

Figure 28 Roller block

3.4.7 HPU and Drive Suite

3.4.8 Carousel Holding Brakes and Bracing

3.4.9 Emergency Stop Circuit

To accurately control the speed of the capstans and safely use

The capstans can only be operated locally.