We provide ongoing control system design, startup, and commissioning services for marine winch systems used on research vessels and offshore towing operations. These projects require precise motion control, robust safety systems, and proven reliability in demanding offshore environments.
The Challenge
Marine winch control is technically demanding. The equipment handles subsea deployment and recovery operations where loads shift unpredictably with sea conditions. The control system must provide:
- Precise speed and tension control under varying load conditions
- Safety interlocks that protect both equipment and personnel
- Operator interfaces with real-time feedback on load, speed, and cable position
- Integration with vessel systems and third-party equipment
- Reliability — failures at sea are not an option
Our Work
Ocean Research Vessel — Multi-Phase Startup
A major project involving winch systems for a purpose-built research vessel. We completed three startup trips to the shipyard, systematically commissioning and tuning the control systems:
- Siemens PLC programming for winch motion control
- ABB drive integration and parameter tuning under load
- Operator HMI with real-time monitoring of load, speed, and cable payout
- Safety system validation including E-Stop circuits and overload protection
- Multi-console control architecture (2 equipment units, 2 control consoles)
Offshore Towing — Scalable Design
For towing vessel applications, we developed a control system architecture that scales across multiple vessels. When the customer needed the same capability on a second vessel, we adapted the proven design with minimal rework — delivering a reliable system faster and at lower cost.
- Winch control with wired pendant (belly pack) operation
- Encoder-based position feedback
- Proven design replicated across vessel fleet
Technology
- PLC: Siemens S7-1500
- Drives: ABB ACS880, ABB SmartWinch
- Safety: ProfiSafe, safety-rated interlocks
- Communication: Profinet, point-to-point
- Programming: Structured Text and Function Block Diagram
Results
Reliable winch control systems operating on multiple vessels. The scalable architecture means proven designs can be replicated for new vessels with minimal engineering effort — reducing both cost and commissioning time for repeat deployments.
Industry: Marine / Subsea
