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Deck & Support Systems
Winches and Capstans
Winches and capstans pull, hold and lift loads on a single line around the drill floor, pipe deck and moonpool. The Category covers air, hydraulic and electric tugger winches, utility and man-riding winches, guideline winches and capstans. Anchor handling winches and windlasses sit under Mooring & Anchoring. Line pull at the working layer and brake design decide most selections.
Operating principle
A motor drives the drum through a reduction gearbox, usually planetary, and a brake holds the load when the motor stops. Air winches use vane or piston motors running on rig air. Hydraulic winches take flow from a power unit, and electric winches use a geared motor, often with a variable frequency drive.
Line pull equals drum torque divided by the effective drum radius. Each layer of rope adds to that radius, so pull falls and line speed rises as the drum fills. Makers rate pull at the first layer and often at the top layer as well.
A capstan has no rope storage. The line takes a few turns round a vertical barrel, and a crewman tails the free end to control it.
Configurations
| Type | Typical use | Key feature |
|---|---|---|
| Air tugger | Positioning tubulars and loads on the floor | Runs on rig air, suits hazardous zones |
| Hydraulic utility winch | Lifting through a derrick or moonpool sheave | High pull from a compact package |
| Man-riding winch | Lifting people in the derrick or moonpool | Dual brakes, slack rope protection, emergency lowering |
| Guideline winch | Tensioning guide wires to subsea structures | Constant tension control |
| Capstan | Warping lines and moving loads on deck | No drum storage |
Key specifications
| Parameter | Why it matters | Typical classes or units |
|---|---|---|
| Line pull, first and top layer | Pull available where you work | kN (lbf) |
| Line speed | Cycle time and control | m/min (ft/min) |
| Drum capacity | Rope length for a given diameter | m (ft) of mm (in) rope |
| Brake holding capacity | Must exceed rated pull with margin | Multiple of rated pull |
| Air or hydraulic supply | Your rig must deliver it at the winch | bar (psi), m³/min (scfm), L/min (gpm) |
| Hazardous-area rating | Electric drives need a zone rating | Zone 1 or 2, gas group, T class |
Standards and certification
Winches used for lifting fall under class lifting appliance rules such as DNV-ST-0378, and EN 14492-1 covers power-driven winches generally. On the Norwegian shelf, NORSOK R-002 sets design requirements for lifting equipment, including winches for lifting personnel. A man-riding winch's certificate must state that it is approved for personnel. A materials winch must never lift people, whatever its rating.
UK LOLER requires a thorough examination at least every 12 months, and every 6 months for winches that lift people.
Failure modes and inspection
Most winch failures start at the brake. An inspection should cover these points.
- Brakes. Check lining or disc wear and spring condition, then run a static holding test at the maker's test load.
- Drum. Check the shell and flanges for cracks and deformation, the groove wear and the rope anchor.
- Gearbox. Sample the oil for metal and water, and listen for bearing noise.
- Motor. On air motors, check vane wear, lubricator function and icing at the exhaust. On hydraulic motors, measure case drain leakage.
- Rope. Look for crushing at layer changes and uneven spooling, and check the rope certificate.
- Foundation. Check bolts and welds, with magnetic particle inspection where cracking is suspected.
A man-riding winch also needs function tests of the second brake, slack rope device, overspeed protection, emergency stop and the means to lower the rider with power lost.
Documentation
- Type approval or certificate of conformity
- Proof load test and brake test records
- Last thorough examination report
- Rope certificate, certified for personnel use on a man-rider
- Maintenance log and any modification records
Integration and compatibility
Air winch pull depends on the pressure at the motor inlet, so long supply lines and undersized hoses cut performance. Check hydraulic winches against your power unit's flow and pressure. Match the foundation bolt pattern and deck reinforcement, and set the fleet angle from drum to first sheave within the maker's limit so rope spools evenly.
Refurbishment and recertification
An overhaul replaces brake linings, seals and bearings, inspects the gears and finishes with a load test and a new certificate. Air tuggers are largely interchangeable, and a used or unused surplus unit with a recent test is a common choice. Buy a man-riding winch only with its full approval file and brake history. Ingersoll Rand and J D Neuhaus are well-known air winch makers. See also anchor winches and windlasses and drilling line and rigging.
FAQ
Frequently asked questions
What is the difference between a tugger winch and a man-riding winch?
A tugger winch is rated for materials only, while a man-riding winch is designed and certified to lift people. The man-rider has two independent brakes, slack rope protection, overspeed protection and a way to lower the rider if power fails. A tugger must never lift personnel.
Can a used air tugger winch be recertified?
Yes, in most cases. A competent person inspects the brakes, drum, gearbox and motor, the winch is load tested and examined, and a new certificate is issued. A cracked drum, worn brake or damaged gearbox has to be repaired before the test.
Why does winch line pull drop as the drum fills?
Each layer of rope increases the effective drum radius, so the same torque gives less pull. Ratings are quoted at the first layer and often at the top layer. Check the pull you need against the layer you will actually work on.
Can a tugger winch be converted to man-riding use?
Not without a design review and a new approval. Conversion means adding an independent second brake, slack rope and overspeed protection, emergency lowering and personnel-rated controls. Only the original maker or an approved designer can usually certify the result, so buying a purpose-built man-rider is often simpler.
How often must a man-riding winch be examined?
Under UK LOLER, a winch that lifts people needs a thorough examination at least every 6 months, or as a written examination scheme sets. Class rules and NORSOK R-003 have their own requirements, and most man-rider procedures add a pre-use function check of brakes and limits.
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