A guide to electric winches
Discover everything you need to know about electric winches in our comprehensive guide.
Table of contents
What is an electric winch?
An electric winch is a mechanical device used to lift, pull and position heavy loads using an electrical system. This system supplies a direct current of electricity to power the device’s lifting mechanism, which works by rolling a drum in order to wind a cable up or down.
Electric winches utilise advanced technology to support operations in the manned and unmanned surface vehicle (USV) market. For subsea projects, electric winches can be operated remotely from a survey vessel or the beach, to make operations safe, efficient and flexible.
Key features of an electric winch
Electric winches come in a range of sizes and capacities, depending on the lifting and pulling capabilities required. Choosing the right electric winch requires careful consideration of their key features and how it will meet the specific needs of their application, such as the weight of the loads, the conditions in which it will be used, how it will be mounted and the availability of power sources.
The key components of an electric winch are as follows:
Electric motor
This is essentially the heart of the winch, providing the power to turn the drum and wind the cable or rope.
Winch drum
The cable or rope is wound around this cylindrical element. The length of cable and winding speed will depend on the size and design of the drum.
Cable or rope
Made from steel or synthetic materials, depending on the strength requirements and safety considerations, the cable or rope is what pulls or lifts the load.
Control system
This can be a remote control or a wired control panel, allowing operators to safely control the winch from a distance for maximum precision.
Automatic brake
Essential for safety, this component automatically locks the drum when it’s not actively pulling, preventing the load from falling back or slipping.
Clutch
This allows the operator to disengage the drum from the gear train for free spooling of the cable or rope when quick deployment is needed.
Power supply
An electric winch is typically powered by a battery or a separate power source. The voltage requirements must match the power supply in order to function.
The importance of electric winches
An electric winch is essential to a variety of offshore and marine projects, as the winch is ultimately what deploys and recovers subsea equipment safely and reliably.
Although this process appears straightforward in theory, it can be fairly challenging when it comes to offshore environments, as the cable can become contaminated with debris or fishing nets, it may not wrap neatly back onto the winch, or it may break.
Electric winches are designed specifically to overcome these challenges and are a vital part of a vessel’s safety system. For remote operations, more responsibility is placed on the winch’s reliability to look after itself, and an electric winch has the ability to function effectively, resolve any safety issues and report advanced performance statistics without any human support.
Different types of electric winches
With electric winches becoming a more widely accepted choice for subsea projects, this type of equipment is now available with variations in operating method and use…
Electro-hydraulic winches
Using hydraulic motors and control systems powered by an electrically operated pump, these winches offer a hybrid approach and a fully integrated solution to carry out a range of offshore operations in both deep and shallow waters. They can be paired with equipment such as side scan sonar, magnetometers, drop cameras and ROVs, to name a few.
Basic electric winches
These winches rely on an AC electric motor driven system, which is used to lift, pull and lower heavy equipment, even in challenging subsea conditions. They can be utilised for a number of offshore activities, and are both safe and easy to operate thanks to their remote control capabilities. Even basic electric winches typically have higher efficiency and lower power consumption compared to electro-hydraulic winches.
Advanced electric winches
Similar to basic electric winches, these more advanced variations also use an electric motor system, but the motor is designed to a higher specification for enhanced performance. They are also integrated with advanced electronic communications and a control system for even greater precision and safety.
6 differences between electric and hydraulic winches
Hydraulic winches have been a widely accepted choice for a number of years. However, electric winches have become an innovative alternative that eliminate the various problems associated with their hydraulic counterparts.
Key differences between hydraulic and electric winches include:
1. Energy consumption
Even when they’re not in use, hydraulic winches require a high powered generator which is constantly running, leading to increased fuel costs and a hydraulic power source being an essential requirement, which may not always be readily available.
Electric winches consume much less energy than hydraulic winches, as they have low standby consumption and don’t require as powerful an energy source to function. This allows operators to reduce fuel expenses for a more cost-effective operation.
2. Environmental and safety aspects
Hydraulic winches are made up of high-pressure hoses which can cause hydraulic oil leaks after deteriorating over time, resulting in increased environmental and safety risks. Electric winches are much cleaner for the environment, with their superior motor efficiency and low standby power consumption leading to a lower environmental impact.
3. Cooling systems
Since they generate a high amount of heat which impacts the hydraulic heat exchanger cooling system, hydraulic winches require the added complexity of having water cooling systems installed. Electric winches are much more self-sufficient, as they have integrated electronic systems that capture and dissipate heat internally.
4. Control systems
The control systems in hydraulic winches are often quite simplistic, utilising valves, relays and contractors for their operation, which only offer a basic level of control and are prone to wear and tear. Electric winches, on the other hand, have an advanced electronic control system which provides a superior level of control, status monitoring and operator feedback, while supporting remote communication control.
5. Noise pollution
Hydraulic winches are notorious for being very noisy and creating a high vibration when in operation. This can be disruptive for the surrounding environment and crew members operating the winch. Electric winches have much lower noise levels and remove the need for hydraulic power units (HPUs), which better supports job site communications, overall safety and the transmission of very clean data.
6. Mobilisation and demobilisation methods
Since they require a hydraulic pump first, hydraulic winches are known for being complex to install, with multiple lifts and additional cooling systems required, with similar challenges when it comes to demobilisation. Electric winches involve a much simpler installation and demobilisation process, with a single lift and a smaller environmental footprint.
The benefits of electric winches
In addition to the advantages they have over traditional hydraulic alternatives explored above, electric winches also offer a number of important benefits…
Reliable safety features
Electric winches usually come with built-in safety features, such as automatic brakes and load-holding mechanisms, which stops the load from slipping or the cable snapping back in case of a break. With remote controls or switches, users can also operate the winch effectively from a safe distance.
Convenient to use
Since they’re powered by electricity from a vehicle’s battery or through an external power source, electric winches can be used in remote locations where access to a power grid is not available - which is ideal for offshore projects.
Cost effective
Over time, electric winches can lead to significant cost savings as they consume less power than alternative solutions and enhance efficiency in loading, unloading, and recovery operations.
Compact design
For subsea projects, electric winches offer a compact design to optimise deck areas and provide easy installation and mobilisation for greater operational efficiency.
Remote interfacing software
Some electric winches come with a custom electronic control system, which makes the winch self-sufficient and trusted to look after itself, while also ensuring the installation and user controls are easy to use.
The use of electric winches in different sectors
Due to their powerful lifting and lowering capabilities, electric winches can be utilised within a number of industries in the offshore market…
Electric winches for offshore renewables
As a rapidly growing industrial market within the subsea sector, offshore renewables are vital in contributing towards a global net zero target, while also addressing the multi-faceted challenge of energy security, affordability and sustainability.
Electric winches are ideally positioned to support offshore renewable projects, allowing operators to unlock high performance lifting and pulling capabilities with less energy consumption and a cleaner environmental footprint.
Electric winches for oil and gas
To remain dynamic and progressive, the oil and gas market requires specialist, high quality subsea equipment to support key decisions around development and maintenance. Electric winches can be used on a rig or vessel to support inspection, maintenance and repair efforts, as well as commissioning and decommissioning projects.
Electric winches for marine science
The marine science sector is a primary market supporting the blue economy, and requires enhanced data and intelligence to protect the marine environment and make discoveries that drive positive change. The ability to lower and raise survey or sampling equipment with an electric winch efficiently and safely ensures high quality data acquisition while protecting the surrounding environment.
The future of electric winches
The electric winch market has expanded significantly in recent years and is expected to continue rising as a result of industry demand - particularly within the growing offshore renewables sector - and the advantages they offer over hydraulic winches.
According to a Future Market Insights report, the electric winch market stood at an expected value of US $1,100 million in 2023, and is expected to grow at a rate of 7.2% CAGR over the next 10 years, with a projected market value of US $2,200 million in 2033.
As companies move into a more technologically advanced, higher performance and environmentally conscious era, it is crucial to recognise the superior benefits of electric winches, which can not only enhance operational efficiency but also contribute to a more sustainable future.
Choosing the right electric winch will depend on the capacity required for the weight you’re attaching to it. As a guide, the winch should be able to pull at least 1.5 times the weight of your equipment or vehicle.
Key factors to consider during the selection process are the design of the apparatus, size and shape, level of automation and intelligence, reliability and power efficiency.
As companies transition to a more technologically advanced, higher performance and environmentally conscious era, it is crucial to recognise the superior benefits of electric winches, which can not only enhance operational efficiency but also contribute to a more sustainable future
How STR can enhance your offshore operations with the largest fleet of electric winches
Our team of experts has designed, developed and produced a superior fleet of electric winches to guarantee high quality, efficient subsea data acquisition for our customers’ offshore operations.
Whether you’re operating in shallow or ultra-deep water, our combination of world-class designs, an unwavering commitment to high quality maintenance, and bespoke technical support tailored to each of our customers’ needs, we provide a flexible, cost-effective solution for a range of offshore projects.
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