The power behind perfect system control

Christian Bart on his passion for Software Engineering.

Special feature: Hoisting winches and Umbilical winches for a complex Offshore installation tool for our client Eager.one

The technology behind a complex Offshore installation tool. Christian Bart, software engineer at DROMEC, develops the software that ensures the precision and reliability of a complex system. “The most satisfying part is when the engineering comes to life, allowing operators to work with it as if it’s something very simple.”

Thinking in systems, working in solutions

As a software engineer, Christian is a crucial link in the development process of winch systems. “Winches are part of a bigger whole,” he explains. “I envision how the entire machine will operate in combination with our winch systems and translate that into a functional document. Then I program the software, not only defining how the machine operates, but also integrating detection systems and safety mechanisms.”

For complex installation tools, it’s not just about movement, but also precision. Synchronization control of multiple winches must be properly tuned. Additionally, the system considers the operator: controls must be straightforward and safe. “Hydraulic components, electric winches, and controls all come together in an integrated system that needs to work flawlessly,” he says. “That requires a thorough approach and a sharp eye for detail.”

Hoisting winches and Umbilical winches for complex Offshore installation

One of the most challenging projects Christian has worked on is an installation tool for our client Eager.one. Eager.one specializes in designing, building, and delivering turn-key solutions for all conceivable lifting and installation processes in both the Onshore and Offshore sectors.

This installation tool is used to install anode cages on monopiles for wind farms. Monopiles form the foundation of offshore wind turbines and must be protected against corrosion. To lower the ring precisely into place, this specialized installation tool is used.

“This complex tool is hoisted from the installation vessel onto the monopile,” Christian explains. “The system operates with five electric winches: three hoisting winches, one Umbilical winch, and one large Umbilical winch housed in a container frame that provides power to the tool. All winches must work in harmony, ensuring the ring can be lowered in a controlled manner while staying level. Additionally, hydraulic steering wheels allow an operator to maneuver the ring into the desired position. The final step of leaving the anode cage behind is achieved by activating hydraulic pins to release it.”

Controls

The control system is advanced yet user-friendly: a touchscreen and joysticks enable operators to control all five winches as a single unit or adjust them individually if needed. “The three hoisting winches are attached to a lowering ring and have a total capacity of up to 60 tons,” Christian says. “Moreover, the system must be programmed so that the tension on the Umbilical cable from the ship to the installation tool, as well as from the base frame of the tool to the lowering ring, remains constant. This is achieved using a Constant Tension control. One of the key challenges is ensuring the correct startup sequence.”

Bringing engineering to life

What makes his work so fascinating? “The best moment is when a machine truly comes to life,” Christian says enthusiastically. “You’ve designed and programmed something, and then you see it in action. Suddenly, a design becomes something tangible, something an operator can use and trust. That gives me immense satisfaction.”

Innovation and inspiration

Christian’s work lies at the intersection of technology and innovation. His ability to understand complex systems and make sophisticated technology simple and reliable makes him indispensable in the development process. “Every project is unique, and that gives me so much energy,” he says. “The best moment is when a client says: ‘This works perfectly, exactly as we wanted.’ Then you know you’ve created something solid that the client can rely on for years to come. And for the future? Providing even more insights into the lifting process as an additional service to the client!”