I. Introduction

The ship’s windlass, as a critical piece of equipment for vessel navigation and anchoring, directly impacts the safety and stability of the ship. In daily operations, windlass maintenance is often overlooked, yet its importance cannot be overstated. Proper functioning of the windlass ensures stability during anchoring and provides essential maneuvering capability in emergencies. This article discusses accidents caused by inadequate windlass maintenance, their severe consequences, common causes of windlass failures, international regulations governing windlass standards, and correct maintenance practices—all to emphasize the maritime industry’s need for heightened attention to windlass upkeep.

II. Accidents Caused by Inadequate Windlass Maintenance

The windlass is one of a ship’s key pieces of equipment, and its proper operation is vital for safety. However, accidents due to poor maintenance are not uncommon, often disrupting normal operations and posing serious safety risks with unpredictable consequences.

For example, on November 1, 2024, a vessel experienced severe hydraulic oil leakage from the windlass motor end cover during anchor retrieval, rendering the windlass inoperable. With winds at Force 9, waves crashing over the bow, and heavy rain, on-site repairs were impossible. The ship had to rely on engine and rudder control to maintain position until weather conditions improved. This incident not only created a hazardous situation but also resulted in financial losses. Another case occurred on November 20, 2023, when the PEH vessel lost its starboard anchor and 12 shackles of chain due to brake slippage while anchoring in deep water at a Middle Eastern bunkering anchorage. The crew attempted to stop the chain with a chain stopper, but it failed, damaging the stopper instead. Fortunately, no injuries occurred, but the incident caused significant operational disruption.

In April 2018, while departing from Balikpapan, Indonesia, the pilot repeatedly emphasized: “Keep both anchors ready for emergency, secure the brakes, reset the chain stopper, and have bow crew on standby.” Initially puzzled by the urgency, the author soon understood when the pilot pointed to a nearby anchored vessel, explaining: “That ship belongs to a well-known Taiwanese company. Three months ago, its emergency anchor brake failed during departure, causing the anchor to drop unexpectedly and sever an undersea cable, resulting in immeasurable losses. The ship remains detained, and the captain faces potential imprisonment.” This revelation left the bridge crew stunned.

These cases demonstrate that inadequate windlass maintenance can lead to severe consequences—disrupting operations, endangering crew safety, and even resulting in vessel detention or legal repercussions for the captain. Thus, windlass maintenance must never be neglected.

III. Severe Consequences of Windlass Failures

Windlass malfunctions often lead to critical incidents. First, during anchoring, a failure can cause loss of control, leading to dragging, collisions, or grounding—all with substantial financial repercussions. For instance, the PEH incident not only resulted in the loss of the anchor and chain but also damaged the chain stopper, deformed the chain release base, and bent safety pins.

Second, during navigation, a windlass failure may cause the anchor to drop unexpectedly, potentially severing undersea fiber optics, cables, or pipelines. This not only jeopardizes navigation safety but also risks massive property damage and environmental pollution. In harsh weather, windlass failures can prevent effective position control, increasing grounding or collision risks. Additionally, repairs may escalate costs and reduce operational efficiency, sometimes necessitating costly tug assistance.

IV. Causes of Windlass Failures

Windlass failures stem from various factors:

(1) Aging and Wear

Long-term exposure to seawater corrosion and mechanical wear gradually degrades components like brake linings, gears, and chains. Hydraulic seals may also deteriorate, causing leaks.

(2) Poor Maintenance

Many ships neglect regular maintenance, leading to chronic issues. Some crews perform only superficial checks before operation, overlooking critical components like hydraulic systems or brakes. Skipping scheduled oil and grease changes accelerates wear.

(3) Improper Operation

Crew errors—such as misjudging water depth or seabed conditions—can overload the windlass, causing brake failure. Rough handling during retrieval may exceed the windlass’s load capacity.

(4) Harsh Environments

Storms, freezing temperatures, or ice can damage the windlass. Cold weather may congeal hydraulic oil, while ice can strain the chain.

Summary: Windlass failures arise from aging, poor maintenance, operational errors, and environmental stress. To minimize risks, crews must prioritize upkeep, follow procedures, and implement protective measures in adverse conditions.

V. International Regulations on Windlass Standards

The IMO and maritime authorities enforce strict standards to ensure windlass reliability under all conditions:

(1) Strength and Reliability

SOLAS mandates that windlasses must withstand harsh conditions, ensuring safe anchoring and retrieval.

(2) Regular Inspections

Periodic checks of brakes, hydraulics, gearboxes, and motors are required, with worn parts (e.g., brake pads, seals) replaced promptly.

(3) Performance Metrics

Construction codes specify minimum retrieval speeds (typically 9–12 m/min) and load capacities to ensure safety.

(4) Training

Crews must be trained in proper operation and emergency response, including assessing seabed conditions.

(5) Backup Systems

Ships must carry spare parts, tools, and backup windlasses for emergencies.

Summary: Compliance with these standards ensures windlass reliability, safeguarding navigation safety. Operators and crews must adhere to maintenance protocols and training requirements.

VI. Proper Windlass Maintenance Procedures

To ensure optimal performance, follow these practices:

(1) Daily Checks

• Brakes: Inspect for wear; replace pads if thickness falls below 5mm or wear exceeds 30–40%.
• Clutch: Ensure smooth operation; lubricate regularly.
• Hydraulics: Check oil levels, air pockets, pressure, and leaks.
• Electrical: Monthly inspections of control boxes and wiring.
• Chain/Components: Monitor wear (replace if exceeding 12% diameter loss), inspect chain pipes, and maintain stoppers.

(2) Scheduled Maintenance

• Quarterly: Clean hydraulic filters, inspect oil, lubricate parts.
• Biannually: Service coolers, test oil quality, check electrical components.
• Annually: Inspect hydraulic lines and valve settings.

(3) Special Conditions

• Post-Storm: Secure anchor lashings and check for damage.
• Long-Term Idling: Preserve with anti-rust coatings and periodic inspections.

Summary: Systematic maintenance extends windlass lifespan and ensures operational safety under all conditions.

Huayang Maritime Center Co., Ltd.

Captain Liu Pengkun

Date: July 10, 2025