Optimising spoolbase operations: future-proofing with innovative thinking

How do you keep your facility relevant in the changing energy landscape? We review the key future-proofing steps in this blog.

Spoolbases are one of the staples of the energy industry, providing key services for the handling, storage and deployment of flexible products like umbilicals, TCP, mooring lines and power cables.

As the demand for flexible products grows, in line with the global increase in deepwater E&P operations and the ascent of offshore wind, spoolbase owners will need to reassess their facilities’ readiness and capability to capitalise on the upmarket, while maintaining high standards of safety.

At the same time, cable and other flexible product manufacturers may be looking to expand their storage capacity to deliver economies of scale by ramping up production.

As ever in the CapEx / OpEx world of energy, there are a few options on the table: upgrading existing assets, investing in new technology or exploring fixed-term contracts for supply of third party equipment. To identify the best route – or a combination of all three options – MDL Integrated Project Services step in to assist.

Key considerations for spoolbase success

Behind every winning performance strategy is a healthy gap analysis. Here’s what spoolbase owners should consider when planning for growth:

1. Tension control - ensuring precise control over tension during spooling to maintain product integrity.
2. Versatility - equipment must handle a range of products with varying sizes, weights and composition.
3. Space optimisation – minimise the footprint of master items and maximise the use of facility or quayside space for reels, carousels and other handling equipment.
4. Integration with existing systems - compatibility with existing infrastructure and integration of controls to ensure safe operations.
5. Safety and compliance - equipment meeting safety standards and regulations for onshore / offshore handling, reducing the risk of accidents during heavy-lift or high-tension operations.
6. Maintenance and reliability – modern, high-quality equipment requiring less frequent maintenance, ensuring fewer operational disruptions.

Since a spoolbase’s key function is – as the name suggests - to safely spool flexible products, frequently at long lengths, proper handling is priority number 1. In fact, correct onshore spooling is the first step to ensuring the longevity of these often delicate, high-value and complex products, before they are loaded out offshore and installed subsea.

If we look at the case for offshore wind, uneven or improperly spooled cables can lead to operational delays or damage that may only be discovered during critical offshore phases – which is a costly discovery, according to the insurance claims to date.

Thankfully, optimal handling of flexibles – at whatever stage in their lifecycle – is what MDL excels in. Our Project Management & Engineering expertise helps identify the most efficient upgrades to existing systems and specify the most economical equipment to introduce into the facility.

MDL is proud to offer market-leading flexible handling equipment, whether from its existing flexlay fleet or designed and built bespoke to client requirements; in either case, they all include differentiating features for future-proofing spoolbases, including:

· State-of-the-art controls for precise product handling and integration with other systems

· Unique safety features to prevent product loss and minimising hazards

· Compact footprint without compromising on capabilities

· Portable design allowing easy repositioning and reconfiguration

· Built to international standards and in line with DNV recommended practice

· Demonstrable reliability with little to no downtime, as a result of MDL’s strict maintenance procedure and engineering excellence in design.

In our previous blogs, we covered the unique features of MDL tensioners and reel drive systems, as well as the importance of choosing the right storage facility for your flexible in in our previous blogs – all of which will be part of your spoolbase upgrade planning. Another clever system that you should consider for your facility is a Level Wind Tensioner.

Levelling up with market requirements

Level winders are commonly used onboard cable-laying vessels (CLVs), for quayside transpooling projects and in spoolbases, providing controlled tension and ensuring even spooling – helping to enhance reliability and efficiency in managing cables and pipes across a wide range of offshore applications. It ensures the fleet angle of the flexible is controlled during spooling; this is critical for achieving even layers on the reel, which helps in maximising the storage space, but also – more importantly - reducing potential issues during deployment, such as abrupt tension spikes due to inadequately wrapped product, that could damage the cable.

For this umbilical manufacturer in the USA, MDL was called in to address technical challenges with the existing level winder and tensioner package, used for transpooling product in the spoolbase.

The issues related to reliability, inadequate traversing force and insufficient line tension for handling current products. They approached MDL for a design and manufacture of a new system to optimise the output from their facility.

MDL proposed an integrated package consisting of a level wind system, together with a bespoke 2-track tensioner - based on MDL’s proven design for safe handling of cables, composite pipe, umbilicals, flexibles or steel pipe products.

The tensioner is mounted on a level wind system that enables the firing line to traverse the internal width of a typical installation reel (5.0m width) in a smooth, controlled manner. The level wind traversing function is driven by a hydraulically-powered screw jack and controlled from either the Local Control Panel or the remote Walk-About Box, for safety of the operation and personnel. Depending on client requirements, the system could be electrically driven to hook up to plant power supply, or operate as a self-contained hydraulically-driven unit.

The bespoke MDL system - designed in consideration of DNVGL-ST-0378 - provides enhanced performance, outstanding reliability and allows for handling of larger product range, adding further value to site operations. While designed for the specific spoolbase in mind, the portable nature of the system allows for it to be easily relocated to a desired facility, via road transport or standard shipping containers.

MDL’s experienced in-house team ensures successful integration into the desired site with third-party equipment and control systems; additional support includes operational trials, training packages, experienced personnel to operate the equipment and tailored engineering including task plans, operating procedures, procedural sketches, layout plans and calculations.

The bottom line

There’s no way around it: you need the right tools for the job to protect the structural integrity of the products, right from the start of their life. With properly specified equipment, the production and transpooling processes are optimised, thanks to features designed to handle delicate products, precise parameters maintained by modern controls and synchronised communications between the various systems involved in the process. This integrated approach helps spoolbase owners and manufacturers maintain high-quality and standards, increase their output while also reducing the risk of defects during production and deployment.

For spoolbase owners looking to grow their offering, MDL provides tailored solutions that support diversified operations. Whether it's handling flexible pipes, cables or mooring lines, MDL’s specialised equipment — like tensioners, reel drive systems and level winders — helps optimise operations, reduce risks and improve product handling.

By upgrading facilities with MDL’s innovative solutions, spoolbases can become more competitive, secure a wider customer base and support wider energy sectors – riding the wave of a multi-energy market at its peak.