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EchoBolt Advances Wind Turbine Bolt Maintenance

Pete Andrews from EchoBolt discusses their advanced ultrasonic technology for inspecting and maintaining wind turbine bolts, which can reduce maintenance costs by up to 90%. He emphasizes the importance of proper bolt tensioning during installation and highlights recent improvements in their automated inspection processes.

Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on FacebookYouTubeTwitterLinkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!

Allen Hall: With wind turbines growing larger and critical bolted connections under strain, the wind industry needs smarter inspection methods to prevent costly failures. This week we speak with Pete Andrews, managing director at EchoBolt. EchoBolt has developed ultrasonic technology that makes bolt inspections faster, more reliable, and saves wind farm operators up to 90% on maintenance costs while preventing catastrophic failures. Stay tuned.

Welcome to Uptime Spotlight, shining Light on Wind. Energy’s brightest innovators. This is the Progress Powering tomorrow.

Pete, welcome back to the show.

Pete Andrews: Hi, Allen. Hi Joel. Good to be back. I was trying to work out when I was last on here, but it was it two years ago. It’s been a while. Anyway, we’ve had a lot change at alt yeah, it’s good to catch up with you guys again.

Allen Hall: It’s been too long and so we’re glad to have you back because I know there’s been a lot of improvements and EchoBolt has been really busy checking bolts all over the place and we’ve, Joel and I have been traveling around quite a bit and we’ve noticed problems with.

Bolts in the United States and we think where’s Pete? Where’s Ebol? We could really use you in the United States to help us on some of these bolted connections because it does seem like there’s a lot of issues from tower bolts to blade bolts to bolts in general, there are a number of problems that exist.

And I wanna start off there, Pete, because I think you’re the knowledge base for bolts. Are bolts being tightened correctly based upon all the measurements that you have done?

Pete Andrews: Say, it’s a very mixed picture. I think you’re right to point out, it’s every wind operator will have issues in their fleets with the bolt of connections, but it’s almost always.

Blade studs that caused the most headache. You do see things on towers. You do see a kind of occasional issues elsewhere, maybe with foundations. I’d say it’s probably, I. In our experience, once, once sites are in operation, there’s not too much that happens that influences the integrity. An awful lot happens at the point of installation, and it’s what we always try and say to customers if it.

If you confirm that the bolts are tightened to the load, you expect at the point of installation, you’ve set yourself up for a fantastic operational li life. But if it’s wrong at the start, you’ve got embedded integrity issues that are really hard to manage going forward. So yeah it’s a mixed picture, but what I’d always say is focus on the QA at the point of installation and things should go easy from there on in.

Allen Hall: It does seem like blade bolts are becoming more of an issue. As you mentioned, the blade insert question of are we over tightening fasteners that go into the blades and pulling out these inserts and causing some of the problems downstream root cracking, instruments becoming loose, blades becoming loose and wobbling on the pitch bearings.

It does seem like we don’t have a really good way of consistently tightening or tensioning. Those fasteners are bolts that are in composite structure just a lot more sensitive to or the composites more sensitive to the tensioning tightening that happens? I

Pete Andrews: think without doubt it’s a harder joint to design and I think probably all of the major turbine OEMs.

It’s the area, I guess probably with the most dynamic loading or the most variable dynamic loading and probably the hardest to anticipate the performance of the joint. I guess we see a couple of things. We see a. Occasionally you do get overt tightening, particularly on torqued joints. Most blade studs tend to be tensioned, where you stretch the bolt rather than turn the nut or the bolthead.

But where it’s torked, you have a very wide degree of variability and there can be, there can be issues with going back and retalking and trying to measure an angle of turn and over overstretching the bolt and failing them. So we’ve seen that. I think on the tensioned joints, typically you get very good variability and the bolts tend to be within a narrow band, but probably not enough is being done to ensure that you’ve got as much preload safely within the bolt as you can.

And I think. The one meaningful action operators can take without having to redesign the joint or try and redesign the fastener, is just to measure the preload and see how much operational headroom you’ve got and maybe look at increasing it slightly. That’s probably the one area. If you’re suffering a lot of TED failures, you can address quickly and cheaply without getting into.

Design fundamentals.

Joel Saxum: Pete this week we were at the Blades USA conference here in Texas and we had many side, everybody’s talking blades, right? So what blade issue do you have? What blade issue do you have? And one of them that Allen and I had a couple conversations on with operators, there was, oh, we have the root bushing pullout issue.

And some people were very familiar with the issue and, but some people just weren’t. They were like, what do you mean by that? I was like, these things are actually loosening in the, breaking bonds and pulling through and all kinds of stuff. So in a blade root, you have upwards of a hundred studs or a, or a hundred of those blade bushings.

How many of them have to start to become loose before it starts to be like a cascading effect? For that blade,

Pete Andrews: the failing of the fixing within the composite structure is not really something we’ve encountered or looked into a lot. I think typically most manufacturers would place a limit on how many alts failed be before you need to stop the turbine.

Some of them have overall limits about the number in the joint and some have adjacent limits. I think it’s pretty normal for people to run with one or two failures and the structured still be still be safe to operate. But I think where you start getting consecutive failures, you have to look quite hard about.

The decision to continue to operate the unit, but particularly since the failures often in segments. So there is typically leading and trailing edge segments where you’ll see higher risk of failure. So as soon as you’ve got a couple of bolts in that area that aren’t doing what they want or what they’re supposed to be, then yeah, I think it’s a much harder decision to carry on.

Carry on operating without replacing those fasteners.

Allen Hall: Are there OEMs that are asking for those blade bolts to be torque still or has everybody moved on to tensioning? I

Pete Andrews: think every modern turbine we work on is tensioned. Some of the, we get quite involved in life extension projects where turbines have got to sort 20, 25 year operating life.

People are trying to make an assessment of, is it safe to continue? Do we need to do wholesale replacement of components, et cetera. And so a lot of the older fleet or some of the older fleet would have talked talk blade studs, but often, we can go in and if we can prove that the bolts are operating in the preload envelope.

The ideal preload envelope, let’s say. We can also look for defects, so we can look if the bots have got cracks in them and help the people make that call to just continue to operate safely with a monitoring regime in place rather than perhaps following a recommendation. From an OEM, which might involve wholesale replacement.

Allen Hall: I think that’s fascinating, but I asked that question because there’s a lot of repowering happening in the United States, and it did seem like turbines that are 10 plus years old. There was a lot of torquing of blade bolts, and now that we’re going to repower, one of the questions is, do I need to go back and look at that blade root area and do I need to address it because I overt, tightened, and or retort over the years and damaged that root section.

Is that something that EchoBolt and its technology can actually check? Because I think that’s one of the variables that we don’t know right now is this bolted connection okay. To live another 10 or 15 years. Is that something that the technology at EchoBolt can derive? We can

Pete Andrews: definitely to derive the bulk loads so we can have a look if.

If the bolt is over or under tightened, what we don’t do is the structural non-destructive testing. So we couldn’t look at the blade root bolt fixing structure and make any comments about the integrity of that. But we can look with you or with operators. What’s the tension or tithing process they’ve followed?

Does it generate the preloads that you would expect? Is there a risk of overti or in the tighten box? So that’s really our specialism.

Joel Saxum: What you guys do is very valuable at different life’s stages of a turbine, right? ’cause what earlier we talked about hey, right at commissioning you should be doing, you should be checking all these bolt connections or tension connections.

Either way. And then we talked a little bit we jumped forward, talked a little bit about lifetime extension during the repower phase. But another critical phase of life, specifically in the States that we deal with all the time is end of warranty. And it’s a worldwide problem. Are you guys getting into a lot of end of warranty campaigns right now where you’re checking everything before it gets handed back to the operator?

Pete Andrews: Yeah, we sort of, you’re absolutely right. There’s a few kind of obvious moments where you want to do more than the standard sort of asset status, asset health check and end of warranty is clearly one of those points. We have done end of warranty projects. Particularly a lot of our offshore customers, the age of the sites are at that point where sites are coming outta long-term service agreements.

The operators may be the owner is maybe taking on the operational responsibility and they want to transition from. What’s gone before to their own maintenance philosophy. So yeah, you’re right that’s one of the moments that we’ve been involved in, particularly when there’s been a serial defect.

And the OEM has proposed an upgrade, so we’ve had that on blade studs where just before end of warranty, an OEM has changed the design of the fastener. To alleviate bladed failures, we were actually able to show that in the population of the modified fastener, there were more defects than in the non-modified fastener.

So right at the end of warranty, we were able to show the customer the proposed solution was actually it actually made the situation worse. So they were able to, carry on the commercial. Debate with the their OEM and hopefully get a better res resolution.

Allen Hall: Okay, Pete, so I want to dig into that a little bit ’cause I know your technology is improving and one of the issues that’s we’ve seen quite a bit more recently is defects in the studs or the bolts themselves in the clin structure of the metal.

Occasionally there are some. Embedded defects that visually they can’t really detect. But it does sound like there’s new technology that can help delineate like that. Stud. That bolt has a defect in it where the next one doesn’t, which is incredibly valuable because depending where that bolt is on the blade ring, it could be critical or not critical.

I Is that technology now available more worldwide because of what EchoBolt has done?

Pete Andrews: Yeah, I think the. The technology we use for looking for very small defects is an ultrasonic technique called phase array, which is a more complex, non-destructive testing methodology than we would use for a preload inspections.

It’s a bit more specialist, but that can be really quite precise here. So down to the one or two millimeter. So scale or resolution for defects? So where we know there’s a problem in a population of bolts and the customer’s really keen to identify all the studs that are in the process of failing, we might use that to, to get themselves like a clean joint, if you like, of defect free fastas.

So they’ve got a good baseline to monitor from going forward, but as I said, that’s a bit more specialist. So it’s not it’s not trivial, let’s say, for customers to carry those inspections out themselves. But our bulk inspection technology that we use for monitoring a thousand bolts a day, to get through all the primary structure of a turbine.

We’ve worked on a lot over the last two years since we last spoke, to really optimize that to be as straightforward and user friendly for customers to adopt directly. And that methodology, whilst it’s primarily designed to identify the load within the bolts where we get big defects in bolts, we often see.

A fatigue rack propagating maybe 70 or 80% of the diameter of the bolt before it ruptures. So once you’ve looking at defects of that sort of size, our standard technology will also identify that, that there’s an issue with that fastener. So it does give you a chance to capture the fastener before it.

Catastrophically fails, which is quite useful, particularly for the blade studs because when they fail they can do an awful lot of damage. There’s all the hitch system, electronics, cabinets, lighting, et cetera. The number of turbines that have been in where the lights don’t work in the hub because there’s been, been half of a blade stud or a nut rattling around in there, smashing it all to pieces. So it is quite valuable to get to get the bottles out before they actually fail.

Allen Hall: I didn’t think about the associated damage when the studs fall out, but yeah, it does seem like it’s a, I guess it’d be actually dangerous and expensive when that happens.

So not only is it a structural issue, it’s just there’s equipment wiring all the. Activity inside of the hub could be damaged too. That’s really interesting. Okay, so the thing about echo belt is it’s all non-destructive. You’re doing things that don’t affect the bolt themselves.

You’re not playing around with ’em. You’re just using ultrasound technology and some really high advanced ultrasound technology to learn about the tensioning of the bolt, make sure it’s been elongated properly. That the structure of the bolt is all intact. So you know that bolted joint can have a long lifetime.

Now, there’s been a lot of advancements that at echo, EchoBolt to one, make that faster because the number of bolts that you’re doing in a day has increased quite a bit. But also the whole system, the way you guys operate, is now really automated from what I could tell. You want to describe what it would be like to have you come on site and go.

All right, Pete, we’re just gonna have you go check out the critical bolts in these turbines go. What does that look like now?

Pete Andrews: Yeah, perhaps if I go back to what it was like before. So when we started the company, we were primarily really a service provider and we were using off the shelf hardware, and we were quite technology agnostic really.

We just we’re trying to find different technologies we could bring into the wind industry to help with this problem. And we were using off the shelf ultrasonic bolt measurement devices, but I. I don’t think any of those devices were really conceived with the wind turbine use case in mind. So they’re very good at, if you have a small number of very high-end fasteners that you’ll really want to be super precise in a laboratory environment or a, a very specialized piece of equipment.

You can be very precise, but you have to be quite a skilled operator and it’s relatively time consuming. Whereas what we were trying to do is inspect a wind turbine a day, the whole primary structure. So the foundation, the tower joints, the your joints up to main shaft plate studs. Pitch bearing to hub, so all the connections that if that connection fails, a part of the turbine would fall off.

So you’re into needing to inspect a thousand bolts plus particularly on more modern machines which are getting larger and larger. You’re into the multiple thousands. So that hardware was just really suboptimal for it. It was a very clunky way of trying to export data. Onto your laptop with CSV files and manipulating Excel, and it just, it, it was taking almost as long to do the post inspection analysis as it was to do the inspection.

So we’ve completely re-looked at the technology purely from the perspective of what’s the optimum device for the wind industry. And we recognize that we are quite a small company, so the ability for ebol to service. The global Wind industries a as a service business with our own technicians is, we can only do so much.

So all of our effort has gone into really streamlining the experience. So now it’s very straightforward for a customer to pick up one of our devices. We have a sort of half day training course. The. The main sort of ultrasonic electronics device is wirelessly linked to iPhone. So you download an i an iPhone app and all the user interface is via phone.

So it’s a really familiar platform for technicians to work with rather than this complex suite of buttons and needing a 10 page work instruction or press this button followed by this. So superficial. Now we have a cloud database where you set up your projects when you’re on the turbine or in the office, you synchronize the projects to your phone.

Once you’re on the phone, on the turbine, you select the project you wanna work on. Take your inspections. It’s probably 10 seconds, a bolt. It’s really very quick. Finish inspections and then resynchronize backup to the cloud. And we’ve got a whole customer platform where you can see all the inspections that have been done, any anomalous readings you can do a level of qa, you can comment on things and say, this reading looks furious.

We’d like to check it again. These bolts look like they’re under load. We’d like to get those RET tightened, et cetera. So we’ve really tried to build this kind of end-to-end technology. Architecture that just solves this very niche problem for the wind industry. So we believe it’s a it’s a much more efficient way of carrying this work out than what it would’ve felt like two or three years ago.

They’re trying to achieve the same thing.

Joel Saxum: So one of the things of course when you introduce a new technology, everybody wants to know, of course, cost efficiency. What’s the business case? All these things. Allen and I talk about this all the time with operators on for our products. But I think one of the things that you’re doing here with EchoBolt, it’s the efficiency of how.

Fast, you can get these things done. So if you’re gonna come in and do, re just retorque or retention a turbine, you’re logging huge equipment, you’re doing all kinds of things. Even if you’re just doing like the the 10 percenting around each connection, that takes a lot of time, a lot of effort, a lot of people, you guys are able to cut that way down.

So is it can you run us through this as a single technician, how fast can you actually get things done? I,

Pete Andrews: I. A large offshore turbine, maybe six megawatts plus, we would always try and do all those primary joints, a hundred percent of the bolts in a single working day. So in a kind of eight hour working window.

Which is a much more efficient than if you tried to re-tighten all of those bolts, as you said, with hydraulic toing or attention and gear. But the really big saving. Comes from the fact that you have a measurement that you can track over time. So you have information about the condition of how the joints are behaving, and because you have that detailed information, you can extrapolate out from a sample.

So you can start to say instead of visiting a hundred percent of the turbines in a wind farm to retighten 10% of the bolts, we’re just gonna visit 20% or 15%. And if the that 20 or 15%, all the joints are where we expect them to be and are not relaxing, then you can quite comfortably start to make some engineering judgment about the behavior of the whole.

Whole wind farm. So we reckon that you could save about 90% of the cost associated with bulk maintenance by moving to an ultrasonic inspection regime. And as a kind of rule of thumb, I, for anyone interested out there, once you combine labor cost, logistics, and turbine downtime. The status quo of we’re gonna reti 10% of bolts every year and a hundred percent every five years is probably costing the industry in the region of $1.2 million per in store gigawatt per year.

If you’re running a wind farm of 500 megawatts, there’s probably five or 600,000. Dollars a year of savings to be made. So it’s, I think once our customers have tried the technology, realize it’s very doable and reliable. We’ve not had anyone make the decision to go back to bolt tightening.

That’s a good use case. Yeah. That’s the, it’s, it is getting yourself comfortable with a change. And different companies will have different levels of, um. Engineering management of change, for their assets. But once people are through that process we’ve found, adoption has really ramped

Allen Hall: up well, if you can save a wind farm a half a million dollars.

In any way. I can’t believe they’re not doing it. And maybe they just don’t realize at this point that Echo Bull exists because you’re mostly based in the UK and you’re busy doing offshore work, which is really important that UK has a lot of offshore wind turbines and those need to be running. And the loss of an offshore turbine obviously is.

Really critical there, but the onshore turbine world also needs your help. And I just think they haven’t realized the amount of money they’re spending on retentioning fasteners automatically because the spec says they need to do it. There are smarter ways to go about and do that now, and Ebot is, I think, the way to, to do it.

And the number of times you have been out in the field and all that learned experience has now culminated into this platform. Which is incredibly valuable. Simplifying the bolt experience for engineering at an operator is immensely valuable because there just aren’t a lot of engineers to go through that data.

So everything that EchoBolt has done in terms of making the platform easier is a huge advantage. So not only are you saving a lot of money on physically going out and Retentioning, but you’re also saving a lot of engineering time. This is, this makes imminent sense. So your phone must be ringing quite a bit right at this point because you’ve, you cracked the nut, so to speak.

Pete Andrews: Yeah, it’s it’s quite an interesting sort of how the business has evolved, has been a really interesting and satisfying things to witness. We’re obviously based in the uk, the majority of our works. The uk but it’s, I’d say we’re probably 60 40 between the UK and other markets.

As you said, we do a lot of offshore work in Europe, but we also do a lot of onshore. We probably do 30% of our turnovers onshore. But yeah, it’s I feel that we have been. Historically when we were running a much more service focused business using technology that was hard to put into customer’s hands, we’ve been somewhat constrained by our own size.

It’s not trivial for us to get teams out to other parts of the world. It’s not always. The most cost effective solution for people. But that said, we’ve been out to the states for a number of projects. We did a offshore project in Taiwan, which was really interesting just over a year ago.

We do a lot around Europe, a lot of the other European wind market, Germany, Denmark Netherlands, et cetera. So yeah, we’ve been growing. I guess within our being, yeah, let’s say the team’s been kept busy, for the people we have, we’ve been growing as fast as we can.

But I think we’re gonna see a bit of a step change now where it’s much more, it’s much more credible to hand the technology over to customers to deliver themselves and get really good results. Um. Yeah, I think the opportunity, it’s it’s a really timely conversation because the opportunity for people to take this on with self-service teams really, really, it’s a bit of a game changer for us.

Allen Hall: So now that EchoBolt has grown in scale and operators are reaching out to you, and they should, because if they really want to cut the cost of the operational side and save themselves literally millions of dollars here, which is what we’re talking about, you need to get a whole the P to EchoBolt.

Pete, how do they find you? How do they find Cobolt?

Pete Andrews: So probably the easiest way is our website. So that’s cobolt.co uk. We’re also on LinkedIn. I’m on LinkedIn. They’re probably the main channels we’ve got. You’ll find us on YouTube. You’ll find us on Instagram, but they’re more just for marketing and like a bit about, outward facing stuff, but yeah, website and LinkedIn are the easiest ways to get in touch.

Allen Hall: Yeah, checked out ALT’s LinkedIn page. You can check out the YouTube page. You can actually see them in action, which is really interesting, so you can understand what the process is and how efficient. Alt is at determining if your bolts are okay.

Pete, thank you so much for being on the podcast again. We love having you. You gotta come on more often because you’re really changing the wind world at the minute. Love having you.

Pete Andrews: Thanks very much guys. It was, yeah, nice being back and we’ll, we will do it again sometime.

https://weatherguardwind.com/echobolt-wind-turbine-bolt-tech/

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Pardalote Studies Australian Blade Erosion and Heat Fatigue

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Pardalote Studies Australian Blade Erosion and Heat Fatigue

Rosemary Barnes, CEO and founder of Pardalote Consulting, joins to discuss their new grant-funded study of blade erosion and heat fatigue in Australia.

Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTubeLinkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

Welcome to Uptime Spotlight, shining light on wind energy’s brightest innovators. This is the progress powering tomorrow

Allen Hall 2025: Well, Rosemary, welcome back to the show.

Rosemary Barnes: Thanks, Allen. Great to be here. For, it’s been a while since we did one of these one-on-one episodes, like a, yeah, a proper, proper guest. 

Allen Hall 2025: Well, this is kind of a celebratory episode because your company, Pardalote Consulting, has been awarded, uh, some funding from the Australian Capital Territory’s government for the Energy Innovation Fund.

Rosemary Barnes: It’s a really good program that the ACT government has to try and get energy innovation In the state. It’s not a state actually, it’s technically a territory. Little more than just Canberra, the city. Uh, but there are actually quite a few, like, really interesting energy-related companies here, partly ’cause of the, the fund I think helps, but also just tracing back like, [00:01:00] uh, y- you know, in the 20-teens, Australia had a really conservative government that hated renewable energy, and the ACT government had a commitment at that time to 100%, um, 100% renewable electricity for the, the government.

And that was one of the only programs that was resulting in a lot of, um, you know, clean energy projects being built, and one of the conditions that they put on that, uh, for people that would win PPAs with the ACT was that you had to have your headquarters in Canberra. So we’ve actually got quite a few, quite a few really cool, innovative companies out of here.

Um, like Neoen’s headquarters here. Windlab, uh, yeah, was, was founded here and still has a lot of people here. Pardalote obviously, and you know, a few other companies as well. So despite it being a small city of like, I don’t know, maybe it’s up to 400,000 or something people by now, um, yeah, there is actually quite a lot going on here for energy.

Allen Hall 2025: And the Energy Innovation Fund is funded by the wind and solar operators in the area, and your particular [00:02:00] effort has really global consequences. You’re focusing on two areas involving how wind turbines survive Australia, but more, uh, of relevance is to just really tough conditions which exist not just in Australia but around the world.

What two areas are you going to focus on?

Rosemary Barnes: Yeah. So the two focus areas are leading edge erosion and high temperature fatigue, which we can probably get into the definitions of those in a minute. But basically my, um– what led me to wanna have a project like this was that when I moved back to Australia in 2021, I– and I started working in O&M, uh, I noticed that the wind turbines that I would look at, the blades that I would look at here behaved really differently to the ones that I worked with overseas.

You know, es- especially with leading edge erosion, like often I would be doing a condition assessment of a, you know, a new wind farm. Um, might only have been operating for, you know, two years. That’s a pretty common time for people to get in and do a condition assessment [00:03:00] because their warranty period is about to end and they wanna, you know, make sure that everything is okay.

Um, and I would just notice that often, like 90, 100% of blades would already have bad erosion after just a couple of years, which is super-duper fast. And then there are some tools available to check, um, like what kind of erosion are you likely to experience on your site. Like is it a higher severity erosion site or a, a low severity one?

Um, and you basically, you know, the status quo globally is to just look at the annual rainfall, um, and the tip speed. And if you’ve got, you know, high for both of those, that’s a bad erosion site. And if you’ve got low for both of those, it’s a, a low erosion site. But when I plotted out the wind farms that I knew had really bad erosion problems onto, you know, a chart with those two axes, I just saw a random distribution of dots.

You know? Like, this was not– uh, this had no predictive value for Australian wind farms. And so that led me to believe that, okay, um, you know, things are a bit [00:04:00] different here. Makes sense, you know, most of the knowledge that we have about how wind turbines operate, it’s been developed and validated mostly in Northern Europe.

You know? Like it’s, it’s Denmark and the surrounding countries that had, like, the bulk of the early wind energy. First few decades of knowledge were, you know, were mostly there. Of course, there were some other, um, places that had wind turbines, but, you know, most of the The OEMs have been operating for decades, came from Denmark.

And I know when I lived in Denmark, the rain there is very different to the rain in Australia. So in Denmark, it’s basically always raining, right? Like, it’s just… Like, even if it’s not raining, you’re still gonna get wet when you go outside ’cause it’s just, like, the air has this just amazing ability to just hold onto moisture.

Um, but it’s very, very gentle. But, you know, over an entire year of most days having gentle rain, that adds up to a lot. Whereas in Australia, and especially if you go, like, north to Queensland, it rarely rains. It’s mostly just dry, and when it [00:05:00] does rain, it’s like a tap turns on, and I, I swear you will get bruised from the rain droplets hitting your skin.

You know, they just have so much energy in them. So I think that that i- you know, when you look at just the overall rainfall, you really hide something important about how erosion, um, can progress. Then, um, there’s other places in Australia that have very different characteristics. Again, they don’t have that kind of really intense rain but, you know, some of those sites are also having really bad erosion.

And so it just occurred to me, I did a lot of research, you know, into what’s going on and, you know, the academics are studying erosion a whole lot, and they’ve got, you know, a lot of standardized tests and, you know, products are developed according to these standardized tests. But the standardized tests don’t actually resemble reality, and especially they don’t resemble reality in Australia.

And so my client started asking me, “Okay, you know, the products that we have are, are terrible. We have to replace them every couple of years. It’s, um, causing big problems with also [00:06:00] the amount of energy that you’re losing.” One of the types of, um, leading-edge erosion or leading-edge problems that we have in Australia is that the, the coatings tend to peel off and make these, like, big flakes which will just massively disrupt the airflow, can cause y- you know, at least a few percent AEP loss, and maybe up to five.

And even worse than the AEP loss is the revenue loss because it affects it most at, you know, lower wind speeds. Um, you get a bigger hit than at rated wind speeds. So there’s a variety of problems going on with leading edges in Australia, which mean that I, I basically… My clients would ask, “What product should we put on to prevent having to, you know, constantly replace this?”

‘Cause it costs, like- you know, 30, $40,000 per turbine to replace the protection, not to mention, you know, one or two days of downtime. It’s expensive, and I basically, I didn’t have a good answer for them. What, what product should they put on? I don’t know. No, we, we don’t know. One, we don’t know what the [00:07:00] specific, um, characteristics are that are…

what the specific local environment, local conditions are that are accelerating leading-edge erosion, one. And two, all of the products tend to be tested around this, you know, there’s this protocol that academics have come up with, and they’ve kind of like assumed that this is representative of how things behave in the field, and it’s– I don’t think it’s particularly true anyway, but it’s especially not true in Australia.

There are a few companies that are testing to different standards. Um, definitely applaud them. But without knowing wha- what are the conditions truly like in Australia, uh, it’s really hard to advise, like, what kind of tests should you be demanding from a product you’re considering to be sure that you’re gonna put it on and not gonna be replacing it again in two years.

Allen Hall 2025: Because that’s really the trouble in Australia is when you get offered products They have been tested generally in somewhere in Europe and maybe in the United States, and then when they go to [00:08:00] Australia, it’s really unknown as to how those products will do, which is a huge risk for the Australian wind market as to what to choose, how to choose, is it– what’s real in terms of test data.

So now you’re gonna go out and do what? Are you gonna put sensors out by the wind farms? Are you gonna try to do more of a statistical summary of the actual environment around wind farms using existing data? What’s the approach here?

Rosemary Barnes: It’s all of the above, but the part that is supported by the grant is that we’re gonna have enough money to be able to buy some scientific-grade sensors and put them on, um, a sample of Australian wind farms.

So we’re gonna be looking at a lot more characteristics about the rain than simply is it raining now, you know, how many millimeters per hour. We’re also gonna be investigating, you know, every kind of characteristic of, of that, um, of that rain, um, including, yeah, like the, the energy that’s in it, for example.

A, a bunch of stuff. I won’t get into every single [00:09:00] parameter. Um, and you know, other things as well, like measuring UV, solar radiation, um, particles, because, you know, in Australia we have a lot of dirt roads, which I know is very common in wind farms around the world, but Australian dirt roa- roads are always dry and dusty, like 99% of the time, so that’s one of the things that y- you know, maybe that’s causing a difference.

Um, so basically putting sensors all over a bunch of wind turbines and then monitoring the erosion, um, a combination of some real-time monitoring and also looking at inspection, um, drone inspection images annually. We also have a- an option where we’ll just be using SCADA data and inspection images, so that’s like a lower cost version where we can combine that with the findings from the scientific-grade instrumented turbines to build up a picture of what types of conditions lead to accelerated erosion.[00:10:00]

Allen Hall 2025: So the SCADA data will, will have some information inside of it, you think, that, uh, will correlate to the weather outside?

Rosemary Barnes: It has some Additionally, we can look up, um, you know, just the weather data, like how many millimeters fell during which 15-minute interval throughout the day, what was the temperature.

SCADA will tell us also what the temperature was, um, what the speed of the turbine was, so you can calculate the tip speed, ’cause that’s an important thing. Um, yeah, so it’s, it’s two, it’s two tiers of data collection. The scientific grade sensors, as you can imagine, are, are really expensive and y- you know, the, the grant project has contributed a, a lot of funding, um, but it’s not enough to put those, yeah, put a little mini lab on top of every turbine across Australia, obviously.

So that we’re using s- doing selectively, and then we can increase the number of wind farms that are included in the study by just doing this, um, cheaper version of the SCADA [00:11:00] plus, uh, weather data that’s available.

Allen Hall 2025: So what are some of the risks on the temperature side for all the high-temperature regions of Australia that have wind turbines?

Clearly it’s generally warmer in Australia than it is in, in Scandinavia and Northern Europe. What kind of temperatures are we talking about on the ground?

Rosemary Barnes: Uh, well, temperatures here can get pretty close to 50 degrees. Um, and if you’ve ever been inside a wind turbine blade on a, even a mildly hot day, you’ll know that the temperature inside a wind turbine, and especially inside the blade, is much hotter than what it is, uh, what the ambient temperature is.

So this project is one– I’ve actually been talking about this project for, yeah, like over 10 years now. Ever since I started, I moved to Denmark, started working for a wind turbine manufacturer, I had done– I had just finished doing my PhD on composite materials, structural design, and analysis. So, um, yeah, very, very familiar with, [00:12:00] you know, how composite materials work and, in particular, the effect that temperature has on them.

I mean, like most materials, when composites get warmer, they get softer, and that is really important for a w- a wind turbine blade. You know, if it gets, um, less stiff, then you’re gonna get a lot more strain, and that is going to affect your fatigue behavior. Y- you know, fatigue is just the application of a little bit of, a small amount of strain.

It’s not gonna cause damage, but when you apply it millions, tens of millions of times, like you do in a, o- over a wind turbine’s operate, um, operating lifetime, then that builds up. And, you know, wind turbine blades are a very fatigue-driven design. Um, it’s one of the most important things to consider when you’re designing a wind turbine blade.

And so when I got to Denmark and I learned how materials are qualified and how the qualification is treated in the certification process, I just realized it’s not particularly conservative, and also that some of the assumptions that are made that [00:13:00] wo- again, they worked really well in more moderate climates where wind turbines have had most of their developmental history.

You know, it’s not such a big deal there if you test at room temperature. Your wind turbine blade is spending most of its operating lifetime at room temperature or below. It’s, it’s rarely, you know, above 30 degrees in Denmark and most of Northern Europe and, you know, also a lot of, um, a lot of America, not, not all of it But, um, in Australia it has just extended periods above that temperature and even exceeding the temperature where, you know, wind turbines have an operating limit and after that they will shut down.

But the operating limits are based on ambient temperature. It’s not based on what’s the temperature in the laminate, which is what really matters for blade lifetime. So anyway, I’ve been obsessed, like honestly obsessed about this issue for 10 years. Talked about it with anybody who would listen . But then when I started working in O&M in [00:14:00] Australia and I started seeing some wind farms with an abnormal number of cracks early…

again, early in their lifetime, you know, I think one of the wind farms I was looking at was maybe three years old or four at the time. I think it was three actually, and had a lot of cracks, and I looked at a few years in a row and it was more and more cracks every year and I’m like, “Oof, this really looks like end of life fatigue behavior.”

A- actually it’s not, y- you know, there’s this concept of a bathtub curve where, um, when you’re looking at failures in components, in, in anything, not just in, um, wind turbine blades, but you know, like you’d start– it’s called a bathtub because, you know, when it starts operating, you’ll get quite a lot of failures.

Anything big, any manufacturing defects or anything are gonna cause failures quite fast, and that kind of drops off over time as all of those, uh, get addressed. And then you have, you know, the bulk of your operating life, it’s like pretty low level, pretty, pretty constant for a long time and then as you get towards the end of the [00:15:00] life, you start to see failure rates rise up again.

That’s your fatigue failures, your end of life fatigue failures. And so when I saw the same types of cracks more and more each year, I’m like, “This looks like, you know, the foot end of the bathtub, not the head end.” And, uh, it made me worried and I’ve now seen that across a few wind farms in Australia at, um, hotter places.

There’s a few blade types that are more prone to it than others, but at this point it’s still a suspicion that that’s what’s going on. I mean, a suspicion backed by a lot of, a lot of theory and knowledge of how the certification process works. But this project now we’ve got some funding to actually go put some sensors onto wind turbines, actually learn what the temperatures are in the blades throughout the whole laminate, um, not just the, you know, on the outside surface or not just the ambient temperature, but actually, you know, develop a temperature gradient across the whole, um, the whole laminate in the blade shell.

Um, and [00:16:00] then we’re going to be doing a bunch of modeling basically to look at what is the effect of these different temperatures that blades are really seeing and how much would we expect to… that to decrease a lifetime. And then we should also be able to say, you know, if you have this issue in your wind farm, you might be able to change your operation a little bit and extend your lifetime a lot.

Because this one, it’s real– like, in contrast to leading edge erosion, leading edge erosion is just, it’s, you know, every wind turbine has it to a certain extent, and it, it’s always there, but it’s a relatively minor cost to fix it. You know, like it sounds like a lot, like 30, $40,000 per wind turbine, but, um, you know, compared to if you’ve got to replace every blade across your fleet because they’re all, you know, at the end of their life after five years, you know, that’s obviously shocking.

And, you know, that’s a bad example, but even in a y- you know, like a less extreme example, maybe [00:17:00] after 15 years you have to do a, you know, a f- a fleet-wide campaign to strengthen blades or something. It’s, you know, m- many millions of dollars for that, and so it c- could make sense to be able to learn, okay, what, what hours of operation should we be avoiding?

Additionally, because when it’s super-duper hot in Australia, usually you’ve got heaps of solar power and the electricity price is not that high. So I, I think that there– and I don’t, obviously, before we’ve done the project, I don’t know what the threshold is. But in both cases, we will be aiming to improve the knowledge of how you can operate to avoid these periods of accelerated damage.

Allen Hall 2025: Do you think you’re seeing more fatigue-like damage due to the blades operating when it’s hot or not operating when it’s hot, with maybe less airflow around the blade and maybe less cooling going on is just a temperature soak At rest? [00:18:00]

Rosemary Barnes: Yeah. It’s interesting because the temperature is higher if it’s not rotating, um, because you get a whole lot of, um, convective heat, heat transfer when the turbine is operating.

So your temperatures are not gonna get as hot when operating as when they’re standing still. However, if it’s standing still, they’re only very lightly loaded. Like, yes, they’re gonna get, um, blown by, by gusts and, um, have a little bit of bending, but it’s, it’s very, very small compared to, uh, if it is y- you know, operational loads.

Uh, assuming that you’re not in the middle of a s- a storm. But yeah, a storm probably doesn’t come with 50 degrees temperatures.

Allen Hall 2025: And what part of the blade is susceptible to these higher temperatures? Is it the resin? Is it the fiberglass or carbon fiber? Or is it the, the glue, the bond joints? What part are you focused on?

Rosemary Barnes: The resin is the main part that I’m focused on. It gl- it could be an issue for glue too, actually. I haven’t even looked into what the, um, yeah, temperature assumptions are with, with glue, with [00:19:00] bond lines. But the failures that I’m seeing in the field are not, are not bond line issues. It’s, it’s, um, a laminate problem.

Allen Hall 2025: What about balsa and foam inside of the blade? Are they affected by the temperatures or are they pretty temperature stable?

Rosemary Barnes: I don’t think they’re affected at these kinds of temperatures, no. They, they don’t really do much actually. The, the core materials, like it, it is very important that they’re, that they’re there, but their job is really to keep the fiberglass separated from its- itself to make it stiffer.

So, um, yeah, that’s, that’s unlikely to be a, a major source of problems.

Allen Hall 2025: So this study is gonna work over about three years, and you have a number of wind farms that are participating. Are you looking for more wind farms to participate in Australia?

Rosemary Barnes: Yeah. Yeah, definitely. I mean, we can, um, have as many as, as people want to join.

We’ve got quite a good selection so far. Definitely can always welcome more. A, a bit limited in how many can get the really, um, good sensor [00:20:00]package, because the grant funding is a, you know, a certain amount, and that’s paying the bulk of those sensors. So, um, those spots are limited. So if anybody wants to really zone in on what is specifically causing erosion on their site, you know, if you know that you have got leading edge protection that is not good enough and you have to replace it soon, but you don’t know what to replace it with, then, you know, that would be the kind of wind farm that might want to consider, yeah, joining this and, um, you know, getting these sensors on their, um…

We’re putting them on top of the nacelles, most of them. Um, yeah, so that would be a good match then. Um, and then, yeah, for the ones that are doing the SCADA data and, um, weather data- There’s not such a, a hard limit on how many we can have join like that. So yeah, we can have more, more like that.

Allen Hall 2025: In the temperature fatigue effort, i- is that still looking for participants or are there particular wind turbine types or manufacturers that you’re [00:21:00] looking for to participate?

Rosemary Barnes: Yeah, I think, um, I, I mean yes, we can have more of those. That’s a simpler, a, a simpler issue as well. The sensors are not so expensive and, um, it’s, yeah, it’s a, it’s a simpler project to join that one. We only need, you know, a couple of turbines per site, so it won’t be such a, uh, an involved process to get everything up on into the turbines.

And in terms of who might like to join that, I would say anybody that is in a really hot area where, you know, where they see a lot of days over 30 degrees, and if they see any days, you know, getting into the high 40s, then I would say that that’s worthwhile. Or even I have seen this issue in some milder sites, um, yeah, depending on the, on the blade type as well.

It is more common with polyester resins. They have a, a lower op- uh, maximum operating temperature than epoxy resins. But then also just anybody that has noticed just, hey, [00:22:00] we’ve got a lot of cracks, and it seems like we’re getting more and more cracks every year, which to be honest, can be hard to keep track of if you’re…

If you’ve got a full service agreement, uh, you know, an OEM managing your wind farm The early signs of this are gonna be category one and category two cracks. They’re not in exactly the same location. It’s, you know, it’s a tricky one. Normally, if you’re looking at a serial issue, then you’re going to have, uh, well, you know, your ideal pattern for a serial issue is the exact same thing happening over and over again.

And so it is harder to pull this out. It also really would be very rare for it to be happening in the first two years or three years, whatever your serial defect liability period is. So it’s quite hard. But, um, another group of wind farms that might like to consider it is if you know that in, you know, a certain number of years you have to renegotiate your service agreement or, you know, it ends and you might have to take over yourself, then this’ll be a really good way for you to [00:23:00] understand, you know, have I got a ticking time bomb here?

Um, because it’s not something that you’re gonna be aware of if you haven’t been, you know, doing some really, really in-depth shadow, shadow monitoring of your blades, you know, running your own inspections and looking at every single damage, not just category three, four, five, but lower ones. So yeah, I mean, there’s a, a wide variety of people that, that could be interested in joining.

Allen Hall 2025: Are you expecting a number of manufacturers that make leading-edge protection or involved in resin creation, some– there’s a number of resin companies and a variety of resins that are used globally, sort of interchangeably at times. Are you expecting some of those companies to participate in this effort just to learn about the Australian environment?

Rosemary Barnes: I think it would be a good opportunity to test out some products and see how they behave in the Australian context. I think that that would be a really good selling point, but I, I have to say that most of the companies doing that sort of thing that wanna enter Australia, they don’t [00:24:00] really consider…

Like, from the perspective of wind farm owners in Australia, if you can’t show us wind farms in Australia where this has worked and, you know, show us a before or after, you know, the old LEP lasted Two years and our LEP is going on four years now with no damage. It, you know, unless you’ve got a before and after like that, you can tell us however many turbines that you’ve got installed around the world, but, um, we don’t consider it validated, y- you know?

It’s not validated for Australian conditions yet. And I do have this same discussion over and over again with, you know, not just leading edge protection, but all kinds of, um, you know, manufacturers of whatever doodads that you put on to improve a, a wind turbine. It’s so different to Australia. Things break so fast.

And I’m talking everything, you know, like vortex generators fall off and, um, yeah, like, uh, you know, bits of lightning protection systems fall off, seals just [00:25:00] crumble and disintegrate. Um, and it, you know, we’re very wary of, of new products. So I, I do– I mean, I’m thinking of it more from my client’s point of view than from the product manufacturer’s point of view.

But one thing that I wanna get out of this pro- project is to be able to answer one of the most common questions that I get is, which is, what leading edge protection should I be putting on my turbine? And for now, I don’t know. I, I know a range of products that don’t work in Australia, and not much more than that.

So, um, yeah. And it’s also, you know, Australia’s a very varied place with lots of different kinds of climate too. So it’s not gonna be like, you know, the product that works in Queensland is the same one that’s gonna work in Tasmania, which is the same one that’s gonna work in Western Australia. You know, um, so it, this project is gonna really pull out what are the site specific issues you’ve got at your site and what kinds of, um, you know, tests would we need to see a product um, perform in order to know that this [00:26:00] is gonna last on your site.

Allen Hall 2025: W- what is the outcome of this project or these two projects? Are they gonna be reports or, uh, a, a continual monitoring system that’s designed for the Australian environment? How do you see this going?

Rosemary Barnes: Yeah, so one part of it is, um, developing a way to identify periods of accelerated damage and to know not to operate during that time.

So we call it protective operation. Uh, so that would, uh, help you if, yeah, you’re trying to extend the life of something or increase the amount of time before you have to repair, then y- you know, that would be useful to have that knowledge. And it will be as simple as just an alert saying, “Hey, accelerated damage conditions.

Consider, you know, if you wanna keep on operating.” And, you know, if the price of electricity is super high at that time, they may want to push through, and if it’s low, they probably won’t want to. So that’s one thing. Um, especially, you know, as wind turbines get to their, near the end of their life. I’ve got some clients whose wind farms only have, you know, [00:27:00] maybe five years operation left.

They just simply don’t wanna repair their leading edge protection again. They just, they, they don’t wanna do that. So they would be happy to, you know, reduce operation a bit and have their turbine limp through to the end of the period. Y- you know, you want everything to wear out at once. You don’t want brand-new leading edge protection on a turbine that’s going to come down in a couple of years.

Um, so, you know, that’s, that’s one part of it. And then the other thing is, you know, turbines earlier in their lifetime, how can we optimize the maintenance schedule with leading edge erosion? Um, so, you know, like it’s a lot cheaper to, uh, replace the LEP if you get– catch it early, but then you don’t wanna be catching it too early and replacing it, you know, constantly when you, you don’t need to.

So, um, yeah, it, this, having this knowledge will enable a site-by-site operations and maintenance strategy with respect to leading edge protection. We also have some sites who are having trouble. They’ve got a full service agreement, and the OEM is [00:28:00] responsible for, um, doing the leading edge erosion repairs and protection replacement, but the owner is on the hook for paying for it.

At the other end, we’ve got people with full service agreements where technically the, um, manufacturer is supposed to be doing the leading edge protection and paying for it, but they argue about what, when does it need to be done. Because, you know, um, the operator might think if there’s no structural risk, then we don’t need to be replacing it.

And in the meantime, you’ve got turbines spinning around for years and years and years with, you know, these huge flakes of leading edge protection s- you know, causing the flow at the tip of the turbine to, to detach and to stall, and horrible aerodynamics, huge losses in power generation and revenue. And they’re having a big fight about, you know, is this necessary to do or not?

And then, you know, they’re just gonna put the exact same product on again ’cause the [00:29:00] OEMs are re- all really, really wedded to their own particular brand. It’s like, “Well, last time we had this product and it was factory applied, it lasted one year before it s- it was worse than, you know, if it wasn’t there at all.

Uh, we don’t really want you to put that one on again.” And so, you know, having the information that they need to be able to, you know, really bring data to these discussions and, you know, makes a, yeah, data not drama. That’s a, a good approach I think, um, for any kind of negotiation and especially in the case of leading edge erosion.

And then for the high temperature fatigue part of the problem, aside from, you know, just wanting to know are your blades aging, should you be looking at remediation action or changing the operation, the other really big key thing is, uh, you might need to have a fight with y- your OEM about if this turbine has been designed and operated correctly.

And so then having the data from this, um, project is going to give you the information that you need to come into that [00:30:00] argument with, again, the data not the drama. Um, and to, you know, in- increase your chances of succeeding in that kind of really tricky negotiation.

Allen Hall 2025: So if you’re an OEM or a manufacturer of equipment, an ISP, an operator, pretty much all aspects of wind operations, you probably ought to be getting a hold of Pardalote Consulting and Rosemary to talk about the opportunity to participate in this study.

How do people get ahold of you to, to do that?

Rosemary Barnes: People can go to our website, pardaloteconsulting.com, and get in touch via the contact form there, or you can, uh, look me up on LinkedIn, Rosemary Barnes. That’s probably the easiest, fastest way to get ahold of me personally.

Allen Hall 2025: Well, Rosemary, congratulations on the Energy Innovation Fund Awards and the new three-year effort.

If you are interested in participating with Pardalote Consulting and working with Rosemary and her team [00:31:00] in Australia, reach out to her on LinkedIn and get that process started, because this report and the data from all this analysis that’ll happen over the next couple of years will be important to the wind industry.

So you need to spend some time and get ahold of Rosemary and get this process started now. So Rosemary, congratulations. Uh, thanks for being back on the podcast, and looking forward to, uh, the next couple of years. It sh- should be exciting.

Rosemary Barnes: Thanks so much, Allen.

Pardalote Studies Australian Blade Erosion and Heat Fatigue

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Artificial Stupidity?

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We all understand that there are ultra-conservatives living all around us, but does anyone truly believe that our schoolteachers are ruining our society by teaching children the truth about U.S. and world history? Science? Current events?

Slavery and Jim Crow laws were bad.  Fascism is bad.  Our scientists are telling us that CO2 emissions are causing world temperatures to rise, destroying our planet’s capacity to support life.

Whom do these concepts upset?

Artificial Stupidity?

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No Such Thing as a “Dumb Question”

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There is nothing dumb about the question posed at left.  Democracies fail, falling into “banana republics” constantly.  The rate at which democracies become tyrannies is so great that some of them never make the news. Can you tell me anything about the governments of Eritrea or Chad?

What makes the situation in the United States is, yes, that it’s happening here in the United States, the very last place anyone would have suspected it.

You might have thought that Americans wouldn’t have voted for their nation to become Russia or North Korea.

You would have been wrong.

No Such Thing as a “Dumb Question”

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