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EchoBolt’s BoltWave Makes Bolt Inspections Easy

Pete Andrews from EchoBolt joins to discuss ultrasonic bolt inspection, the Bolt Wave device, and blade stud defect detection.

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 YouTube, Linkedin 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.

Pete Andrews: Pete, welcome to the program. Good to be back. Yeah. See you face to face. Yeah. Yes. This is wonderful. It’s a really great event to catch it with loads of the. UK innovation that are happening in the supply chain. So it’s, yeah, really nice to be here.

Allen Hall: This is really good to meet in person because we have seen a lot of bolt issues in the us, Canada, Australia, yeah.

Uh, all around the world and every time bolt problems come up, I say, have you called Pete Andrews and Echo Bolt and gotten the kit to detect bolt issues? And then who’s Pete? Give me Pete’s phone number. Okay, sure. Uh, but now that we’re here in person, a lot has changed since we first talked to you probably two years ago.[00:01:00]

You’re a bootstrap company based in the UK that has global presence, and I, I think it’s a good start to explain what the technology is and why Echo Bolt matters so much in today’s world.

Pete Andrews: Yeah, absolutely. So, um, as you said, we’re a uk, um, SME, there’s a team of 13 of us based here in the uk. Yeah. But we do deliver our services internationally, but really focused on Northern Europe.

Yeah. But increasingly we’ve done more in the US and North America, a little bit in Canada. Um, but our big offering really is to help wind turbine operators and owners reduce the need to routinely retire in bulks. So we have a quick and simple inspection technology that people can deploy, find out the status of their bolt connections, and then.

Reti them if necessary, but the vast majority of the time we find that they’re static and absolutely fine and can be left [00:02:00] alone. So it’s a real big efficiency boost for wind operators.

Joel Saxum: Well, you’re doing things by prescription now, right? Instead of just blanket cover, we’re gonna do all of this. It’s like, let’s work on the ones that actually need to be worked on.

Let’s do the, the work that we actually need to, and instead of lugging, like we’re looking at the kit right here, and I can, you can hold the case in one hand, let alone the tools in a couple of fingers. As opposed to torque tensioning tools that are this big, they weigh a hundred kilos, and those come with all of their own problems.

So I know that you guys said you’re, you’re focused here. You do a lot of work, um, in the offshore wind world as well. Yeah. I mean, offshore wind is where you add a zero right? To zeros. Yeah. Everything else is that much more complicated. It costs that much more. It’s you’re transitioning people offshore to the transition pieces.

Like there’s so much more HSE risk, dollar risk, all of these different spend things. So. The Echo Bolt systems, these different tools that you have being developed and utilized here first make absolute sense, but now you guys are starting to go to onshore as well.

Pete Andrews: Yeah, that’s right. So I mean, as as you said, that there’s really [00:03:00] three main benefit areas we focus on.

The first one is the health and safety of technicians, right? As you said, some of the fasteners used offshore now are up to MA hundred. So a hundred millimeter diameter bolts,

Joel Saxum: four inches for our American friends. Yeah, absolutely.

Pete Andrews: And they probably weigh. 30 kilos plus per bolt. Yeah. Um, so just the physical manual handling of that sort of equipment and the tightening equipment for those bolts is a huge risk for people.

If you think 150 bolts lifting or maneuvering, the tooling around on on its own can cause all the problems. So as well as the inherent risk of the hydraulic kit failing. So occasionally we see catastrophic tool failure. Is, which have really high potential severity, you know, sort of tensioner heads ejecting or crush injuries from Tor.

So that is really a key focus for our customers, just to [00:04:00] keep their teams safe, but also you have to be the cost effective and the the major cost benefit we allow is that we don’t have to revisit every bolt and every turbine like you’d have to do if you were retyping. So we believe there’s something of the order of a million pounds per installed gigawatt saving.

By moving from a routine REIT uh, maintenance strategy to a focused condition based inspection, you significantly reduce the amount of intervention you make and keep your turbines running more and reduce the boots on the ground on the turbine. So three real kind of, um, key. Benefits for people adopting our technology

Allen Hall: because we routinely see tower bolts being reworked or retention depending on who the manufacturer is.

And I’m watching this go on. I’m like, why are [00:05:00] we doing this? It seems, or the 10% rule, we’re tighten 10% this year, and they’ll come back and see how it’s going. That’s a little insane, right, because you’re just kind of. Tensioning bolts up to see if one of them has a problem and then you just do more of them and we’re wasting so much time because echo bolts figured this out years ago.

You don’t need to do that. You can tell what the tension is in a bolt ultrasonically, which was the original technology, the first gen I’ll call it, uh, that you could tell the length of the bolt. If the length of the bolt is correct within certain parameters, you know that it is tension properly. If it’s shrunk, that probably means it’s not tensioned properly.

That’s a huge advantage because you can’t physically see it. And I know I’ve seen technicians go, oh, I could take a hammer and I can tell you which ones are not tensioned properly wrong. Wrong. And I think that’s where equitable comes in because you’re actually applying a a lot of science simply [00:06:00] to a complex problem because the numbers are so big.

Pete Andrews: Yeah, I mean that, that, that’s been the real. Driving force between our offering is to simplify it. So ultimately we’re based on a non-destructive testing technique. It’s an ultrasonic thickness checking technique, but when from the non-destructive testing background, it’s crack detection, people have time, they can be, it’s a very precision measurement.

People have to be trained in the wind industry. We’re trying to inspect. A thousand, 2000 bolts a day at scale. It’s a completely different, um, ask of the technology and the way the technology has been developed historically has required too much technician expertise, too much configuration and set up time, and hasn’t delivered on the, on the speed that’s needed to be efficient in wind.

And that’s where our bolt wave [00:07:00] unit we’ve, that we’ve developed over the last. 18 months, let’s say, where all of our focus has gone to make it as slick and as easy for a client technician to pick up with minimal training. It’s through an iOS interface. Everyone understands it intuitively. Um, it’s a bit like using the camera app on your phone.

You know, you’re just hitting measure, measure, measure, measure, measure 10 seconds a bolt as you move the, um, ultrasonic transducer across, and then the data gets moved. Automatically to the cloud, to our bolt platform. And customers can view it in near real time. The engineer in the office can see the inspections happened.

They can see if there are any anomalous bolts, and then there can be communication there and then whether an intervention is necessary. So it’s sort of really changed the way our customers think about managing their, um. They’re bolted joints.

Joel Saxum: Well, I think these are, these are the kind of innovations that we love to see, right?

Because [00:08:00] we regularly talk about a shortage of technicians, and this isn’t, I was just learning this this week too, like this is not a wind problem. This is a everywhere problem. No matter what industry you’re in. Use are short of technicians. But we’re seeing like a tool like this is developed to be able to scale that workforce as well.

Right. You don’t need to be an NDT level three expert to go and do these things. ’cause there’s a very few of those people out there. Right? Right. We know the NDT people, a lot of NDT people, and that’s a hard skillset to come by. Yeah. This can be put in the hands of any technician. Yeah, a quick training course.

Just, Hey, this is how you use your iPhone. You can check Instagram, right? Yeah. Okay. You can off figure. Yeah, have fun. See you at lunch. Um, but they can, they can make this happen, right? They can go do these inspections and you’re getting that, that, uh, data collected in the field. Centralized back to an SME that’s looking at it and you don’t have to put that SME in the field and try to scale their ability to go and travel and do all these things.

They can be in the office making sure that the, the QA, QC is done correctly. I love it. I think that that’s the way we need to go with a lot of things. [00:09:00]Uh, and you’re making it happen.

Pete Andrews: Yeah. And it’s a real kind of. F change in mindset for us. So originally when we started Ebot, we were using third party hardware.

Yeah. Which required a bit of that specialism. Yeah. A bit of care about the setup of the project, getting multiple parameters configured before you got going. And it wasn’t really something we could put in the hands of a customer.

Joel Saxum: Yeah.

Pete Andrews: Which meant Ebot scale was limited to what our own team could go and do, and regionally as well.

You know, so we’re UK based. Probably 60% of our customers are uk, but now we have this Northern Europe offshore wind is obviously on our doorstep, but then increasingly we’ve done more and more in North America, so we’ve probably been to five or six sites now in North America and expect that to be a growth market because we can, we can now ship the devices over there, give some virtual training help.

Uh, [00:10:00] people set themselves up and then that opens up that market, you know, so it’s been a real change in strategy for us, but has allowed us to have far more impact than we otherwise would just try to be a pure service.

Allen Hall: Well, let’s talk about the big problem in the states of a minute, which are the root bushing or inserts that are loose in some blades.

When you lose that pushing, you also lose the tension on the bolt that can be measured. Is that something you’re getting involved with quite a bit now because of just trying to determine how many bolts are affected and, and where we are on the safety scale of can we run this turbine or not? Is that something that EE bolt’s been looking into?

Pete Andrews: Yeah, absolutely. So I, I’d say there’s sort of two halves of what we do. There’s the, there’s the bulk wholesale monitoring of. Typically static connections to eliminate this routine retitling where it’s not needed typically, typically. But then we have these edge cases of certain [00:11:00] connections and certain platforms that have known bolt integrity problems, and we are working with clients to really, um, manage those integrity risks.

Blade stud is an absolute classic, you know, sort of, I think almost every turbine OEM on some, if not all of their platforms has got. Embedded risk into their blades, pitch bearing connections. Um, so yeah, exactly as you said, our customers are using the technology for two things really. One is to ensure the bolts have been tightened to the preload that was specified or the target window.

And quite often we find there is an opportunity to increase the preload and therefore increase the resistance to fatigue failure. So. You know, particularly on older sites where the bolts perhaps not in the condition they were on day one. Well, they definitely won’t be. Um, when people have gone and retti them, they haven’t got back to where they, they should be.[00:12:00]

So we can prove that and increase a bit of that resilience, but then also start to look for the segments around the joint where, um, the bolt might start loosening or failures are occurring, and find areas where they can really hone in. And actively manage risk. And that sort of leads to what we’ve decided to do for the next year, particularly with Blade Stud in mind, is evolve this technology.

So whilst it’s also measuring the elongation, we will do a defect scan at the same time. So you’ll monitor your blade stu, um, connection and we’re hoping that we can set the device to flag to you there and then. We believe this bulk has got a defect while you’re here, get it changed out before it fails and, and all the knock on problems, um, from there.

Joel Saxum: So what you’re just pointing to there is a, is a workflow, right? So to me that is typical [00:13:00] of some of the amazing, innovative companies in the UK that I’ve run into throughout my career. And that is, you’re a group of SMEs, you know, bolted connections. That’s what you do, right? But then you’re like, hey. If there’s a tool, we could make a tool that would make our lives a bit easier, then it’s like, well, we could make the entire industry’s lives a little bit easier as well.

So let’s iterate on that. And now you’re able to send these kits around the world to look at these things. Hey, you have a problem with this specific model. We can help you with this because we know the failure mode and we know how to look for it. Let’s do that for you. Also here, you’re doing bolt bulk measurements.

We got that for you. But it all kind of flows back to the fact that Echo Bolt is a team. A bolted connection, SMEs that are making tools and being able to also provide consulting if need be. Yeah. Right. Um, to, to an entire industry. And I think that, um, this is my take on it, right? Wind is stop number one. I think you guys are gonna do a fantastic year, but there’s a lot of, uh, opportunity out there in bolted [00:14:00] connections as well.

Allen Hall: A tremendous amount blade bolts being broken from defects in the crystalline structure. What appears to be a more. Rapidly developing issue across fleets that I’ve seen. I went to a farm this summer and the number of blade bolts that were there on the table that were broken on the conference room table was And the whiteboard office.

Yeah. Yeah. This one,

Joel Saxum: this one.

Allen Hall: Your hard head is not gonna protect you from this one. It’s, it’s, it was this, um, I couldn’t imagine the amount of time they were spending hunting these things down. And of course, the only way they were finding ’em was they were broken. You like to catch ’em before they break because it becomes

Joel Saxum: a safety risk.

Just not too long ago we saw an insurance case where there’s an RCA going on and it is pointing at an entire tower came down. Right. And it is pointing at a mid, mid tower section bolted connection. How often do you guys run into those problems? Or are you contacted by insurance companies or anything like that to, to take a peek at those?

Pete Andrews: We haven’t done anything directly for insurance [00:15:00]companies, but we have been engaged by. Engineering consultancies that are doing RCA type activities. Okay. Um, things like at the end of defect liability periods mm-hmm. A customer has, has seen, they’ve had a lot of, uh, issues from an OEM, maybe an OE EM has offered a modification or an upgrade, assessing whether that upgrade is actually solved the problem or not.

We’ve got involved in, um, but the tower. Issue specifically. It’s actually very rare we find, um, problems with tower connections, but where we do is often where they haven’t achieved good flange flatness, ah, during installation or the bolts have been, let’s say, left out in the elements for a period and lubrication has been, has deteriorated before the bolt’s been installed.

So there are cases out there, but what I would say is. [00:16:00] To think about your whole life cycle, so ensure the bolt’s installed correctly and we can help with that with a QA to say, yes, this torque or tightening method has got you to the load that you want. Do some through life monitoring, but often if you install it correctly, it will it’s operational life.

You will have very little concern. But then in the UK market, we’re increasingly getting involved again at the end of life, right? Life extension where life extension turbines are 20, 25 years old. How does an operator make a decision to carry on running without replacing all bots? Um, and that’s where increasingly we being asked to use the technologist just to say, actually the joint is fine.

The bolts have run in a good, um, operational envelope. Run them on. Don’t replace a hundred percent of them like you might have been recommended to from your, um, yeah. Turbine supplier side. [00:17:00]

Allen Hall: So Pete, if someone’s doing a repower where they’re basically putting a new one in the cell on an existing tower, they’re making a lot of assumptions about all the bolts from the ground up that they’re gonna be okay.

And I know we’re talking about that. We’re in a lot of installations where. If the turbine has gone through a repowered or two. So now those bolts are 20 years old. Yeah. And trying to get ’em to

Joel Saxum: 30 35. 35

Allen Hall: 40. Yeah. I don’t know what they’re doing. By those bolted connections. Are they just like replacing the bolts?

Are they hitting ’em with a hammer again? Is that the, yeah,

Pete Andrews: I mean, they might replace ’em, but you’ve got a problem with the foundation bolts. ’cause they’re obviously often anchor bolts set into concrete, so you have to reuse them and. With the projects, both in wind and in process power industry with the chimney stacks to try and ascertain whether foundation bolts that are set into concrete are still suitable for operations.

So look for corrosion losses, look for [00:18:00] defects. Um, so yeah, they’re all things that need thinking about before you just make the snap decision to repower. But I think

Joel Saxum: a lot of that, uh, going back to a couple minutes ago, you were talking about at the commissioning phase, making sure that you have proper qa, QC of how these things were installed day one, and then making sure that before commissioning of a turbine, they’re checked.

I think that’s really important. We’re starting to see that in the blade world now too, where we’ve been talking about it for a long time, and now when you talk to operators, they’re like, we’re getting inspections done on the blades before they’re hung. Or at the factory before they’re hung. After they’re hung.

Like they want a good foundation baseline. Are you seeing that in the bolted connection world too?

Pete Andrews: Yes. Sort of. It’s just emerging for us. What we’ve found is, so most of our customers are in the operational phase ’cause they are the ones feeling the pain. Yeah. Of the routine retitling work. When they do major components, they sometimes engage us to come and say, can you check [00:19:00] before and after the blade was removed?

What was it? Before we took it off from a a bolt load perspective, what is it afterwards? Can you then recheck after 500 hours When we retalk it? And what we’ve seen there often is the initial install hasn’t got them to where they needed to be and they’ve had to go and do the break in maintenance or the 500 hour REIT to get the bolts to the right load.

So one of the questions that we have is whether. Some of the defects are actually being initiated very early on in that initial running in period and whether if, if actually you’d taken the time at, at the point of assembly to make sure you were correct, whether that avoids some of the knock on integrity concerns.

So yeah, it’s interesting area.

Allen Hall: Well, bolts are what hold wind turbines together and you better know you have the right. Tension and [00:20:00] torque on your bolts to get to the lifetime of the wind turbine and to, and to check it once in a while. And I know there’s a lot of operators I can think of right now in the United States that are sort of doing that job somewhat.

I I think they have missed out on opportunities to save a lot of money and to call it echo bolt. How do people get ahold of you? Because that’s one thing I run into all the time. Like, Hey, hey, you gotta talk to Ebol, call Ebol. How do they get ahold of you?

Pete Andrews: So the easiest ways are via our website. Which is echo bolt.com.

Um, LinkedIn, you’ll find us at Echo Bolt on LinkedIn. Reach out. Our email would be info@cobolt.com. So any of those route and you’ll, uh, reach me and the team and more than happy to speak to you about any of your faulting concerns or problems. We are, uh, yeah, we’re passionate about your problems.

Allen Hall: Pete, thank you so much for being on this podcast.

I, it is great to actually see you in person and see the bolt wave technology. It’s really [00:21:00] impressive. So anybody out there that needs bolt tensioning to checking tools, you need to get ahold of Pete at Echo Bolt and get started today. Thank you Pete. Thanks guys. It’s great to be here.

EchoBolt’s BoltWave Makes Bolt Inspections Easy

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ACORE to Ring Opening Bell at New York Stock Exchange to Celebrate 25 Years

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ACORE to Ring Opening Bell at New York Stock Exchange to Celebrate 25 Years

Washington, D.C. – ACORE will ring the opening bell at the New York Stock Exchange on Wednesday, July 29 at 9:30 a.m. ET to celebrate its 25th anniversary of powering investment in American clean energy.  

For 25 years, ACORE has been working across the entire clean energy business process, uniting technology, policy, and finance to accelerate America’s transition to a clean energy economy.

ACORE’s President and CEO Ray Long will ring the bell alongside members of the ACORE Board.

If you are interested in a conversation with ACORE CEO Ray Long, please let us know at communications@acore.org.

When: Wednesday, July 29 at 9:30 a.m. ET

Where: New York Stock Exchange, 11 Wall Street, New York, NY. Media wishing to attend in person should RSVP to Chris Higginbotham beforehand. The ceremony will also be livestreamed at https://www.nyse.com/bell.

###

About ACORE: 
ACORE is a nonpartisan nonprofit organization that operates at the intersection of affordability, reliability, and clean energy deployment. Our work is focused on stabilizing energy prices, strengthening the electric grid, and driving investment in cost-effective technologies to ensure that clean energy delivers for people, businesses, and the U.S. economy.   

ACORE’s membership includes clean energy investors, developers, energy buyers, power generators, manufacturers, and energy providers. In 2024, nearly 80% of the booming utility-scale domestic clean energy growth was financed, developed, owned, equipped, or contracted by ACORE members.

Media Contacts:

Chris Higginbotham
higginbotham@acore.org

The post ACORE to Ring Opening Bell at New York Stock Exchange to Celebrate 25 Years appeared first on ACORE.

https://acore.org/news/acore-to-ring-opening-bell-at-new-york-stock-exchange-to-celebrate-25-years/

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GE Vernova Q2 Wind Losses, Envision AI Turbine for Fortescue

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GE Vernova Q2 Wind Losses, Envision AI Turbine for Fortescue

GE Vernova posts a record quarter as gas and grid surge while wind orders drop 40%. Plus Envision grid-connects its first AI turbine for Fortescue. Visit https://woma2027.com/ to register speaking and sponsorship interest!

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!

If you haven’t visited woma2027.com, you should do so right now because we are putting together all of the, uh, events at WOMA 2027, which is March 3rd through 5th in Melbourne at the Pullman, Matthew, Pullman East? Pullman East Melbourne. And it’s packed full. Our, in fact, actually, we have so many people applying to attend the event, we’re getting a little nervous on if the size of the venue is not large enough, and we, we have a lot of people already chime in wanting to be sponsors, which is great.

But I wanna talk about what you will experience at WOMA. We’ve done it for two years now, and the feedback has been great. And Yolanda, you’ve been to the one just this past February, and participated in panels and saw some of the, uh, workshops and was involved in a lot of WOMA 2026. What are you expecting in 2027, and what did you think of 2026?

Yolanda Padron: I thought [00:01:00] 2026 was great. I loved seeing everybody there. Uh, got to meet a lot of new people. It was, it was sweet. There was a lot of r- people returning from WOMA 2025, um, and a lot of new people that were told that that was the event to be at to learn about wind, which was really, really nice to hear. Uh, something that I loved, especially since we’ve been through quite a few conferences since then and before then, was just the fact that, like, you’re, you’re just talking about problems and just talking about solutions, and you’re talking about real stories, and it’s nothing that’s super, super public.

You know, like, you, you can have real conversations with real people. I know during a panel I mentioned a, a solution to an issue that I had seen that was kind of niche, and then, uh, like three minutes later, like I had had some people come up to me and we all talked about the problem that we saw and then [00:02:00]talked about their problem, and it was really similar, and obviously in a totally different continent.

And it was, it was good to, to be able to have those conversations that you usually wouldn’t have elsewhere, especially if everything’s just really, really public and just big and you’re having a lot of people sell at you, and it’s, it’s just something that we’ve really shied away from. What, what was your favorite part of it?

Matthew Stead: I, I think, um, it was really the fact that it was a a technical, useful, helpful conference rather than having some rando talking about things that they’re told to talk to you about

Allen Hall: It’s real answers from real problem solvers. And everybody’s gonna be in Melbourne on the 3rd through the 5th of March 2027.

If you’re interested in attending, you need to go to woma2027.com. If you’re interested in sponsoring, it’s also woma2027.com. There’s limited [00:03:00]sponsorship left, so if you wanna do something, you better get in quick. And if you wanna attend the event, and I suggest that you do, that you visit woma2027.com and get registered today

The Uptime Wind Energy podcast, brought to you by StrikeTape. Protecting thousands of wind turbines from lightning damage worldwide. Visit StrikeTape.com. And now, your hosts

Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Rosemary Barnes, Matthew Stead, and Yolanda Padron. It’s been a busy day as we record because GE just announced its second quarter earnings and a bunch of things about the business. They had an investor call early, early, early on the East Coast, and even earlier for those on the West Coast of the US, and it was a very good quarter for GE, but a really lopsided one.

Uh, GE Vernova reported second quarter orders of [00:04:00] $24.2 billion, up 88% with a backlog that has now climbed to $176 billion. Free cash came in at $5.1 billion. Man, $5.1 billion is a lot of cash, everybody, which is more than the company generated in all of last year. So they made more in one quarter in cash than made in all of last year, and management is raising its full year guidance, but the strength is coming from gas power and the electric grid, not from wind.

The wind segment saw orders fall 40% and revenue slip 10%, and the company still expects wind to lose about $400 million this year. Although in the investor call, they did say that the forecast for wind in Q3 and maybe even Q4 was to be essentially break even on the EBITDA scale. So that’s a, a, a good number.

It does seem like GE is being more [00:05:00] aggressive on pricing and selective on the projects they are choosing to participate with. Repowers was way down, if I remember correctly. Uh, they are not doing a lot of that at the moment. So there is a slowdown they’re seeing in wind, but they’re more than making up for it in gas turbines and electrification.

Orders for gas turbines are out to ’30, ’31, and I think they’re gonna close out all of ’30, ’31, um, book orders for gas turbines here shortly. So if you want a gas turbine, Matthew, you’re gonna have to get in line because your GE has a long list of, of clients in front of them. What does this mean for wind?

When I hear the discussion where GE is focused on gas and electrification because of the huge cash flow that comes in their door- Does that mean a good positive things for wind because they have the cash to kinda hang around wind? Or is it gonna be set aside for other [00:06:00] more profitable business segments?

I

Matthew Stead: mean, GE’s had a number of setbacks over the years. Um, you know, we know, we know all about them. We’ve been talking about them, you know, multiple times. But, you know, they’ve gotta just wait it out, don’t they? Um, you know, wind is not gonna go away, so they just need to wait it out, get their problems out of the way, get their cash flow in, build the order books again, just wait for things to improve.

Um, I, I think one thing I just wanna pull out, the Sands Ear, i- isn’t that a massive achievement?

Allen Hall: It is. It’s, it’s a colossal engineering achievement on its own. Forget about just delivering and manufacturing all those turbines and getting them installed. And that’s a pattern energy project, and Fairwind I think was involved with that in terms of project development, EPC items.

It’s huge. It’s gigantic. But it may be the last one we see in the United States for a while.

Matthew Stead: And but Vineyard, you know, they’ve gotta resolve that, don’t they? We’ve spoken about that before. Get that one out the way, clear out the decks and, yeah. That’ll come good.

Allen Hall: Rosemary, of our former GE [00:07:00] employees, I guess we have two of them here.

I’m one. Not of wind, but of another division. What’s your thoughts on GE Vernova at the minute?

Rosemary Barnes: These days I see them through the O&M lens. That’s how I work with them, is when my clients need support for all their wind farms and It’s just, it’s just never enough. It’s not a GE-specific thing. Uh, you know, across Australia, anybody with a full service agreement does not…

Uh, the, the company performing that agreement just gives the impression that they just do not have enough, um, uh, enough people. Y- you know? It’s just, just hands or maybe it’s budget. Uh, I guess it, it’s both at the same time. Yeah, I mean, I see some good things like their, the pace of new technologies has slowed and they’re consolidating, which was needed, but it’s just hard to imagine that it’s even gonna be enough considering how many fewer blade engineers that they’ve got now.

Like, how are they, [00:08:00] how are they going to get the, you know, the issues with the platforms that they are, uh, pushing, how are they gonna get all that under control with so many fewer engineers? And will they ever be able to, you know, go back to innovating a- again when they’ve lost so much of their, you know, institutional knowledge?

Allen Hall: Two things they did not mention during the phone call today or in any of the documents that I saw was TPI Composites and that EPC has acquired that and is now operating the factories, uh, making GE blades. And LM Wind Power was not discussed either, although LM Wind Power has been integrated into the overall financials of the company, so it’s not a standalone financial entity like it was last year.

So you can’t really r- read the tea leaves of what’s happening at LM, but nobody talked about or even asked on the investor call what was happening on the wind side. They were very interested in gas turbines and what the order rate was going to be, and GE was concerned [00:09:00] on their side, saying that they’re trying to ramp up production to make more gas turbines, but there’s limitations to how much they can do.

Rosemary Barnes: I guess that’s the s- the zeitgeist now, right? Or it’s the, I don’t know, like, it’s, it’s a sign of the times. Everyone’s obsessed with data centers, and for some reason, data centers are obsessed with gas turbines, um, even though, like, it’s not a fast solution to, uh, y- you know, to, to anything. So I don’t… You know, I’m not saying that building a, you know, a wind farm or solar farms, batteries, those are not without challenges.

But I really don’t think that the, yeah, gas turbine challenge is so much easier than the, um, yeah, than the renewables challenges. It’s a bit weird to me how everyone has just kind of latched onto, “Oh, you need new power, then it needs to be gas.” It’s just a bit weird to me.

Allen Hall: GE was predicting a peak of orders in gas turbines to happen sometime in 2026.

They, they think that the demand curve is gonna trend downward because everybody is already in [00:10:00] line essentially, and it’s five years out, so not many other people are gonna join that line to make it seven, eight years out That also indicates that sort of the d- the demand for gas turbines may be waning a little bit, or there’s just a backlog, they just can’t produce more.

Is that going to then maybe finally open up the best solar wind discussion for AI data centers?

Rosemary Barnes: Yeah, I wonder if it’s partly because y- you know, in a lot of cases… So people wanna build data centers, and then those data centers need power. You can’t just plug into the grid in an easy, timely manner. So then now they’ve gotta BYO their own power, and in fact, in Australia they’ve just announced a, a policy where you will have to…

You can bring your own power, and it will have to be renewable, actually, in Australia. So, um, at least that’s, at least that’s a win for, you know, generation source.

Allen Hall: Yeah. The, the AI data center discussion and gas turbines in the United States has more recently been focused [00:11:00] on, on the AI data centers that use those gas turbines, and the number of gas turbines that they’re choosing, and that they’re choosing gas turbines that fall under some sort of EPA threshold on size.

And what is happening, and which, uh, SpaceX has done and some others have done, is they go underneath that threshold on the size of the gas turbines, and then they, you know, and they daisy chain them together, right? So you, you… Instead of having one massive, I don’t know, two-megawatt generator of some sort, you have a bunch of 200 kilowatts, and you just stack them all together.

And the concern is, is that are some of these data centers violating EPA, the… If not the actual rule or the intent of the rule in terms of emissions, and it’s causing a little bit of a stink. It’s, it’s raised enough of, uh, the noise floor about it that you’re, you’re hearing it on podcasts, you’re hearing people involved in AI data ce- [00:12:00] data centers push back on it saying, “It’s all legal.

It’s all legal.” So it’s gonna come to a head pretty quickly in the United States.

Rosemary Barnes: It was some real, like, real sketchy loophole finding, right? Like, I can’t remember the exact wording, but you’re not supposed to be able to just chuck in a diesel generator or a gas turbine in without any kind of planning, right?

But they found a loophole where it’s like, okay, well, you know, it’s just like a truck except for that there’s no truck, and so it was called, like- off-road or non-road use or something. And it’s just, like, clearly not the, um, the meaning of the, of the law, right? The spirit of the law had, like, obviously been broken.

In Australia we have a saying, the pub test. It doesn’t pass the pub test. Like, if you said that to someone in a pub, then they would be like, “What the hell is that? That is not right.” They have closed the loophole. However, I think that they also kind of quietly just allowed them to keep the ones that they had or had planned or something, so [00:13:00] it’s, like, overall by far not ideal.

But I think that it’s just, like, you can, you can do that for a single site, but it’s obviously, like, the more that you do ridiculous stuff like that, that you lose the community ac- acceptance, which they barely had and definitely don’t really have anymore. Um, and secondly, yeah, like people, uh, people close the loophole and they respond.

It’s, it’s much better, and we see it with wind as well. Like, yeah, you can do things technically by the law, but if you wanna have a, you know, sustainable, uh, industry through the years, through the decades, you actually have to kind of, you know, think, “What happens if I do y- push to the furthest extent of the law, um, to get away with whatever I can?”

What’s gonna happen is regulation is gonna come down on you and you’ll lose the ability to kind of self-regulate.

Allen Hall: We’re gonna take a quick break, but when we come back we’ll meet a wind turbine that runs on artificial intelligence, Rosie.[00:14:00]

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In the red dirt of Western Australia, a mining company and a Chinese turbine maker are trying something new. Envision Energy says it has grid connected its first [00:15:00] artificial intelligence wind turbine prototype for Fortescue’s Nullagine Wind Project in Pilbara. The full project will use 17 of Envision’s EN182 turbines, each rated for 7.8 megawatts and built to handle mining sites, desert heat, and tough grid rules.

The turbines- The turbines pair a self-erecting tower from Nabler Wind with a hub standing an astonishing 188 meters tall. Behind it all sits Envision’s Energy Foundation Model software that company calls the world’s largest physical AI system. The goal is to swap diesel and gas for wind across the mine’s fleet and processing sites.

So this is an effort by Fortescue to power mining operations with electricity. It’s a pretty ex- exciting [00:16:00] project if you’re watching. The Envision artificial intelligence piece is an aspect that I didn’t know much about, and I still am trying to gather more information on, because there’s not a ton of info about what AI means in terms of a physical system.

And maybe Rosie, you know a little bit more, or Yolande, you can brief us on what this really is.

Rosemary Barnes: We just need to start with a pronunciation lesson, Allen. Sorry.

Matthew Stead: Not Pilbara, Pilbara. Pilbara.

Rosemary Barnes: I, I don’t actually… I hadn’t heard that part about AI and that it doesn’t… I, I don’t know. It’s, it’s such a buzzword that it might not mean anything, you know.

However, there’s so many cool aspects to that project that aren’t related to AI. Um, yeah, the tower height, the tower erection technology. I’m interested to hear that they have taken the heat of the environment into [00:17:00] consideration, ’cause that’s one of the, my obsessions actually, as long as I’ve been working on wind turbines, and ever since I found out how, you know, the materials qualification and certification process works, that it just doesn’t take into account the really high temperatures.

That’s one of the projects that Padlo has going on at the moment, is, um, putting sensors on some turbines to, like, look into that more. Um, yeah, because we do see in Australia a lot of sites have, you know, even within a few years, they might have 20 years of operation left, but we already see a whole lot of cracks that look suspiciously like end of, end of life fatigue cracks on them.

So yeah, we are looking into that more, and it’s very interesting to hear that Envision have taken the heat into consideration. I hope it includes the blade structure as well as just, you know, other turbine components, electronics, and that sort of thing.

Allen Hall: It does sound like they’re pairing batteries or BESS with wind turbines, where the BESS is located at the base of the turbine.

That would make sense in [00:18:00] Australia, particularly around where mines are, because it tends to be very remote, and storing electricity would make sense. The Discussions I’ve seen on YouTube deal with more on the energy trading side, that the wind turbine stores energy, of course, and it does it very efficiently into the best system, and then the AI system sits on top of that to help arbitrage the energy that’s stored in the battery to make more money.

Not a bad way of doing it, but it does lead to a ton of questions about national security, the use of AI, the, uh, and how this is all going to integrate together from a asset manager side. Yolande, I know in the United States we have a lot of restrictions about the technology that is in wind turbines and the, and the firewalls that exist there, where you, you can’t even plug into a wind turbine without having a lot of approvals.

Is AI coming in wind [00:19:00] turbines in the US and the rest of the world, or is this mostly a Western Australia event?

Yolanda Padron: We talked a little bit about a trading company a couple episodes ago, right? And that was a… It sounded like it’s, it’s coming. Um, I, when I first read the article that we’re talking about for Fortescue, I thought this was more of, like, a SCADA self-learning AI type thing, where, like It, it kind of learns from the, from itself, and then maybe it, it tells you you’re more likely to be seeing some sort of blade issue that wasn’t shown before

Rosemary Barnes: I heard, um, Andrew Forrest speak at a smart energy conference earlier this year, and he was talking about not for, um, not for wind, but for the solar and battery projects that they’ve already got there.

He called it a self-healing grid, and AI was the technology that enabled that. And so he, [00:20:00] he was saying, and I can’t remember the, the details specifically either, but when there was a, a disturbance, something that would’ve caused the, you know, without the AI, um, you know, layer looking after everything, a fault that would’ve shut the whole site down was able to self, self-heal with no interruption to supply.

Um, and that that was the kind of AI that, uh, they were talking about. I believe that the new wind farm addition to that is the same sort of thing, where they’re looking at, you know, a very complex system with… I mean, they don’t have energy prices to deal with, uh, in that case because it’s self-contained.

They’re not conne- connected to any external grid. Um, but you know, they’ve got wind, they’ve got solar, they’ve got, uh, so obviously weather conditions related to those two going on. They’ve got batteries, they’ve got, you know, yeah, the, um, availability of every single different… of probably many [00:21:00] thousands of different components in that system that, um, y- you know, you need to make sure that if there’s a failure or when there’s a failure in any one or combination of those things, that you’re always going to be able to reroute around that and kind of heal itself.

So it probably does include some of, of what you were saying, Yolanda, but I think when they say this is the biggest physical AI, like, I think that that might be a little bit of a meaningless term because y- you know, like, there’s AI… It, it could be like… I, I don’t know. It, like, what, what does that mean?

Like, if you have AI that is, um, you know, playing some role in controlling America’s electricity grids, then that would be the biggest, the biggest one, even if it was, you know, like a tiny little, playing a tiny role. I, I, I don’t know what that specifically means and… Is it bad marketing ’cause it’s just confusing and makes you assume that it’s, um, just meaningless buzzword cool [00:22:00]sounding thing

Allen Hall: It’s probably genius marketing because they attach AI to whatever the product is.

So we have AI lightning diverters at Weather Guard. EOLOGIX-PING has AI CMS, and Partload has whatever Partload does, AI-Partload. So that’s the smart move, th- uh, because it does seem to raise the value

Rosemary Barnes: But you know what? Partload is anti-AI because 90% of our work is you get, you know, drone inspections, and they use AI, and then it w- and it works really, w- it works really…

I’d never wanna make it sound like it is bad technology because, you know, the status quo before we had drones with using AI was to just not inspect your blades. So, you know, like, we’re doing much better than that now. But everything that we do is where AI was not able to do it or AI did it wrong. So y- you know, um, like I- we use AI in that everything that comes into us is AI.

Allen Hall: Well, if the same AI [00:23:00] technology that is reviewing blade images is being applied inside of a wind turbine, what do you see as a likely outcome there, Rosemary?

Rosemary Barnes: Well, it’s not, I mean, it’s not the, it’s not the same. And like I said, uh, it’s very easy for me to be like, “Oh, AI, you know, makes all these mistakes,” but it, I only see the mistakes.

I don’t see the 90%-plus of correctly categorized things. I don’t, they’re not relevant to me. Um- Uh, but I think for controlling a complex system, like it, it is… That, that’s a really great application. I mean, I think it’s like with any like super hyped up technology, it’s like really useful in a few things, and that’s what leads to the hype, and then people start to just wanna apply it everywhere.

It becomes the, you know, like when the only tool you’ve got is a hammer, everything looks like a nail. Like, that’s where we’re at. Like AI is this, um, is this hammer that we’ve got, and everyone wants to solve every problem with it. And I do it myself, you know. Like I hate writing LinkedIn posts, and so I’ll work with, with Claude or, um, I [00:24:00] use NotebookLM as well to, you know, I draft my LinkedIn post.

And you’re like, “Well, th- no, that sucks. Do this, do this, do this.” And then, you know, like half an hour later, you’re like, okay, I could very easily have written my own post in less time, and I could… I, I try again and again because I just, I, uh, you know, hate that kind of writing so much. But yeah, I think that like economy-wide, that’s the problem, that everyone is just trying to whack every problem with AI regardless of whether it’s the right one.

Allen Hall: Okay, so there’s gonna be products that are gonna incorporate AI or have AI somewhere hyphenated in the name of the product. What products should not be using AI right now?

Matthew Stead: Yeah, I think there’s… Uh, I wanna add to the… You know, go back a few steps. That calling this the largest, you know, physical AI device is complete rubbish really.

That’s stupid, really. It’s like, like, like what you said, Rosie. It’s like putting an AI machine on a road, and then it becomes the world’s largest AI infrastructure. I mean, that was, that was pretty stupid, um, [00:25:00] really. And that, that’s just marketing. My, my view is if you can’t explain what it does, you shouldn’t be using the word AI So in marketing, you know, you can’t just say, “Oh, it’s AI ’cause I don’t understand what it does.”

You should actually be able to explain, “This is what this product does, and this is why it does it, and we use AI to help make that occur in a smart way.” Rather than just being randomly talking about, um, AI solving all of these complex issues and not actually knowing how it’s done is rubbish.

Rosemary Barnes: To answer your question, Allen, I think AI shouldn’t be used for most creative stuff.

Like video, um, creation, everybody hates it, and companies keep on pushing it, and it sucks. And I think also it’s kind of… It, it makes people so angry, I think it’s gonna backfire if it hasn’t already for most, [00:26:00] most people that are using it. Um, yeah, so that would be one thing. And also, uh, you shouldn’t use too much AI for, like, I see it heaps on LinkedIn now, and it’s, it’s kind of…

Like, at the first time you use AI, you’re like, “Whoa, th- this is pretty, pretty good. Like, this is something, you know, like I could… That’s very similar to the stuff that I, yeah, used to post on LinkedIn or the infographics that I used to make.” But the issue is that, like, it looks that way the first time, but then once you use it a bit and you can recognize that it’s AI, then you see it everywhere and it, it turns you, really turns you off whoever’s put it out there.

And so, like, there’s so much on LinkedIn now where it’s, like, just AI-generated things. It’s… Even if, you know, like, if an expert has created it and edited it afterwards and made sure that the output is accurate, then I wouldn’t call it AI slop. But it is also, like, it’s always too [00:27:00] wordy. It’s, um, you know, it’s just like the style is just clearly e- the h- if the point is that you’re trying to express, “I’m an expert.

These are my expert opinions. I know what I’m talking about,” AI is not doing that for you. Like, you write your post or create your graphic with AI, it’s just not doing that for you. So I think that that is another example of where people shouldn’t be using AI.

Allen Hall: That wraps up another episode of the Uptime Wind Energy podcast.

If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn. And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show. And please, please, please don’t forget to subscribe so you never miss an episode.

For Rosie, Yolande, and Matthew, I’m Allen Hall, and we’ll see you here next week on the Uptime Wind Energy [00:28:00] podcast.

GE Vernova Q2 Wind Losses, Envision AI Turbine for Fortescue

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