Weather Guard Lightning Tech

Funding vs Engineering, Edinburgh and WOMA Plans
Allen, Joel, Rosemary, and Yolanda discuss Modvion’s €39M grant for wooden wind turbine towers, leading to a discussion about funding vs. engineering readiness in the wind industry. Plus they highlight Veolia’s blade recycling advances in PES Wind Magazine. And the Weather Guard team announces they’ll be in Edinburgh for the ORE Catapult Offshore Wind Supply Chain Spotlight!
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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 Facebook, YouTube, Twitter, Linkedin 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: A portion of the Weather Guard team. We’re headed to Scotland for the ORE Catapult Offshore Wind Supply Chain Spotlight, which is gonna happen on December 11th in Edinburgh. We’re gonna attend that and it’s gonna be a, a number of great offshore companies there. We’re hoping to interview a couple of them while we’re there.
But Joel, this is a real opportunity, uh, for offshore companies in the UK to showcase what they can do and they can get on the Uptime Wind Energy Podcast.
Joel Saxum: Of course. So we’re flying over the sixth and seventh there over the weekend. And we will be, uh, in Edinburgh, uh, on the eighth. So Monday morning through Thursday.
Thursday and Thursday is the or E Catapult event. And yeah, we’re excited to see some of the companies that are gonna be there, interview some of them, get the, the picture, uh, of the uk um, supply chain, right? Because I think it’s a really cool event that they’re doing. I’d love to see other countries do that.
I’d love to see the US do that. Um. Just say like, Hey, this is, these are the companies, the up and [00:01:00] comers and the, the people that are changing the game and, and kinda give them a platform to speak on. So we’re excited to do that. It’s gonna be a one day event. Um, love to see some people join us, but the other side of that thing is we’re gonna be over in Scotland.
So we’re, well, we’ve got a couple meetings in Glasgow, a couple meetings in Borough. So if you are around the area, um, of course we’re linking up people on the uptime network, but, uh. If you’re around the area and you want to, you wanna chat anything wind, or maybe you got lightning protection problems, get ahold of us.
’cause we’ll be over there and, uh, happy to drop in and uh, share coffee with you.
Allen Hall: It’s just part of Weather Guards and the Uptime Wind Energy Podcast outreach to the world. So we’re gonna be in Scotland for an entire week. We’re heading down to Melbourne, Australia for probably a couple of weeks while we’re down that way.
And we will be somewhere near you over the next year probably. It’s a really good, uh, free service that we provide, is we want to highlight those businesses and those new technology ideas that need a little bit of exposure to grow. And that’s what the Uptime podcast is here to do. So join us [00:02:00] and if you want to reach out to us, you can reach us via LinkedIn, Allen Hall, Joel Saxon.
We’ll respond to you and hopefully we can meet you in
Speaker 3: Edinburgh. You’re listening to the Uptime Wind Energy Podcast, brought to you by build turbines.com. Learn, train, and be a part of the Clean Energy Revolution. Visit build turbines.com today. Now here’s your hosts, Alan Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes.
Allen Hall: Welcome to the Uptime Wind Energy Podcast. I’m your host, Alan Hall in the Queen city of Charlotte, North Carolina. Soon, the home of Maersk North America, I think we’re going to find out. And also the new Home of Scout, if you haven’t seen the little, what was formerly a MC little vehicle that’s gonna be made, well engineered in Charlotte and then built in South Carolina.
So we’re looking forward to that. And with me as Yolanda Pone in Texas. Joel Saxons up in the great state of Wisconsin and Rosemary [00:03:00] Barnes is back in Australia. And there’s plenty of things to talk about this week, and I, I think our pre-recording discussion has centered on wooden wind turbines. And if everybody’s been following, um, mod Vion, they have received a 39.1 million Euro grant and they are making of all things.
Wooden wind towers. So, uh, up in Sweden, there’s plenty of wood to make towers out of, out of it. And it’s a laminated process. And if, if you’ve looked online, I encourage everybody to go look online. It’s kind of an interesting technology they have where they’re layering wood together to build these towers sections.
And so instead of using steel or other materials, concrete, you can make them outta wood. Uh, so the European Union is backing this, and as Joel has pointed out. This is not the only money they have received to develop this technology.
Joel Saxum: Yeah. Back in 2020, they received a six [00:04:00] and a half million euro. Grant as well.
And then they had some investment money come in, um, and it was in Swedish Knox. Okay. Or of course they’re in Sweden, so Makes sense. But that was a, a convertible note around 11, 12 million, uh, euros as well. So when you add this 39 million Euro grant on, you’re looking at about 55, 50 7 million euros in funding over the last five or six years for this company.
Allen Hall: How does the European Union decide where to invest? These innovation funds at,
Rosemary Barnes: you know, it’s interesting ’cause I visited MO when I was in Sweden a few months ago. I actually have a video, uh, about to come out hopefully next week. Um, about, yeah, I got a tour of their factory and, uh, interviewed one of their engineers who’s been with them like the whole time.
Um, and I visited them just a few days after I visited C 12. I made a video about that as well. That’s a floating vertical axis wind turbine. C 12, just like four days after I visited them, they, um, received the [00:05:00] news that they had been awarded a similarly sized European grant. So, yeah, in the tens of millions, I can’t remember the exact number.
And I was thinking, what would I do if I got, you know, 40 million euros, which is like nearly 80 million, I think Australian dollars. Like I could really come up with something major and develop it in that time. It’s not, they haven’t been given the money to come up with the right solution, right? They’ve been given the money for the solution that they already have.
And I think that it’s really interesting that these European grants, it’s set up like that where they’re supporting, uh, assume that they’ve got a certain technology readiness level that you have to be at before that they will support you. And that kind of means that you’re locked in to a solution by the time that you’re at that point, right?
Rewards only that kind of model where you have a charismatic person with a vision that they just pursue to the end. It does not reward getting the smart people who could find solutions to the real problems. It [00:06:00] doesn’t reward that because you, no one’s getting heaps of money, like $10 million early on to be like, here’s a problem, now find a solution and we’re going to.
Fund that through the 10 things that you try that don’t end up working, no one is funding that, right? So all of that has to be done on the basis of your own pockets or the ability of your charisma to convince other people to support it. And I just think that it’s probably like. Not the right way to spend your, you know, if you’ve got like $500 million to spend to get the next big thing in wind energy, you shouldn’t be picking a bunch of companies that are tier L five.
You should be getting the smartest people and giving them money to found a company and um, yeah, come up with solutions that way.
Joel Saxum: Is it wooden? Wind turbine tower worth it.
Rosemary Barnes: And ev everyone will have to have to watch my video. ’cause I asked, I asked quite in depth questions ’cause I went into it very, very skeptical thinking that this was a su sustainability play.
And I’ve got two issues with that. Like, first of all, wind turbine tower is [00:07:00] not that unsustainable. I mean, wind turbines on average are paying back the energy that it took to make them in, you know, six months or so. But what was interesting is, you know, wood is a, a composite material, right? It’s got the, um.
Fibers, cellulose fibers in a malignant matrix. It’s, it’s, it’s a composite material, just like fiberglass is. Why don’t we make fiberglass towers? I mean, it’s partly ’cause of the cost and it’s partly ’cause joining them is quite tricky as well. Um, and yeah, those are probably the, the main two things, but I’ve actually done a bit of work into it.
If you could make a fiberglass tower, you could go. Way, way taller than you can with, with a steel tower, with, you know, transport constraints and whatever. So the wooden tower actually has a lot of the advantages that you would find if you had, were able to make a fiberglass tower. So they are expecting to be able to go taller, um, with, you know, they’re as constrained by transport because, you know, the fibers are all running this way.
It’s fine to cut it, um, like longitudinally, um, slice it into pieces and join the all site. Doesn’t, um, [00:08:00] reduce the, the. The strength really. So there from that point of view, there’s something to it. If you can go taller, make it easier to go taller with towers, then that’s a real problem that needs a solution.
There are other solutions. There’s like NARA Lift, you know the one just got bought by Ford Spanish company where they build a turbine on like a tiny tower and then slot pieces in underneath it to come up. That’s another great solution. Um, people are also looking at 3D printing concrete towers and thing, things like that.
So it’s not like this wooden tower is the only way that we’re gonna be able to do that, but it’s a real problem with a plausible solution to it. So. I think that they’re ahead of many, many, many, many of this kind of company. Just just from that, that at least they’re solving a real problem.
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Is it the fact that founders in that sense can speak about problems and tell a story, which it feels like if you watch Shark Tank, this is sort of the Shark Tank wind energy connection. I always think it when you watch Shark Tank. Is someone who gets money there or what’s the equivalent? In the UK it’s called Dragon’s Den.
There’s [00:10:00] a a certain personality type.
Rosemary Barnes: How often am, am I saying? Are we all saying what we’ve got here is a solution looking for a problem? Like there’s a real disconnect between. Engineering a good solution and, um, that, that will work in the field versus fake it till you make it to attract investor money.
I think it’s like this, this Silicon Valley like model where with software you kind of can fake it till you make it and it, you know, like update quickly, learn quickly. But with a hardware product as big as a wind turbine. You can’t, like if the engineering isn’t right, the product will never succeed. You can’t bluff your way through that.
Um, the projects that are done, like with the right engineering can’t attract enough. Funds. So they, they fail before they ever prove it. But the ones that attract enough funds are doing it because they’re like, uh, designing for investors rather than to build a successful project. And so it’s like you’ve got these two alternatives, both of which are guaranteed to fail.[00:11:00]
Um, I think that that’s the, like the biggest problem for how hard it is to get like legitimate innovation in energy
Yolanda Padron: up. I feel like it’s almost like a, it should be a training. For engineers in school to be able to at least pretend like you can not care about the details as much, you know, for 20 minutes in the day or something.
’cause imagine how successful some of these projects could potentially be if you were at least for a meeting like par with. Those people who just have that personality type.
Allen Hall: Not all engineers are gonna be founders of company and not all founders of company are gonna be engineers. And that has an influence on what the little tiny pool of people that can be able to do this where you’ve taken a very complicated problem, come up with a solution and being able to sell it or market it, which is even harder.
You gotta market before you can sell it. [00:12:00] The engineering. Type person tends to wanna focus on the details, the of the product, not on the problem that someone is struggling with and what that means to that person. Here’s, I think where that line gets crossed, and you can do both, is that, that the engineers that are just.
Focused, super focused on learn, learn, learn, learn, knowing what you do not have and going to get those skill sets because you don’t have to be the world’s best engineer, nor do you have to be the world’s best marketer, but you have to know enough to be dangerous and you as an engineer. Training I had in school was keep.
Pounding, keep trying to learn more. And I, I feel like Rosemary’s in the same vein, right? So she’s always trying to learn more and that’s why she has her engineering with Rosie, uh, YouTube channel is because she’s constantly trying to pick up new things. But you also look at Rosemary. Oh, Rosemary, I don’t mind if I use you [00:13:00] as an example here, but you didn’t come out of, uh, Australian Elementary School, whatever that is, being a a, a really good speaker, like that’s something you’ve learned over time.
You’ve been able to. Work in a very large company, you now, you’re in a very small company, the one that you own, and you’ve had to bridge that. And that means you have to know what the budgets are, what the money, where this money’s coming from. You have to sell to large corporations. You have to learn all those skills.
That takes time, and each one of those skills you learn is extremely painful. So you have to have the resilience to say, you’re shooting arrows at me all the time. I’m not dead yet. I’m gonna keep moving forward because I could, I can see a way that I can make a business that produces a revenue that I can pay the mortgage with.
Joel Saxum: That’s what it takes. Another, another side of this is, is if you’re trying to, to get, you’re getting to the point where you’re building a team out, right? I think it’s very [00:14:00] important for a founder to under, to understand their limitations at certain points in time. Because if you build a company and you’re just like, I like engineers, so I’m gonna build a company with five engineers and us six are gonna make something happen that may not be the best, you know, the best strategy if you’re gonna want like.
I did, we used to do this thing, um, in a, in a company that I was a partner in where we had those, it’s a, basically like a spider graph, right? And you take, you answer all these questions and it ranks you on points of like, where you are for problem solving and where you are for the, you know, the big picture where you are for details.
And then it overlays them all. So you look at your management team, you overlay ’em, what you wanna see is a perfect circle that you’ve filled every one of these. Areas, these silos with skills on your management team or on your execution team, or on your project team or whatever it may be. You can’t really
Allen Hall: have an ego in a sense.
The thing about starting a company is everybody is shooting Arrow, is that you, when you first go to a customer [00:15:00] that first time, they are gonna blow holes in you because you haven’t thought of all these different things that they consider to be very important. And you come out of it like, boy, yeah, yeah, I was not ready for that.
Yes,
Rosemary Barnes: but you’ve gotta want that. See that not as an insult to your ego, but as information that you need to, to grow. I think. ’cause I work a lot with startups as well as having one of my own. Um, and one thing that I do is I really, really early on screen them to figure out what kind of founder there are.
’cause there’s, there’s two kinds. There’s the one that wants to develop a significant product that will be successful in the world. And then there’s other ones who just love their idea and want to keep on working on it forever. And that second type, they don’t, they don’t want to learn anything wrong with their product.
They don’t want to know about, um. You know, showstoppers because that’s gonna prevent them from doing what they love, which is working on this idea. So I only wanna work with the, the first kind, who would see a, being informed about a [00:16:00] showstopper for their project. They would see that as a real win. So that’s my always, my philosophy is just, uh, just gonna break it.
What, whatever your idea is, I’m gonna do whatever I can to break it. Whether that’s physically or whether that’s commercially break the business case. You just throw everything you can at it intentionally. And with my own products too. You. Do everything you can to make it a failure. ’cause that’s how you learn how to make something that cannot fail, you know?
And that’s what you need to succeed. It’s not enough to have an idea that, you know, like, like a lot of times with wind energy, you come up with something that might make be better, right? Than the status quo. So let’s think about, you know, um. Wind turbine. They’ve all got three blades. They all have a, um, the upwind facing rotor.
You know, they’re, they’re very, very similar. There are all sorts of ideas that could be better. Right? That could be a better way to do it. You know, there’s different ways to make the, the blade maybe out of sailcloth instead of fiberglass. You can have two blades. Um, you can have a [00:17:00] downwind rotor. You can, like any, all of these ideas have been tried before, but being a little bit better is, is not.
It’s not close, it’s not close to being enough like it is so far from, from being enough. It has to be so good that it can’t fail. That is the only way for you to overcome the, um, the gap that you have to what the status quo is. And so many people like, but my, you know, but my design is 1% more efficient.
People could, you know, get all this amount extra. They, they’re not, that is not enough to get you over that massive hump between where you are now with an idea. What it would take to get people buying enough of it that it will ever reach its potential. That’s what people don’t see.
Allen Hall: That’s exactly circling back what we’re talking about.
The idea has to be a big improvement. Whatever it does. The wheel was a big improvement. The pencil was a big improvement. Paper was a big improvement. [00:18:00] Sliced bread, huge improvement. It just made your life easier. It has to be something that makes. Life easier, not just a little bit. And Rosemary is 100% right about this.
It has to be a lot. So when, when I hear people in wind that are working in technology talk about a quarter percent, a half a percent, say 2%, that’s usually not enough to get somebody to react to it. It has to be a bigger number. Now, the two percents of the world. Incrementally, we will make the world better.
Rosemary Barnes: It, it’s fine if it’s a, if it’s a small technology that will just fit in with a status quo without making anyone’s life harder than 2% is amazing. If it requires anyone to do anything different, then it is not close to enough.
Allen Hall: Don’t miss the UK Offshore Wind Supply Chain Spotlight 2025 in Edinburg on December 11th.
Over 550 delegates and 100 exhibitors will be at this game changing event. Connect with decision makers. Share your market ready innovations and secure the partnerships to accelerate your [00:19:00] growth. Register now and take your place at the center of the UK’s offshore Wind future. Just visit supply chain spotlight.co.uk and register today.
So we have somebody on the other side of the table, which is Yolanda, who sees all the crazy people come up to ’em. If you’re sitting across the table from someone who wants to sell you a product, I, I can’t even think of what. To be selling you, honestly. ’cause there’s not a lot of, um, maybe, maybe they’re selling aerodynamic improvements.
Maybe they’re selling some blade whizzbang thing or CMS system. Maybe CMS system. Can you suss that out? Can you just tell that this person is not locked in on reality? It’s, does that show up in a meeting?
Yolanda Padron: Well, initially, a lot of times some people just won’t. They don’t care exactly what your problem is or what the, you know, a problem might be big, but it might [00:20:00] not have as big an impact on generation as the spend to fix it would be.
Or a lot of times the, the problem that you may be seeing is just. You know, it, it’s a risk that you’ll, you’ll take because of the, the cost of the solution. I mean, if, if you have, if I have $2,000 budgeted to fix or deal with an issue and you’re offering me a solution for $45,000, I just can’t take it.
You know? I mean, as great as you might sound and as much as you believe in your project, uh, on your product, you just can’t take it. And I think there’s some people who. Come to the table really caring about what the issue is and finding a solution together for the sake of the industry, as was weather guard and is.
Uh, but there is also [00:21:00] just some, some teams who just really, really just want their product, who will come to an engineer and won’t even bring an engineer to the table, who will just not even care about testing. Their, their product in a, their an accredited facility. And we’ll say, I mean, I had people come to me in a sales pitch and then when I asked them for testing results, they would say, well, will you fund this testing?
It’s like, no, I. I, I won’t, you’re, you’re selling me the product. Like I don’t,
Rosemary Barnes: I don’t think you understand. I saw so many companies that that was their biggest failure. They couldn’t get real world testing and that, that’s why I know that weather guard and paddle load are like poised for at least once you have a good idea, you’re gonna be able to develop it.
Because the testing is, the testing capability is built in and I definitely could get people to pay to test. [00:22:00] A product that I developed because I know exactly what their problem is. I know exactly how much it’s worth to them, and they know that I understand it better than than them even. So I think people don’t, um, like it’s a very wind specific thing, but it is so hard if you just come up with an idea and you don’t know anybody that, um, managers wind farms.
It’s so hard to convince someone to put something like even to just allow you to put it on for free. That’s a really, really hard sell.
Allen Hall: So what is the advice for. Small businesses that want to be large businesses that are, have wind products that they’re offering today, what are the steps they need to take to make it a reality?
Rosemary Barnes: They need to understand the, the problem really well, or the problem that they’re. Potential customers had and they also needed to understand the other pain points in that person’s life. Because a lot of times I’ve seen people get so, um, kind of worked up that, yeah, they’ve got a business case on [00:23:00] paper that, you know, the company should, in theory, make way more money from having this product.
They’re not having it, but people don’t have enough time. Um, it has to be. Solving, either solving a problem that is taking up their time already, and you will immediately take up less of their time with when your solution is, when they even start to implement your solution. It’s not enough that they do a year project and then they start to have their problem solved.
Um, so either, yeah, it has to be so much better or it needs to be totally painless to implement it. That’s the, that’s the two, two options that you have. There isn’t a third option.
Yolanda Padron: I think it’s really important to balance your humility. Uh, and just your ego a little bit. Of course, you need to be proud of your product and you want to believe in it and everything.
Uh, but you need to be humble enough to listen to the person and listen to their issues and listen to maybe your product isn’t perfect and it needs some tweaks [00:24:00] and mower likely than not, it will need some tweaks. So just don’t. Continue going forward to something that just won’t work.
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Register now at WMA 2020 six.com. Wind Energy o and M Australia is created by wind professionals for wind professionals because this industry needs solutions, not speeches.
Allen Hall: So everybody’s preparing to go to Melbourne in February of 2026 for Woma [00:25:00] Wind Energy, o and m Australia and the promos have just hit LinkedIn.
Everybody’s talking about it. We’re getting a, a quite a number of sponsors. Joel. We have a, a couple of sponsorship levels still available, but not many.
Joel Saxum: Yeah, we are fresh out of round table sponsors. Um, we’ve still got a couple hanging out there for some. Receptions and lunches and things like that. But, uh, yeah, we’ve got, uh, a lot of our friends joining up, a lot of emails coming in to ask of can I get involved somehow?
Um, which is great because to be honest with you, even if we don’t have a spot for an ex ex exhibitor spot or a sponsorship spot, getting to talk with people at an early engagement level is fantastic. But we’re, ’cause we’re finding more and more subject matter experts through these conversations as well.
So we’re able to bring, if, if we can’t. Engage on a sponsorship level, fine. Still reach out because the, there might be a spot for you up on a panel as one of these people that can educate, uh, and share, uh, with the Australian wind industry
Allen Hall: and as the promos are saying, Rosemary. We [00:26:00] want solutions, not speeches.
So this whole event is about solution, solution solutions, right?
Rosemary Barnes: And problems.
Allen Hall: What kind of problems are we gonna talk about?
Rosemary Barnes: I mean, I think that’s the, the interesting part is that it brings those two, two parts together. That’s what we’ve been talking about with technology development. That the, you know, the critical thing is to know, understand very well what your customers.
Facing in terms of problems. And so this is the event where everybody is there to talk about exactly what problems they’re actually spending time on day to day. And those are the ones where, you know, it’s a much easier pathway to succeed. So if you’re a, a. Technology developer, you know, a company that has some new technologies, then this is the event to come to to make sure that you get that fit right.
Allen Hall: And Woma 2026 will be held the 17th and 18th at the Pullman Hotel, which is in beautiful downtown Melbourne. And you need to be going online. Go to Woma 2026 WOMA, 2020 six.com. Get registered. There’s only 250 seats [00:27:00] available and a number of them have already been reserved. So it’s shrinking day by day.
If you want to attend and you should attend, go ahead, register for the event. If you’re interested in sponsorship, you need to get a hold of Joel. And how do they do that?
Joel Saxum: Uh, you can reach out to me on LinkedIn, um, pretty easy to find there. Uh, or send me a direct email. JOEL Do a xm. I have to say that out loud because.
I gets confused a lot@wglightning.com, so Joel dot saxon@wglightning.com.
Allen Hall: So go to Wilma. 2020 six.com and register today.
This quarter is PES WIN Magazine, which has arrived via the Royal Mail. There are a number of great articles and uh, I was thumbing through it the other day and the article from Veolia, and we had Veolia on the podcast, uh, a couple of years ago on blade recycling. And there’s a number of, of cool things happening there.
You know, Veolia was grinding down the blades and then using them, [00:28:00] uh, mixing them with, with cement. Reducing some of the coal and other energy forms that are used to, to make cement. And they were also using, uh, some of the fiber as fill. So that process, when they first started, we were talking to ’em. Then there’s been a lot of iterations to it.
It’s like anything in recycling, the first go around is never easy. But Veolia has the.
That wraps up another episode of the Uptime Wind Energy Podcast. Thanks for joining us as we explore the latest in wind energy technology and industry insights. If today’s discussion sparked any questions or ideas, we’d love to hear from you.
Reach out to us on LinkedIn and don’t forget to subscribe so you never miss an episode. 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 we’ll catch you here next week on the Uptime Wind Energy [00:29:00] Podcast.
https://weatherguardwind.com/funding-edinburgh-woma/
Renewable Energy
EchoBolt’s BoltWave Makes Bolt Inspections Easy
Weather Guard Lightning Tech

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.
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