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GE Vernova Q3 Results, Offshore Wind Struggles Worldwide

Allen, Rosemary, and Yolanda discuss the IEA’s 27% cut to offshore wind forecasts, GE’s wind financials, and Ming Yang’s revolutionary 50MW dual-rotor turbine. Register for the next SkySpecs Webinar!

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!

You are 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, Allen Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes.

Allen Hall: Welcome to the Uptime Wintery Podcast. I’m your host, Allen Hall in the Queen city of Charlotte, North Carolina.

Rosemary’s in Australia on her way to Sydney and Yolanda Padrone is here on site at a wind farm in Texas and there has been a, a number of news articles this week. Joel’s over actually in Copenhagen enjoying, uh, the sites and sounds of that great city, the International Energy Agency slash its five year offshore wind growth forecast by.

Are you ready for this? 27% citing policy shifts, obviously in the United States and [00:01:00] project cancellations across Europe and Asia. The big one in Asia is the Japan’s Mitsubishi pulling out a couple of projects there when costs, um, more than doubled according to them. And Denmark is changing from, uh, negative bidding auctions in favor of contracts for different, so there has been a, a big pullback in offshore wind.

It’s not zero, you know, it’s not going to zero at any time. I think there’s just a lot of projects that appear to be reassessing the interest rate environments, the ability to get turbines, the cost of ships, everything. And rosemary in Australia, it does seem like there’s been a little bit of a pullback there too for offshore wind.

Uh,

Rosemary Barnes: yeah. I mean it’s, it’s hard ’cause we’re still like in such a, just a nascent part of the. Industry. It’s still really far from clear whether we need or are going to get any offshore wind at all. Victoria has some pretty solid commitments to it. The government [00:02:00] does so. That’s probably as close as, um, anything to being certain that we’ll get some offshore wind.

But, um, probably we’ve all learned, America has shown us that a political com commitment is not as, you know, a government commitment is not as locked in as what we probably would’ve thought it would mean, um, a few years ago. So, yeah, we’ll see. I think Australia is struggling like the rest of the world.

We’re struggling a bit just in general with getting projects to, um, FID and. You know, getting construction actually underway and offshore wind is just like, you know, the same problems but on steroids. So it’s no surprise that you’d be seeing more challenges there. There’s been a few projects that have, um, been canceled or paused, but you know, they weren’t at the point where there were definitely going ahead.

So it’s, you know, like there’s a huge pipeline that makes almost no sense for how many projects there are in planning. Obviously some of them are going to [00:03:00] not go ahead, probably most of them. Um, and yeah, so we’ll, we’ll probably see many more cancellations and I think we’ll see at least a few offshore wind farms and probably those early examples are gonna dictate a bit how easy it is for other people to follow, or how much anyone even wants to follow.

Allen Hall: Well, is it gonna become a case where. Certain countries are, uh, focused on certain energy sources like France and Nuclear, and the UK will be offshore wind, onshore wind, and solar. Germany sort of a mix of everything, coal for a long time and they’ve gone away from nuclear there. But it does seem like every country has its own specialty and is that where we’re headed, that we’re just gonna see the best solution for each particular part of the world?

Rosemary Barnes: It’s really hard to get very decarbonized grids if you specialize too much. Like there. There really isn’t a technology that can just do everything, um, on its own. So, you [00:04:00] know, solar power is very, very cheap, but the sun sets at night. So obviously you’re gonna, at the very least, need some batteries to get you through the evenings if you’re relying mostly on solar power and then wind energy, obviously it’s not windy every day, even in really windy places like Denmark in the uk it’s still, you know, there are wind lulls, so you’re not gonna be able to rely solely on that nuclear power, just kind of chugs along at a fairly, um, you know, constant output.

If you turn it up and down too much, then you’re gonna end up, you need to like overbuild a lot. If you try and size your, your new, your electricity system just based on nuclear meeting, peak load, that’s a whole lot of reactor that’s gonna be not doing much most of the time, aside from the technical complications with being able to turn up and down.

And then even, you know, some of the traditional fossil fuels don’t do a very good job at responding flexibly. Coal power has, you know, similar issues to nuclear and it’s probably even harder to turn up and down. Um, [00:05:00] and then I guess gas is gas Peakers could, you could probably do everything with gas peakers if you want it.

They can turn on and off very quickly. But, uh, the. Gas picker plants are not very efficient. So there’s very high fuel costs and not to mention the, um, climate impact of just burning gas all the time and all of the, um, upstream emissions that come from a gas system. So I don’t think it’s possible for anyone to specialize too much, but of course, every country has technologies that they’re familiar with and comfortable with.

It’s never gonna be the sensible engineering decision to just go all in on one technology.

Allen Hall: Will batteries be the connector? For most of these technologies, and I bring this up because there’s been a lot of more recent discussions about data centers and Yolanda hop in here too because, uh, you work for an operator that was involved with batteries.

But the more, and I’ve been following this relatively closely the last month in doing more and more research in it, but like the, the [00:06:00] Colossus two that Elon’s building in Tennessee, there’s a big part of that distribution. From generation to delivery to the AI data center is a massive amount of batteries because of the up down nature of that load that they need a buffer.

Well, we see more batteries be deployed because of the AI data centers. And is that, can that be leveraged the other way to help balance out a grid that does have a lot of solar? It does have a lot of wind because the data centers are gonna be generically spread around. Countries.

Yolanda Padron: Yeah. Uh, yeah, I think it’s, it, the data centers should definitely, I, I mean, it does look like everything’s trending, right?

To have them, um, include batteries as part of their, of their scope to be able to balance everything out. I know we’re seeing, especially in the us like a lot of the, um, the behind the meter [00:07:00] projects coming online and taking advantage of the, the wind and solar, but. For those rolls where we might not get the perfect generation that they need to be able to exist.

Right. Like the batteries will definitely, uh, be that bridge, uh, to fill the gap there.

Allen Hall: Yeah. And even in the Colossus case where they have gas turbine generation and they’ve taken over an old power plant that was across the river in um, Mississippi, they’re still putting massive batteries in rosemary.

Because the data centers are, I think the consumption has always been that data centers are gonna be this kind of constant power input and that the computers are all gonna be working at maximum all the time. But what they’re finding is that it is not because they’re being trained at their moving up and down from like 10% of capacity to a hundred percent.

So the grid’s not made for that?

Rosemary Barnes: No. I mean, uh, the, the grid’s [00:08:00] not, I mean, when did the, was the grid. Designed or was it even designed, you know, like a hundred years ago and we kind of just, um, patched, patched it together as we needed to. It’s not like there, there wasn’t some yeah, like type of load that the grid was designed for.

People have always just made do with what they had available and then adapted to the characteristics of that. I mean, I don’t know, do you have off peak water heaters in the US because in Australia we have like, you can get a separate, a separate. Signal coming to your house that will turn on and off, uh, your electric water heater in off peak times.

And in the past, like traditionally, that was always overnight and it was specifically done. Like we specifically put all of this infrastructure in place to do that because there needed to be something to use the electricity that coal power plants were generating overnight. So, you know, like it was, um, you, you take what you can get as far as electricity generation and then you, you use it in the most effective way that you can come up with.

Allen Hall: Let me understand that for a minute because I’ve never heard of [00:09:00] this before, and I, I, we, you and I have been talking about energy for 20 odd years at this point, but, so they would turn on your water heater in your home to act as a load for the coal fired electricity plant.

Rosemary Barnes: You have a separate circuit that has off pa loads on it, which is usually just a hot water heater.

And then you can get, um, at. Different tariff from your electricity provider. There’s the regular and then the off peak timing. ’cause this is before anyone had any smart meters and you actually like, you know, the dumb old meters, they knew how many kilowatt hours you had used in a quarter, you know, but they didn’t know hourly.

Um, so this was a way that you could give a cheaper rate for people to heat their hot water. Overnight when there wasn’t enough natural load to be able to use up all of what the coal power plants needed to keep on putting out. ’cause you can only turn them down to a certain base load. Makes sense to use resources efficiently, like of course it does.

Um, that’s why it’s, I just find it really [00:10:00] weird how, um, like really. Emotionally upset, but people get really, get their feelings hurt by the idea that the energy transition might mean that you would change your behavior based on, um, you know, like what the, uh, electricity generation happened to be like that day, but it’s always been done.

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GE Re Nova’s Wind Business’ Engineering. Somewhat of a comeback and a third quarter. Results came out today as we record and revealed, uh, EBITDA losses narrowing to just $61 million from 317 million a year ago. An improvement of over 1000 basis points, which means 10%. Uh, the turnaround strategy, from what I could tell, is starting to work.

The wind services for onshore wind is up by 50. 3%, uh, in offsetting some equipment, uh, payments. And then the CEO Scott Straza emphasized that the company’s focused on profitability over volume with better pricing and reduced offshore contract losses, driving the improvement. They’re still waiting for a payment, it sounds like, from one of the cancellations.

Of around $500 million. So that’s still hanging out there. I wonder who that is. Uh, [00:12:00] but, uh, the, the booked orders this quarter are slightly down for wind. In general, GE thinks, Renova thinks they’re gonna close out Dogger bank and vineyard wind in 2026, which is sort of what we’ve been talking about on the podcast.

It’d be hard to finish both of those this year. So this is sort of a positive sign in, in, in terms of the larger GE with all the electrification and grid, uh, and gas turbines that GE is selling. There’s a huge upside there. Although the market was not particularly happy with this announcement today, I think it dropped a couple of percentage points.

Although since becoming a separate company, they’re up like 300%. It’s crazy. So if you invested on that opening day, which was like what, back in April a couple of months ago, you have done extremely well and I, is there hope for the onshore wind market for GE in the us or is it mostly [00:13:00] going to be. Yolanda, is it gonna be overseas?

Is that where GE needs to go right now because of the slowdown in us,

Yolanda Padron: I think until things for when stabilize a bit more in the US it’ll have to be outside of the us Right. Like their, like you mentioned, their current model relies a lot on having, I mean working a lot more on repairs and everything than actually building new sites.

Um, and I think. We’ve talked about wind in the US maybe ramping down a little bit while everything stabilizes a bit more for that. Yeah, I think it, it makes sense for GE to, to look elsewhere for now.

Allen Hall: Is there a stabilization of the marketplace coming? I know a lot of the talking heads and the, the banking units and if you listen to podcasts, financial podcasts, they’re saying, well this is really good for wind and solar to go through this little period of, uh, becoming more efficient.

And I [00:14:00] think. Uh, the prices of wind turbines have dropped pretty well and solar have dropped a lot. The, the industry is very efficient at the moment. It really has more to do with financing, from what I can tell.

Rosemary Barnes: Wind energy, is it cheaper in the US than it was like two years ago, three years ago, five years ago?

Allen Hall: Yeah. So because you’re generally putting up fewer turbines ’cause the turbines get larger and that they’re more efficient. Right. Um, the. They’re designed more specifically for the winds in a particular area, like low wind and middle wind conditions. I think overall they have been more efficient and as you know, having worked at LM every penny counts.

Rosemary Barnes: Maybe I have the opposite beauty to you. I’m having a, a bit of a, I don’t know, slump in my optimism. I’m, in general, I’m a naturally pessimistic person and um, it’s one of the reasons. That I work in, the energy transition is because I actually feel much more optimistic about progress the more that I, I [00:15:00] know about it.

But at the moment, wind energy, I, I, I’m pretty sure it is not accurate to say wind energy is cheaper, getting cheaper in Australia. It’s costing more. To put turbines in in Australia than it used to. And then I’m also super cynical about, you know, the efficiency savings and cost savings, especially of big companies like ge because what I see is them, they, uh, you know, have a bunch of quality problems from, you know, the work that they were doing in the late 20 teens, um, maybe, yeah, early 2020s.

Bunch of quality problems. So then that costs money. ’cause you know, you’ve got warranties to pay out on and um, things to fix and sales that get canceled. And it seems to me like their solution to that. Their money saving is we’ll just fire most if not all of the engineers. So that’s really good way to save money this year, but it’s not very good way to make sure that you don’t have more warranty problems next year and the year after.

Not a good way to make sure that you’re [00:16:00] able to. Uh, you know, come up with solutions to problems in a timely manner. It’s kind of like, is this the beginning of the end? Because once they’re gone, how do you get them back? I mean, maybe in one or two years time, it’s gonna be an amazing time to be a blade engineer because, um, you know, everyone will be, will be desperate, desperate for, for you.

But it’s, um, uh, I, I, I don’t, I, I can’t get on board with the, you know, the efficiency gains that like, that we’re seeing at the OEMs at the moment.

Allen Hall: I know you’re just a wee kindergartner when the year 2000 was around, but if you think about 20 years ago, there was, at least in the United States, no one was thinking about wind and really few people were thinking about solar and maybe unless you lived in California.

But today, solar is everywhere. You can drive down the street and see solar in most places, and wind is in a lot of parts of the United States and the world at the same time. So. The amount of growth in the industry in the last 20 years has been truly [00:17:00] remarkable. And to say it’s gonna go through some cycle, I think is normal.

Every industry goes through booms and busts.

Rosemary Barnes: I think in the past it was more of a manufacturer by manufacturer basis, so you know, vest would have some quality problems and then they would, you know, get it back under control and a few years later they’re fine Again. LM had quality problems and then got it back under control.

And you, like I said, it kind of cycled through. But now, like who is not having blade problems at the moment? Nobody. I honestly, I don’t. I, I don’t think there’s anybody not having, having problems at the moment. Um, and yet people are laying off more engineers than they’re hiring, that’s for sure. By, like, by a significant margin.

What I think that the industry needed was to do a better job of selling the same platform over and over and over again, so that it got really well known, and then moving up to the next one. After sufficient testing of new [00:18:00] features, then, you know, move up to a new platform and sell a lot of that. Use less engineering by having less design.

Yeah, less designs that you are trying to support at the same time, less new designs that you’re trying to develop. That’s the way to reduce the cost you’re spending on engineering, not to continue to have, you know, millions of different designs and features and constant, constant growth for the sake of growth.

Um, maybe that’s a segue into the next topic. Um, but you know, like you can’t do that without a whole lot of engineering. So it is like, you know, you, you choose, either you have heaps of engineering and heaps of innovation, or you kind of just, um, settle down and do one thing really well, and then you can have less engineering

Allen Hall: as wind energy professionals.

Staying informed is crucial, and let’s face it difficult. That’s why the Uptime podcast recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues [00:19:00] facing our energy future. Whether you’re an industry veteran or new to wind, PES Wind has the high quality content you need.

Don’t miss out. Visit PS wind.com today while the contrast couldn’t be starker while Western manufacturers struggle, as Rosemary has pointed out. China’s been Yang. Spart Energy Group is preparing the world’s most powerful wind turbine, a two-headed 50 megawatt giant that. Dwarfs anything that’s currently operating, uh, production supposedly begins next year at a facility in Guangdong Province.

Uh, Ming Yang plans off of this tournament at below $1,400 per kilowatt. So remember we’re talking about Rosemary and the price per kilowatt is going down where the Ming Yang is truly really trying to drive it down. If, if you look at the. Numbers in comparison to European manufacturers, that’s a pretty low number.

Even in comparison to existing Chinese manufacturers. That number is still like a 20% [00:20:00] discount.

Rosemary Barnes: Is that the price that you would get it for a project in Europe? So with, um, you know, IAC certification ’cause I know that they work to a different certification standard in, in China and that it costs a bit more to, um, have it, you know, designed to pass the.

The is a stunt that everybody else uses.

Allen Hall: Exactly. So the question is, and going back to the engineering thing, it’s a two-headed turbine. So it’s got that V platform, it’s an offshore floating turbine of course. And it’s got that V connection and it’s got two heads, two uh, the cells, and two massive rotors on it.

That has to have a lot of engineering behind it. I hope it does. They haven’t built one.

Rosemary Barnes: Yeah, it’s, uh, so they’ve done, they’ve done some parts of it before. I mean, they’ll make like a really, a really huge offshore turbine, but it’s not like there are. Hundreds or thousands of 25 megawatt turbines out there in the ocean.

There are not hundreds or thousands [00:21:00] of floating wind turbines of any kind in the ocean, and there are not hundreds or thousands of, um, multi rotors of that, you know, v design that they’ve done. So it’s three, it’s three really big hard things or combined in one. Um, and yeah, it’s a big. A big step before they probably, they probably don’t know the, all of the, the risks and failure modes of any of those three individual things.

And now they’re gonna combine them and get new, new problems from combining things together. So. It will be for sure. A lot will be learn from this. Um, I, it seems like too big of a step to be like, yeah, you’re gonna be able to order one of these and have a gigawatt wind farm with these put in and, you know, 2028.

That’s not within this realm of reality. But as a learning exercise, I mean, that’s what China does really, really well. They don’t plan to the extent that, um, [00:22:00] Western companies do. They don’t. Get every I dotted and t crossed before they will actually execute on a project. And you can definitely learn way more that way, but with much bigger risks

Allen Hall: in terms of certification and standards.

For a turbine that is non-standard, how many years would it take to create just the specifications and the test process to validate it? I, I think we’re talking about a minimum of. Five years of all the committee meetings, you’d have to have to even get close to having something where like A DNV could put a stamp on it, right?

Rosemary Barnes: Yeah. I mean, there’s a whole bunch of potential failure modes that don’t exist in the turbines that we have today and the standards that we have today. I mean, the standards haven’t even kept up with just regular, like garden variety, one turbine on a stick, three blades, you know, all of that. There’s heaps of, heaps of common failure types that aren’t really covered [00:23:00] by the standard, so.

Um, yeah. I mean, when you get up to, to two turbines and I think that they counter rotate is, is that right? That they’re going opposite direction? I think you need that so that you don’t get funky tower dynamics happening. Um, however, uh, there are still going to be weird things happening with the aerodynamics.

Like di dynamic flow stuff is gonna cause weird things and that causes fatigue is the, you know, the main problem that you get from. Just, you know, just small. It might be, yeah, even just small loads that you didn’t expect in places that you didn’t expect them. Um, and fatigue damage can happen very quickly if it’s a, you know, if it’s a really big, big load.

But if it’s a, just a small but larger than expected load somewhere, it can take two years, five years, 10 years. Um, but then you get fleet wide failure. Um, and so it’s, it isn’t something that it’s very easy to, uh, test for at a scale. You know, with a scale model. So, [00:24:00] you know, in that sense it probably is the right thing to do to build a full sized one as soon as possible and, and learn those things.

You know, it makes me feel uncomfortable because wind turbines are things that people have to climb up in there to install them. People have to climb up in there to maintain them like a lot in the early days, especially with a new system. And so the fact that it could, you know. Fall apart. Risks are reduced if you make sure no one’s climbing it when winds are high.

’cause that’s usually when you’ll see failure. But it’s, it’s still higher than I would feel comfortable with. I wouldn’t like to be climbing inside, um, this turbine ever. Um, but yeah, it, it is. I can’t deny that that is probably the fastest way to, you know, progress technology.

Allen Hall: Alright, Yolanda, if, uh, Rosie’s offshore wind company decides to buy these 50 megawatt wind turbines as an asset manager and thinking about how, [00:25:00] how you would operate these turbines, what would be your top complaints right now?

Or top worries?

Yolanda Padron: Rosie mentioned earlier, right, that it would be in a perfect world. All of this innovation would be driven by engineering. Right? And being able to test these things over and over and over again, and being able to see exactly what problems we’re facing and how we can solve them for the most part.

Right. And just kind of all going up together in getting these, you wouldn’t really know. And we go back to that risk issue, right? You wouldn’t really know. What you’re buying at this point? Me personally, of course it was. If it was Rosie, I’d trust her with my life. So yeah, if Rosie’s doing it, yeah. But anybody else, you know, we won’t, we don’t know what they’re testing.

I mean, you, no one wants to be the Guinea pig,

Allen Hall: right? Well, someone will have to be, if they plan on selling it, someone will have to be the Guinea [00:26:00] pig. But it’s probably an operator in China, or maybe Mi Yang itself will have to deploy them. But. At some point, just listening to the, to the news in Europe, there’s a lot of push to bring in Chinese turbines that don’t have a lot of.

History or verifiable history, doesn’t it just raise the asset risk? I would say, whoa, whoa, whoa. Slow down everybody. The finance group, slow down.

Rosemary Barnes: You don’t see a lot of them in, um, Europe or you know, outside of the, um, outside of China yet. And. I mean, I wouldn’t consider it de-risk just because you’d seen a demo turbine turbine in China.

I wouldn’t consider it de-risk because you saw a whole wind farm of these in China, because they do do separate designs for separate, um, geographies. Uh, you know, they, like I said, with the certification, they, they change the design to be able to. To pass that. And, you know, even if you are making it safer, if you’re, you know, adding material, it doesn’t, it doesn’t always mean that it’s becoming more reliable.

Like you have to, you know, the track record [00:27:00] needs to be for the turbine that you’re actually buying, not something that they’ve assured you is very similar.

Allen Hall: 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 if 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 Window G Podcast.

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EchoBolt’s BoltWave Makes Bolt Inspections Easy

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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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Carbon Capture and Synthetic Fuels

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As we’ve noted in the past, the idea of capturing CO2 from the atmosphere is completely unfeasible, since 99.96% of the air around is something other than CO2 (mostly nitrogen).  However, there are environments that change this equation radically, cement plants being one of them, where the concentration of CO2 emissions is as high as 30% (versus .04%).

Now, this brings the subject of synthetic fuels into the realm of possibility.  Sure, if you want to make gasoline, diesel, and jet fuel, you’ll need two other things: hydrogen (which can come from electrolyzing water), and a considerable amount of energy, as these processes are heavily endothermic, meaning that energy must be supplied from external sources.

The good news is that we have enormous amounts of off-peak wind and nuclear that are wasted every day.  Please see: Doty WindFuels.

Carbon Capture and Synthetic Fuels

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What Trump Is Actually Doing

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With each passing day, there are fewer and fewer American voters who believe the bullshit at left.

Is Trump working hard to stay out of prison? Enrich himself and his family?  Of course.

Could be possibly care less about anything else? Obviously not.

What Trump Is Actually Doing

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