ORE Catapult Showcases UK Wind Innovation
Emily Rees and Magnus Willett from ORE Catapult discuss the upcoming UK Offshore Wind Supply Chain Spotlight in Edinburgh. The event brings together innovative companies that are establishing the UK as a global leader in offshore wind energy, from small startups to major manufacturers.
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Emily and Magnus, welcome to the show. Hi, it’s great to be here. Thanks so much. Thanks so much for having us. You, you’re both preparing for the UK offshore wind supply chain Spotlight 2025, in which Joel and I are looking forward to attending up in Edinburgh on December 11th. Uh, and it’s an event that showcases where the UK stands in Global Offshore Wind Development.
Uh, but Emily, I, I know there’s some challenges in the UK at the moment and, uh, the UK is working through those. Want to talk to some of the. Those challenges and how the spotlight is gonna help work through those. Yeah, uh, of course. So, um, I think that, you know, we as the uk like have identified quite a while ago that offshore wind was a really massive opportunity for us.
You know, we’ve got a really amazing offshore wind resource, [00:01:00] um, and. So we really wanted to take advantage of it and, you know, push forward with a, with that industry. Um, the things that we’ve come up against is that, um, ability to then provide homegrown, um, supply chain, you know, actually have, uh, businesses in the uk being that, that main supply, um.
In the first port of call, you know, there was the, uh, a lot of the, um, sort of components that we, we sort of have to, to build the fixed bottom offshore wind was all coming from abroad, so it’s like, right, well, how do we reap the benefits internally of this really amazing industry that we can build? And so, um, having, uh, supply chain spotlight events where we can really shine a light on the different companies internally in the UK that are actually providing services and providing, um, the supply chain for offshore wind, um, is, is super critical.
And the, the catapult, um, the offshore renewable energy catapult, uh, where Magnus and I both from, um, is, you know, [00:02:00] really key into making that happen. I know when you look online at the re catapult and you see like the people that you partner with, the organizations, the, I mean OEMs, um, all of the innovative technical technology companies that are coming out there, it it, it’s, it’s so great to see.
Right. And then this is me sitting in my, my American chair a and I talked about this. We talked a little bit about it off air, about the fact that wind energy in general, when you’re, when you’re talking offshore wind, onshore wind, it is a huge. Industrial and economic opportunity for all the countries that are involved in it.
And simply because things like this don’t come along that often, right? Like you have the, you know, the automo, I look at it like that, like the automobile was a thing, right? Like, oh, we went from horses to this. This is a huge opportunity. It made a lot of people, a lot of money, put a lot of people to work.
Wind is the same thing in my perspective, and maybe not at that grand of scale, the automobile, of course, but. You are seeing with your organization, the involvement with people like we have the, the Siemens facility in [00:03:00]Hull, and I know you guys do a little bit of work with them, uh, bringing that manufacturing onshore into the uk.
But not only is it bringing manufacturing what you’re doing here with the UK offshore wind supply chain spotlight is taking. The small companies, the, the, the, the two person companies, the 10 person companies, the 50 person companies, and saying, Hey, we also have really smart people here that are doing really cool things in operations and maintenance or like, you know, helping with some cool innovation for, uh, construction or development.
So there’s a lot of things happening in the uk. I mean, one of the reasons why we’re talking to you guys right now is we want to, we wanna show the rest of the world that you guys are taking advantage of this opportunity and hopefully spur more people on to do the same thing. Absolutely. Right. I’m, I’m, I think the, the key thing for us is in the UK we’re now at a point where we’re trying to maximize the supply chain opportunity and, and, um.
The supply chain is a, is a big pyramid, right? You have, you do have your OEMs and your tier ones at the top, but that stretches all the way down into the university spin outs. And, [00:04:00] um, and the kind of the one two person bands and the, and Orca pull we’re, we’re here to support them as much as we are to support those larger organizations.
Um, and we’ve, we have to, you know. Uh, supported likes of GE and, and, and Siemens through our, our big testing facilities and blade test facilities, drive train facilities. But we’re also testing kind of two, three person, um, organizations. New, um, dynamic cabling solutions for floating wind, right? So we span across an entire, um.
An entire supply chain. And I suppose part of the Supply Chain Spotlight event that we run, um, every year is, is to, is to give all organizations an equal playing field, to present themselves, to project developers, to OEMs, to government, as to why their technology, why their business can solve some of the biggest challenges that offshore wind has in the uk.
But also globally, right? Um, this is a global [00:05:00] market and the, and the uk, um, is, is is a leader in the deployment and the operations in the maintenance phase. And we have a huge amount of knowledge and we wanted to share that, uh, globally as as, as well as here in the uk. I know we have some questions and some topics we wanna get to, but I want to focus on that one point you said there, Magnus, of the the level playing field.
’cause when we were exploring this supply chain spotlight, one of the things that popped up to me was it doesn’t matter who you are, you get the same booth, whether you’re Siemens cesa, or you’re, you know, the two person band, same. Same, same style. Yeah. You, you get, everybody gets a level playing drill because everybody’s solution is needed.
I like that a lot. Yeah. It, it, it, it’s one of the core principles for us every year when we sit down with our, with our events team and our supply chain acceleration teams, it’s, you know, that’s a firing principle is to make sure that everyone gets a, a fair and equal opportunity to participate. And, and Magnus, the consequences of not having a supply chain in the UK are, are really severe when you look at it because of the.[00:06:00]
The amount of deployment the UK is talking about, the, the complexity of some of these projects, particularly floating offshore. There’s a lot of, uh, technology that needs to be developed and it needs to be developed very quickly, and especially on the servicing side, the o and m side. Uh, there’s a ton of knowledge sitting in the UK that can solve these problems, but it, it does feel a little odd.
I, I’d have to say, as a small business owner, I know how hard that is, is to take that first leap into. Showing a product, trying to get it introduced. If you come to the spotlight and in a couple of weeks in, in, it’s in December, so it’s not that far off. When you get to an event like this, this is the opportunity you need to get started or to expand, which makes I, I think, answers so many questions about how the UK is going to move forward in offshore wind.
We will work, um, through a number of different initiatives to understand, um, the challenges the industry is facing. [00:07:00] So we have a pretty good handle on, you know, what are, what are the challenges that they’re facing now, but also the challenges. What are the, what are the challenges they’re gonna face in five years time?
Right? Um, commercialization of technology does take a while. Um, and so we need to understand those challenges. And so Spotlight is, is is also part of that, right? It’s that knowledge sharing that, that exchange of information between, between the, the various different elements of the supply chain and the project developers to say, this is our challenges.
This is the solution we have and try and do and try and bring them together under one roof, um, and, and showcase their technology. And it’s important we get it right. You know, we, we, we, we have a, uh, an an, an ongoing energy transition. There’s an economic opportunity there. We have to try and maximize that, um, and provide as much opportunity for job creation, for IP creation.
Economic development and, and, and, and, and everything and, and far and few in between. So it’s super important we get that right. And part of that is just, [00:08:00] just you shine a, shine a light on these companies. A lot of things are happening in the UK at the moment, particularly offshore wind. But there’s been several wins and, and particularly into the way that the, uh, systems, I’ll call an overall systems of offshore wind are established from, uh, geez OCS to CFD to re catapult to all the s subject matter experts that are, that are there.
I wanna talk to that a little bit about, because I think a, a lot of other countries don’t realize necessarily the strength that is already in the United Kingdom. I think that the, the key thing here is that the sort of mentioned earlier that the, the, the UK has, um, been very, um, on board or at least signed up very early to this opportunity that we had to take advantage of a resource that would give us energy security in a, um, in a renew.
Right. So offshore wind being that opportunity. [00:09:00] So what that meant though is that, um, a long time ago, I mean, it was 20 years ago that the, the, the rocks that you mentioned, the renewable obligation certificates were the first piece that was put in there to try and incentivize companies to. Um, purchase their electricity from renewable sources.
So it’s like, right, okay, we know that we want to be starting this opportunity. Let’s, let’s, uh, put in a mechanism that’s, um, and, and incentivize that happening. But that what then evolved from that was then, um, we realized that, okay, we need to do more to really incentivize this happening. We need to put in some, um, some proper incentives to, to get developers to be really sure that they’re gonna be able to make money.
Out of these quite at the time, you know, quite high, uh, high risk on big developments. Um, and that was when we had feed in tariffs or fits. Um, and then we moved into A-A-C-F-D, which is a contract for difference scheme, which essentially means that the government [00:10:00] guarantees that, that a company that’s created, that’s generating, um, renewables will get a price for their.
For their electricity. But the great thing about contract, the difference and why they’re better, well, or they’re a different mechanism, let’s say, to just standard, you know, guaranteed price, which is what a feed in tariff is, is that if a company actually makes more money, if they’re, they can sell that electricity for higher, then the strike price that was agreed with the government for the contract for difference, they actually have to pay that back.
So it’s almost like a, um, it’s a, it’s a. It’s much less of a, um, uh, a penalty, I suppose, just for the gov, you know, just for the, uh, an administration kind of trying to provide a, a, a revenue support. There also potentially is benefits if say there’s a, like, so for example, um, when we had incredibly high gas prices in the UK and all of the renewable energy, um, generators were actually making more money than they were anticipating, um, over 600 million.
Pounds was put into the u [00:11:00] was brought, put back into the UK like, uh, system. So, yeah. Anyway, the, the contracts for difference has been, has been really beneficial in that front. But actually what it’s been done is it’s meant that we’ve driven competition to, uh, to ’cause developers actually really want to get involved.
It also provides much better assurance for these big projects, which then incentivizes better margins for the developers. So make bigger turbines. Get your, you know, smarter financing, like put in place, um, operations that bring down your cost and then you can make more money and, you know, off you go. Um, and it’s really been a massive success story in bringing down the cost of offshore wind and therefore making it a actually realistic and viable.
Uh. Energy, uh, and electricity, uh, generator in comparison to our, our, you know, gas, um, generating, uh, plants and things. Why do you think that other Northern European countries haven’t followed suit in the same scheme? In, in those countries there’s quite a lot [00:12:00] more, uh, sort of government mandating of like, this is the way that we are going forward.
And there’s much more of a support on that front. I suppose Norway’s quite a good example of a, of a, a country where you’ve got a lot of. There’s a much higher, uh, support that’s provided from that, um, from that governmental sort of standpoint and let, it’s like, it’s like what the UK is also trying to do is it’s trying to generate competition, whereas it’s not necessarily, so I don’t get the impression that from those, the other European countries that maybe are not implementing CFDs is that they’re not necessarily so worried about the competition to drive down the cost.
Whereas the UK has been very much, that’s been a real. Um, motivator for implementing the revenue support systems that we have, but they absolutely have revenue support mechanisms to make offshore wind and wind energy, you know. Work for them. It makes absolute sense because it fits with the strategy that we’re talking about here, right?
[00:13:00] Like it’s, it’s, it’s, the idea is bring innovation, bring new strategy, bring competition, uh, embolden the, the country to come up with new solutions for manufacturing, for operations and maintenance, for all these different things. And that’s what you guys at the Ora Catapult are there to do. That’s your remit.
We’re here to bolster this supply chain, to make these things happen. I mean, we, we, we have gone through challenges, um, in terms of, um, the CFD, you know, particularly with the inflation re increases over the past few years. But the government has listened. Um, and then they, uh, and have made some changes. And, and that includes what’s called the clean in clean industry bonus, which is, is gonna help, um.
Uh, provide some funding into, um, uh, or encourage, uh, developers to support local, homegrown, um, supply chains, which are low carbon. Um, so really investing in sustainable su supply chains for the industry. Um, so I think, yeah, we’ve, we’ve, we’ve absolutely had our [00:14:00] challenges with the, with the CFD, but we’ve got a government who seem to, to be willing to listen to the industry and, and find that compromise between what’s right for the, the UK taxpayer.
Um, um, and then also what’s right for, for building industry. Um, and that’s, you know, we have a number of different mechanisms at re catapult to, to support the supply chain, but also to support the project developer and, and, and the OEM to help grow that sort of, uh, sustainable clean energy supply chains that can do things like, um, and she should do a lot of the manufacturing, um, uh, for floating wind.
Um. Foundations and, and, and the assembly of, of, of turbines and everything. So it’s, you know, it, we, we’ve had our challenges as well and we’re listening and we’re adapting with to, to an evolving market. I think. So what are those areas that are the focus for ORE Catapult to push forward offshore wind?
What technology areas are you focused on right now? We look across the whole, uh, life cycle of, um, [00:15:00] of, of the, of the project development, uh, of our offshore wind farm. Um, a big challenge in the UK at the moment is that it, it typically takes about 14 years for. For a project to go from sort of initial leasing all the way through to kind of FID construction and, and actually, um, generating power.
So, so that’s a, that’s a, a huge amount of time. So we, one of our kind of focus areas is around project pipeline or we, we call PO Project Pipeline, which is, um, environmental, uh, so data collection and trying to fast track that consenting. Process not to, to, to, uh, remove away from environmental protections which are in place, but to try and use new technologies, which can better inform our decision making in the consenting process.
Um, so that’s one, um, that, that, that we focus in on. We focus in on supporting the next generation of turbines. Um, so. Uh, when I first started in the industry, uh, six, six years ago, uh, uh, or, [00:16:00] or castle, sorry, six years ago, you know, it was, it was a novel to have a sort of a, a 10 megawatt, uh, uh, turbine, right?
Or, uh, and, and, and I think 12 megawatt was sort of the standard. And now you, you’re hearing 22 megawatt kind of, uh, uh, commonly referred to 20 megawatt, uh, turbines. Um, and even, and even bigger, right? So. That’s a huge challenge and that’s a huge area of supply chain development that can, that can come with that.
Not just the big fancy blades and, and, and, and, and towers and the cells, but the, the ancillary technologies which go around that, um, floating wind absolutely has to be, is, is, is a key, key area for us as, as well. And that’s sort of how do you integrate new, new turbine solutions with new. New platforms and what are the challenges there?
Um, but a big, big focus, um, in the UK and, and a big sort of strength that the UK is in that operations and maintenance space utilizing the data that we’re generating. And, and, and that’s something that, you [00:17:00] know, in the uk if you look at our supply chain, that’s a huge part of our USP. That’s the part that we can export.
That’s the part that we have a knowledge to share with, with the rest of, um, rest of the world. Going back to the UK offshore wind supply chain Spotlight 25. So that’s gonna be in the beginning of December this year in Edinburgh. How many companies are gonna be there from the uk? Off the top of my head, I don’t quite know.
And it’s usually, uh, somewhere between about, um, 80 company, 80 to a hundred companies exhibiting. Um, so those are companies who we have supported through one of our support mechanisms. Oh, man. I mean, Alan, think about that. Here in the United States, if we were to put this event on tomorrow. How many companies would you have show up that are innovative, that are doing some technology, that are doing something to support the supply chain?
I mean, of course, besides, like, we have a lot of ISPs and people out here doing the, the boots on the ground work. But I mean, I, I think you can count ’em on your hands, your fingers and toes. I think we’ve got 80 or a hundred that we can even put in an event. Yeah. Well, I’ll tell you honestly, one of the things that I [00:18:00] have, I found quite, um.
Inspiring. Right. When I, when I came into the, the Wind industries, I was like, I’m, I’m a relative newbie, right. You know, Magnus has been with the Catapult for six years. I’ve only been with the Catapult for a year. Um, and so it, my, I’m, I’m quite fresh faced, you know, I, I get quite excited about various, you know, opportunities in the wind space, but I was super inspired to see how many companies are pivoting from using expertise from that they’ve used in other offshore industries.
Right. And they are bringing it to. To offshore wind and the applicability of it, because it feels like one of the big issues I had coming away from oil and gas and coming into offshore wind is I felt like when I was in my oil and gas services company, we didn’t talk about the things that we could provide at the offshore wind industry from a services point of view.
And I honestly was absolutely like when I arrived and was like, hang on a second, there’s so many places that you can apply that expertise and that knowledge. [00:19:00] So many, and that is why the UK is doing really well, right? And it’s one of the really inspiring things that we are doing is we are going, Hey, you’ve got all of this experience and knowledge for operating for offshore in the North Sea.
How about, how about just, you know, you can use it for, for offshore wind and we can benefit that industry from it. That’s not, that’s not just the uk. The US has that too. It’s not just oil and gas, right? It’s automotive. It’s aerospace. Like it, there is, there’s a lot of expertise across the UK and the number of companies that we see, so.
Their, the light bulb moment that their technology could apply to offshore wind. And they ha you have a conversation with them and they go, oh, that’s great. We could provide that. And it’s, and it opens up a new door to them. Um, and that, that’s really, um, I suppose if I could put a core, core part of what we do, it’s, it’s, it’s providing that expertise.
It’s, it’s, it’s, it’s providing the, the knowledge and the knowhow about the [00:20:00] industry to these companies. And, um, yeah, spotlight is part of giving them that. That and that opportunity to scream about what they can do. There are so many great companies in the UK and I think they miss the opportunity to be in renewables that the expertise like Megan’s, like you were talking about, they have expertise.
They’re extremely bright engineers and scientists and technology people, and even on the accounting side and the project management, there are so many experts in that field that are sitting in the UK that never thought about. If I can get an offshore wind that expands my business, I grow into this new marketplace, it gives me a little more of economic security.
That’s huge. And now is the time to get into a, a spotlight or to just even to wander the floor to see what it’s about. And I think this is an easy opportunity because to go to the spotlight 2025, it’s relatively inexpensive. You’re gonna Edinburgh, it’s not hard to get to. It is a massive opportunity to [00:21:00] look around and just kind of feel out what is there for you.
Absolutely right. So it’s, it’s a very, very, uh, relatively low cost, um, uh, e event to attend. Um, the companies who are there, we, we support to be there. So, um, we provide them with the ex exhibition space. Um, and, and they, they, they get to showcase their technologies as, as, as well. And, um, learn. Learn from one another, right?
So they’re not just trying to speak to project developers and, and to, to government or, or, or even to us. They’re there to speak to one another and figure out how can we collaborate more together? We have complimentary technologies. Um, you know, how do we fit, how do we, how do we, how do we put that jigsaws together?
And that’s, that’s, that’s, that’s a real key, um, thing there as well. And, and that’s the thing is that when we talk to, uh, UK companies, we’ve had a number on the podcast that have tremendous products. Absolutely tremendous products. They don’t realize. Maybe next door, [00:22:00] just up the road as another company is doing a complimentary piece and connecting those together I think is key.
Even though the UK relatively is a small country, some, some in some ways is very kind of hard to get around and it’s hard to figure out where all these places are because a lot of these small, innovative companies are not necessarily, don’t have flashy names or great. Big websites or don’t spend a hundred thousand pounds on a booth somewhere, so it’s hard to find them.
But in, in these kind of events, these, these more dedicated, focused events on technology and growth, particularly in the uk and these spotlights are fantastic of connecting companies together. This is the, this is your opportunity because a lot of other conferences are so much more expensive. They’re further away.
They’re probably in Germany or in Denmark or in Spain. This is the one, this is the one to see what is really happening at the Ground Street level in the uk. And we need to get people to sign up because one of the things it’s gonna happen is [00:23:00] that you’re gonna run outta tickets for this, even though it’s in December.
It’s gonna get busy as soon as everybody realizes, like, yeah, I, I need to get over there. So this event is in Edinburg, it’s UK Offshore Wind Supply Chain Spotlight 2025. It’s in Edinburgh on December 11th at the Royal Highland Center. Which, from what I can tell, looks like a beautiful facility. Is there anything else I should know before I get ready to come to that event?
I mean, it’s right, be right beside the, the, the Edinburgh airport. So it’s super, super, super easy. Um, I think for me the, the, the kind of, the big plea would be from a, an international audience, from the audience, um, uh, is, uh, across, across the US is that there is innovative companie. In the uk who could maybe compliment your technology, right?
So we’ve talked about the, the uk, UK to UK company collaboration and, and action. There’s, this is a global challenge, right? There’s, this is a global market. Um, we need more collaboration between, between countries, more opportunities for [00:24:00] collaboration. So if, if you have, um. Uh, audience members who want to learn more about the UK and, and are developing a technology or they have a solution or a service and they’re thinking, you know, we could be doing this, but there’s a uk, there might be a UK company there, there, there probably, there probably isn’t.
There’ll probably be a spotlight as well. And Emily, you’re promising good weather in December in Edinburgh, right? Obviously there won’t be any rain. Nice and warm, sunny, balmy, almost. Yes. I think balmy is exactly the words that I would describe Edinburgh in December. It’s charming and wonderful, and you’ll get the proper Scottish, uh, gravitas that comes with the, the, the grayness and the rain.
I mean, it wouldn’t be right without that experience, so you, you need to google this event to sign up. That’s the easiest way I found it. It’d just go UK offshore wind supply chain spotlight 2025 and you’ll see it. You can click in and register. It’s inexpensive. It’s in December. You know you want to go, you wanna be in [00:25:00] Edburg in December.
It’s beautiful. So Emily and Magnus, thank you so much for being on the podcast. Love having you, and looking forward to the event. Thank you so much. It’s been a pleasure. Thank you very much.
https://weatherguardwind.com/ore-catapult-uk/
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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