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PEAK Wind Masters Site and Turbine Selection

Lene Hellstern, Director of Engineering at PEAK Wind, discusses the complexities of onshore wind siting, the advantages of using LIDAR technology, and strategic considerations for turbine selection.

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Allen Hall: We’re back with Lene Hellstern, the Director of Engineering at PEAK Wind, and we’re talking about onshore wind siting, which is a really critical issue that a lot of operators have difficulties with. And I’ve seen it in the United States and it’s not good.

And I’m wondering from your perspective, what are some of the problems, Lene? Well first, welcome back to the podcast.

Lene Hellstern: Thank you. And thanks for having me repeat experience last time, so I hope so. I thought I’ll pop in again. 

Allen Hall: Well, it’s good to have you back and thanks

Lene Hellstern: for coming to Copenhagen.

Allen Hall: Yeah, well we love Copenhagen.

It’s great. Uh, I just wish it was a little bit warmer. Yeah, the sun is terrific. Yeah. When you’re in it, well, at

Lene Hellstern: least I fixed that. Right. Yes. It’s not raining. It’s not raining. Yes.

Allen Hall: We, we quite enjoyed it. Uh, but I’m trying to get an understanding of what the underlying issues are with onshore wind siding and why some of the operators have difficulty later on.

Let’s just start with the sighting [00:01:00] itself. Yeah. Is usually, we’ll see a wind mast out on site for several months, maybe a year, maybe two years. To try to get some wind data. We would

Lene Hellstern: really like that. Yeah. Okay. But, uh, the preferable measurements are lidars.

Allen Hall: Oh, lidars. Yeah. I have not seen a lot of lidars in use.

Lene Hellstern: No. You, you need to get some more.

Allen Hall: Why?

Lene Hellstern: Um, because they reach higher.

Allen Hall: Okay.

Lene Hellstern: Um, and you can, uh, you can, you can move them around. Right. And the hassle of installing a Met Mass that’s a hundred meters tall, is, uh, is it a problem? Quite, uh. Quite it, it cost a lot more. Yes. Um, and, and the lidars, they, they just, they’re better and they measure higher.

And you can, you can have one sort of mother lidar and then you can move the other around and you can cover your wind resources and site suitability much better on the site. So I would definitely recommend

Allen Hall: lidars. Okay. How the lidars use a [00:02:00] good bit of power to make them run, correct? Yes. So you need a decent power source?

Yes.

Lene Hellstern: You do? Yes.

Allen Hall: Okay. Yeah. I, is that one of the difficulties why they don’t use a lidar? Is it just in a lot of remote areas, they don’t have the power source to run it?

Lene Hellstern: It could be, or it could be the, the lack of knowledge. Right. Traditionally we have used med masks, yes.

Allen Hall: Forever.

Lene Hellstern: Uh, so, so it could be, and then there are also some, um, uh, some issues with uncertainties because the lidar is the, the standards are not up to date.

I would say that’s the political way correct way of saying it. So. Eh, the standard actually introduces more uncertainty on the lidar that’s really not necessary to, due to a calibration with a me mast. Um, so that there’s some, there’s some things that needs to improve in that area

Allen Hall: because a lidar should be a lot more accurate than a met mast.

Lene Hellstern: Yes. Yeah. Yeah. But, but the, the downside of the lidar, so that, that is not often we see that, is if you don’t have enough particles in the air, you have [00:03:00] an issue because then you are, you’re simply not gonna be able to measure. The, the, uh, velocity of the particles because they’re not there. And then you have a low availability on your measurements.

But, you know, most places there’s, there’s a quite a lot of dust. There’s pollution. Um, so there, there are things in the air that we don’t see, but the lighter sea and then you can make the measurements.

Allen Hall: And as the hub heights have gotten taller, it gets a lot more difficult to get a met mass up that high.

So the lidars go can measure winds. How high up in the air? How many meters? I

Lene Hellstern: think at least 250 meters. Wow. And, and you want, you want to, you know, traditionally you would only measure at hop height, but you wanna measure at the, the, the rotor surface, right? So you wanna measure at tip height, and you wanna measure at lower top tip and lower tip to, to see what, for instance, what’s the wind share across your, uh, rotor disc.

Um, which

Allen Hall: you cannot really do with a met mast at all. You can’t do that. You have no [00:04:00] wind share knowledge. From that instrument? Sort of, yeah,

Lene Hellstern: you can, because you can make, you always, you, you have a met mass that’s at least at hop height, and then you have, uh, anemometers and wind veins and I don’t know what on all the way down.

Um, and you can with, without that equipment, you can, you can measure on the lower part of the rotor, but not the upper part. So, so you, you do get some possibilities to measure wind share, but not as good as, um, for instance, a lidar. Yeah.

Allen Hall: So how many lidars would you typically need on a 100 turbine site?

Lene Hellstern: Well, that depends.

Allen Hall: Okay.

Lene Hellstern: Because you have a, if you have complex terrain,

Allen Hall: right?

Lene Hellstern: Yeah. You may want a lot. Right. That’s what I

Allen Hall: was wondering if the more hills and valleys, the, the more lidars you will need, or more samples you’ll need, or maybe the longer duration you’ll need. Yes.

Lene Hellstern: Yeah. And you, you would wanna, you know, it’s always the best to measure it.

I think it’s [00:05:00] ideally five years. Nobody does that five years. Nobody. No, no. But you should at least have two, right?

Allen Hall: Yes.

Lene Hellstern: Uh, and then you should do a proper long term correlation. Um, so, so that’s, and how does

Allen Hall: that, how does that accomplish Right now, let’s just say we have a met mass. What I typically see is, has been a met mast out in the middle of the United States where the winds are pretty good.

Speaker 3: Yeah.

Allen Hall: And they have data. They have some data. Yeah. So typically I’ve seen them out there a year, maybe two years, and then. The, but the sites are massive. Yeah. They’re, they’re square miles. Yeah. Dozens of square miles. So it’s big.

Speaker 3: Yeah. I

Allen Hall: dunno whether it’s in kilometers, but a lot of square kilometers. So then they are trying to interpret interpretate that data that they have from the Met Mass on top of that.

I think they’re looking a little bit forward in terms of who, what other wind farms may be surrounding us in the next several years. Yeah.

Lene Hellstern: And that’s, that’s one of the challenges we have because there’s a lot that. Uh, you, there’s a lot of guessing.

Allen Hall: Yes.

Lene Hellstern: Um, and so if [00:06:00] you are planning a wind farm, you wanna know what goes on in the area.

You wanna map out the already existing turbines, uh, and what, what hop height, what rotor size, because you wanna be able to model them in your calculations.

Allen Hall: That was really good. Get to my question about how difficult this process is and how you try to address it. In the United States, we turn over wind turbines every 10 years, so there’s a repowering happening and.

Almost always, the rotor size gets substantially bigger. 20 to 30 to 50% bigger. Right. So there’s fewer turbines, same location. Yeah. And the turbines are roughly in the same spots, but they’re just bigger rotor diameters. How do you then prepare for that? Do you use the old data or is the old data even applicable?

If I’m really dramatically increasing the rotor size, do I need to be doing more? LIDAR measurements before I make that repower, or how do I even cite that? Right.

Lene Hellstern: Uh, you can, if you have some good SCADA data from your turbines, you can do some [00:07:00] modeling. And many of the sites actually have a met mast. They do a lot Yeah.

As a reference, right? Yes. Right. But that will be on it, it will have sectors where there’s a lot of weight from the existing.

Allen Hall: Okay.

Lene Hellstern: So, and so I would, I would, I would try, I would filter your SCADA data from your site and see if, can I, can I use this? I’ll take a look at the mid mass state and see, can I use this?

If not, I’ll start a me mass campaign. Now the problem is if you’re reusing the spots now, well first of all, that’s a little bit difficult reusing because your foundation is dimension to an old generation turbine. Uh, let’s say take someone a hundred, a hundred, uh, meter rotor, right? Right. But now you’re going up in size.

Um, so that means everything gets heavier and bigger, right? So your foundation may not be suitable. The old foundation, normally they’re over dimension. So you can, you can extend life or you could repower on them, but you would want a bigger turbine. [00:08:00] So you don’t necessarily want to use the opposition, right?

And then you would wanna know what is in the pipe. You know, when can I get my, when can I start digging? Right? When can I start installing? Uh, what is in the pipeline at that point from the OEMs? Because sometimes it actually takes five years from, you start planning until you, you, you start digging. And in that time, if you, you, if you space with today’s models, you are gonna have two shorter distance between the turbines because the new turbines on the market that you would wanna buy has increased significantly.

Um,

Allen Hall: and that’s a real problem. Yeah. Like that, this, this. Between the, the siting time, the met mass, the LIDAR data, getting enough data and having to make the decision about a turbine relatively early because the production lines are not operating at full capacity right now. Yeah. It’s hard to get a turbine.

So you are 3, 4, 5 years out. Yeah. How do you plan for that on an onshore site?

Lene Hellstern: Well, [00:09:00] you, you gotta guess a rotor and guess a, a turbine site. Okay. Right, right. So, but

Allen Hall: do, do the engineering staffs that a lot of operators have that inside knowledge because it seems like smaller operators, I’m, I’m not the urals of the world, have power and they can see inside the factories and they have a really good connection and they develop that connection over a long, many, many years.

Speaker 3: Yeah.

Allen Hall: Where newer operators usually do not have that sort of insight. So where do they go to get help?

Lene Hellstern: Well, well, they could go to, right? We could help them a little bit, but. You can also look, if you look at the evolution of the turbines, you can, and I, I’m, I’m hoping we are at a little bit of a pause here in the, in, in the growing size.

So we, we can refine the turbine, we can refine our manufacturing facilities. We, we get better at service and installation. But you can pretty much, you know, guess the rotor. Uh, I’ve, I’ve done that a lot in, in this job and my previous job, because you [00:10:00] look at, if you look at when the. When did what? Come on the market and from what, OEM.

Right. And then you, you know, there’s, there’s other topics you need to look into for, for instance, site suitability. Right? Right. What are, what are the conditions on the site? Um, are you a, we, we categorize in different classes. I, e, c, 1, 2, 3, um, or turbulence classes. A, B, C. And then there’s the, the class I like the least that is the Class S.

Which is special. And then you never know what it is before you start digging in all the paper. Um, but, but you, that’s sort of the first things you need to find out. What class are you? And then there’s a small in that because, um, you may think you are a, a class two or have a class two side, but then it turns out that your air density is unbelievably low.

So sometimes you can actually squeeze in a class three. Turbine on a class two [00:11:00] side and get that much more production.

Allen Hall: Do a lot of operators know that?

Lene Hellstern: No.

Allen Hall: I wondered. Okay. Yeah. Well

Lene Hellstern: maybe the, it’s not so much the operators. It’s the developers. Developers. Sure. Yeah, yeah, yeah. That has to, to, to dig a little bit more into the lovely engineering science around turbines and.

And, and then do more site suitability because you can actually improve your, the value of your project quite significantly.

Allen Hall: That’s what I wonder if, if you spend a good extra amount of time maybe spending a little more money to get LIDAR measurements Yeah. And to do them for a slightly longer period of time, does that have a return on investment?

Lene Hellstern: You get, you get less uncertainty. Right. And then I think some of the issues or some of the mistakes that the developers do, they. They do a wind, they do a, a production estimate, but that is not the same as a site suitability or uh, [00:12:00] you know, also, some people also think if I do a wind resource assessment, then I’m covered.

No, because that is the input to the site suitability. Now you also need to do the site suitability. So you know, I would start out doing a wind resource assessment, right? Then I would do a site suitability and then you do your production calculator.

Allen Hall: And how long does that process take, generally?

Lene Hellstern: Oh, that’s always a cue.

So it could take, uh, it depends on who you use for this, right? But it could take four to to eight weeks.

Allen Hall: Okay. That’s not horrible. No,

Lene Hellstern: no, no.

Allen Hall: Alright, so it, it is relatively efficient compared to other things that happen in wind.

Lene Hellstern: Yeah. If you are have a complex site, it can take longer because you need to run a lot more calculations due to, uh, the comp complexity of the terrain, right?

Mm-hmm. You can have issues with inflow, angles, uh, ware, wind share, uh, [00:13:00] all the lovely technical things. Yeah.

Allen Hall: Well, and because we’ve developed so many sites to date, all the best wind sites have turbines in them mostly right now, and. We’re, we’re starting to get along the fringes of that good wind area.

Yeah. And in some cases, does that change the way you do the analysis and do the approach?

Lene Hellstern: Yes, but, um, some of us have done that for a long time because it’s not good enough to have good wind if you don’t have good grid. Um, so, so for me, a good wind side, you know, we, I, I spoke with someone yesterday about.

The best, uh, uh, wind resource in Sweden. Um, but, but if that area doesn’t have a good grid, then you know it, I can’t harvest the wind. Right. Right. Um, and it’s the same in, in the US right? You, you have some grid issues. Um, so we have a lot of

Allen Hall: grid issues. Yeah.

Lene Hellstern: And if you don’t, everything is [00:14:00] combined.

Everything works closely together, right. Uh, the technical, the commercial and the finance. So if, if, if that is not. Well, um, covered in a, in a, or, uh, investigated in a project, you don’t have a good project. Um, is

Allen Hall: the grid the limiting factor in a lot of onsite onshore sites?

Lene Hellstern: I think the world is becoming more and more electrical, which it is, which I think it’s good.

Mm-hmm. And I don’t think that they, we can point at any government that was super duper on, um, expanding the grid. Um, no. I know there are issues in Texas. There are also issues in Denmark where I’m from. There are, yes, there’s issues in Europe. So, um, we, we need, we need massive in investments from the government to build out this grid.

It’s, it’s not, um, enough to say we want clean energy and then do nothing. Right. Well

Allen Hall: this is where, where, where the ons onsite versus the onshore versus the offshore comes in. Yeah. [00:15:00] Is the grid.

Speaker 3: Yeah.

Allen Hall: So in the US and other places, uh, there’s been. A, a lot of concern about offshore wind, but offshore wind, you can get to a grid relatively easily.

Yes, usually. Yeah. Yeah. And it’s less bureaucracy to lay cable in the ocean than it is to run transmission lines over land.

Speaker 3: Yeah.

Allen Hall: So is this starting to flip a little bit because of the onshore limitations in the grid that we’re seeing more offshore, just because it’s easier.

Lene Hellstern: Well in Europe, but I would not say that in the us Right.

But, uh, but, um, um, it, it, it is easier, but it’s also much more complex to put up these, uh, offshore projects. They are in development for many, many years compared to onshore.

Allen Hall: Right.

Lene Hellstern: So, so onshore is a little bit of a, depending on country you are in, if it’s overpopulated right? It’s, it’s difficult, but it’s, it’s a much more of a quick fix, uh, [00:16:00] onshore.

For, uh, lack of energy. Right, right. But, but it just requires it, yes, it requires the grid and yes, it requires that you don’t do it in a popula populated area. We don’t want to do that. Right, right. We want, we want the open fields, um, where we’re not disturbing anyone. True. Yeah.

Allen Hall: True. But we also want infinite electricity.

Absolutely. So you have to weigh those two off.

Lene Hellstern: I, but I think the turbines are beautiful. So I would, I would love to be able to see one from my house, but I can’t. Yeah.

Allen Hall: We have actually quite a few we can see from our, from our house. Yeah. Yeah. And no one complains. No. They complained for the first few weeks after they were installed and after that it’s been completely quiet.

Yeah. But,

Lene Hellstern: but I do understand if you place turbines too close to a house Right. Sure. That, how that can be disturbing. Sure. Um, I, I totally understand that. Yeah.

Allen Hall: Can we talk about AI data centers and independent grids and how that’s factoring [00:17:00] into some of the decisions about where to place wind sites?

Because it does seem like in a lot of places in the world, these AI data centers are going to go in. Yeah. And they’re making decisions about using natural gas to power the turbines or using wind and solar and a little bit of battery to, to run these centers. Yeah, but that doesn’t necessarily. Wire a connection to the grid.

Does that make it easier in a sense that you don’t necessarily have to have a grid connection, you could put something out in a remote area that it still had good wind and still has good solar with a little bit of battery? And are you starting to hear more action that way, or interest in that?

Lene Hellstern: I’ve, I’ve seen that there’s been, uh, quite some centers that has, uh, made, uh, PPA agreements with, with wind turbine owners.

But they are normally not super close, uh, uh, located to the wind farm. Okay? And I would also say that I would find it a little bit difficult, [00:18:00] uh, if they were remote, because you need a, you need a constant power source and, and the wind doesn’t blow all the time, right? No. So you need, you need a lot of, uh, combination mechanisms, right?

You do to make sure everything runs stable.

Allen Hall: But you may not have neighbors in that case because you could select a site that’s a little bit further away from. Society in a sense. Yeah. Where the, the wind siding may be a little more complicated though because we, we probably haven’t looked in those areas because it’s not connected to the grid.

So you may not have historical wind data doesn’t make the problem just bigger. So I do think in the United States you see like Amazon and Meta and Google talking about using wind and solar to power some of these data centers. Yeah.

Lene Hellstern: And, and they are, and I know that there are, uh, agreements that has been signed.

But I, I am, I don’t think they are close, uh, you know, in close proximity necessarily.

Allen Hall: Okay.

Lene Hellstern: But of course the, the, the electricity needs to be to be transported in the grid. Right. [00:19:00] And it’s not like it’s a microgrid around the data center.

Allen Hall: I think you may see more microgrids.

Lene Hellstern: Okay. Well that could be interesting.

Well, that’s what

Allen Hall: I’m wondering because there may be more microgrids that won’t even be microgrids because the amount of power that they’re gonna use, they’re gonna be decent sized grids.

Speaker 3: Yeah.

Allen Hall: That. Th that becomes even a more difficult engineering challenge.

Lene Hellstern: Well, I think it’s gonna be too expensive.

Allen Hall: You think so?

Yeah. Compared to natural gas or just because No, just,

Lene Hellstern: uh, buying, doing a PPA with a wind farm that may be a hundred kilometers away. Yeah. Right.

Allen Hall: Okay. Um, well that’s interesting. Yeah.

Lene Hellstern: I think the whole, um, uh, burying the cables in the, you know, the whole installation, uh, is, is simply, it’s simply to, uh, it’s complicated cap.

Is too high.

Allen Hall: Okay.

Lene Hellstern: It’s, it’s much more affordable just to buy a PPA.

Allen Hall: Yeah. It may be. Yeah.

Lene Hellstern: Yeah.

Allen Hall: Okay. Well this is, this is fascinating. Can I pick your brain or bother you just a little bit longer?

Lene Hellstern: Yeah, [00:20:00] yeah, sure. Okay.

Allen Hall: So

Lene Hellstern: it depends on the time. Yeah.

Allen Hall: We got 20 minutes. Good. Can I steal 10?

Lene Hellstern: Yes, sure.

Allen Hall: Okay.

Lene Hellstern: This is not my core area, just so you know.

Allen Hall: No, no, no. I wanna, I wanna get, I wanna get back into Yeah. The, the meat here, which is turbine selection.

Speaker 3: Yeah.

Allen Hall: I have my LIDAR data. Mm-hmm. I have my MET Tower data. I have say I have two years. I am really the best wind resource knowledge operator developer that you’re gonna meet.

Speaker 3: Yeah.

Allen Hall: Great. Super. What do I do next in terms of picking a turbine?

How do I even do that? And how does that process look like if I’m talking to OEMs about something that’s still three years from being developed?

Lene Hellstern: Well, you need to start, you, you need to have your planning, uh, your permits in order.

Allen Hall: Sure.

Lene Hellstern: So depending on what country you are in some operate, what you need to apply for the [00:21:00] specific location of the turbines more, it’s more a box.

Uh, so it’s, you say, I am, I wanna apply for 300 megawatt, 500. Uh, please. In, in this area. Um, so then you start looking at your site, suitability, uh, what, what boundaries am I working within? What is my average wind speed in different, these different heights? Uh, what’s more, how do I get levelized cost of energy as low as possible?

Because some people still sit and look at the net capacity factor, but those days are over, right? They are,

Allen Hall: yes.

Lene Hellstern: Yeah. So when, when all alarms should go up, if they say. Good lift capacity factor. Yeah. Super. What’s your live life cost of energy there? Um, so, so then you, now you start, you have a good idea on what kind of a turbine class should I look at?

Then you start looking at who is, do you wanna do self service? Do you wanna have a full service agreement?

Allen Hall: Exactly. That’s what Im really wondering how that works then, because if I [00:22:00] know the basics of the wind site, do I just. Put a proposal together and slide it to Vestus and slide it to ge, or is there still more I need to do before I start talking to them?

Lene Hellstern: You need, you need to ask you yourself and your organization. Okay. Or PEAK. Yeah, but, but we would ask you as well, what is your o and m strategy, right? Do you wanna do self perform? Do you want a full service agreement? What, what’s, how risky do you wanna make it? Is that

Allen Hall: a deciding factor in determining what turbine you want to purchase?

Yeah.

Lene Hellstern: Because then you may not need D-O-E-D-O-E-M to have a service organization close to your site. Right? Let’s say, okay, so

Allen Hall: let’s say you choose vestus because they have a, they want to sell you a full service agreement, generally sPEAKing. Yeah. Where a, a GE typically doesn’t care or not so involved in that.

Lene Hellstern: Okay. But then, but you wanna know, do they have a service organization close to right. Right, right. Or are they gonna re uh, are they, do they need to build it? Right? Is this a new [00:23:00] platform? Do they not have any experience with this platform, the people in this area? Because then you, you know, that’s always, so it’s teething issues, right?

Allen Hall: Sure.

Lene Hellstern: Yeah. So,

Allen Hall: so how does that play into your decision making then?

Lene Hellstern: Well, you know, if you have a, if you have, let’s say, four volumes in this area,

Speaker 3: right?

Lene Hellstern: Yeah. And then you had, you, you look at what, what do they, what turbines do they offer? What service agreements can you get? What availability, you know, how does the contracts, you wanna benchmark the TSAs and the SMAs?

Yes. Um, and to see what kind of, who’s the best player here? There’s a lot of pieces to the puzzle. Well,

Allen Hall: that, that’s exactly what I wanted to get to was, I’m trying to understand how deep you’re going in this. So you’re actually looking to see if they have a service site nearby? Yes. And what the service people have been exposed to in terms of turbine type.

Yeah. And also you’re going a little bit deeper to see how successful they have been. Maybe you, you’ve called the sites

Lene Hellstern: around if I have that information. Yes. Yeah. [00:24:00] Okay.

Allen Hall: Yeah. So you’re making a lot of decisions not based upon necessarily what the OEM is offering as a product, but you’re also looking at what does the next 10, 20, maybe even 30 years looks like.

Lene Hellstern: Yeah. And then you wanna know what, you know, what, what turbines, what pipeline is there, and then you wanna do the tender. Right,

Allen Hall: right.

Lene Hellstern: Let’s say now you’re down to three because the fourth one, that, that was a no-go. Right? So now you have, that’s why I always, I say four turbines per site. You need to pick, pick four different OEMs.

Now you’re down to three. Right? And then you, you, you, you, you issue a tender and you, you get the proposals in. Okay? And then you, you start negotiating and you do your tech, your technical due diligence, right? To sort of dig a little bit deeper and understand the OEMs right. Also give them a chance to say.

Hey, this was an issue before, but we fixed this problem and you can see it documented. Oh, you go, yeah, but you’re still, you’re not there. So I need to account for that. So then you have a dialogue with them, and then, [00:25:00]then you have, you, you then the third one is too high and now you have or can’t deliver, or you know,

Allen Hall: doesn’t have a production schedule that meets your deeds.

Lene Hellstern: Yeah. Yes, exactly. And now you’re down to two, and then may the best one win. Right.

Allen Hall: Okay. So you’re talking about. Several months of gyration. Yes. Meeting with the OEMs or OEMs coming to you even to give their pitch. Meanwhile, you’re evaluating their technical expertise about their turbine, and you’re questioning how the previous generation of those turbines have performed looking forward to say, have you fixed the the existing problems?

And what does the next generation look like? Yeah.

Lene Hellstern: Oh, well, what did they look into? Developing a new

Allen Hall: platform.

Lene Hellstern: Okay. Right.

Allen Hall: So are you thinking about risk in terms of new technology? I’ll, I’ll throw the easy one at you two piece blades.

Lene Hellstern: No, thank you.

Allen Hall: Okay. That’s a, that’s a good response. Yeah. Because I think a lot of, there was just a lot of unknowns about that.

Speaker 3: Yeah.

Allen Hall: Yeah. And then now that we have some service history, yeah. We may wanna rethink that. Yeah. Are there other types of [00:26:00] technologies that would lend themselves to requiring further review?

Lene Hellstern: Yeah, but there’s, I, what I’m hoping is that, that maybe we can pause a little bit on the sizing thing in the. Right.

And then refine the components a little bit more and then, and be more innovative, um, instead in the components. In the components, yeah. And, and improve the manufacturing quality installation service. Right? Because, um, sometimes what I see in the industry is not, it’s an old component, but actually it’s the people that’s the issue, right?

Mm-hmm. We don’t, we are not, we are not trained, you know, we don’t have the technicians trained really in a. We don’t have the people in the manufacturing trained well enough, and so, so we make mistakes. So, and

Allen Hall: are you looking for OEMs that are doing more reflective activity at the moment that they’re basically causing new designs?

And then we always do that, that when we

Lene Hellstern: always look at, when we do technical diligence, how is the training [00:27:00] in the, in the manufacturing, you know, what kind of programs do the different people need to go through? How do you get to a seniority? How do they train them? How do they test them? How many years does it take, right?

Because you can’t do things in five minutes.

Allen Hall: Right?

Lene Hellstern: What’s the turnover at a manufacturing plant?

Allen Hall: See? But this is why you would choose PEAK wind to help you do that process. Because I don’t think a lot of developers, and especially in the United States where we see a lot of it, I see a lot of it developers are about putting turbines in the ground.

Yeah. And then selling that farm to the next owner, right? Yeah. So those long-term agreements don’t really play into a lot of this, and from what I’ve seen, but I think in Europe it’s a lot different.

Lene Hellstern: Yeah. No, but we also have, you know, there are different concepts. There is a built to sell.

Allen Hall: Yes. Right? Yeah.

Lene Hellstern: That’s, then you, you, they, they tend not to, uh, be so focused on the technology. Right, right, right. And then there’s the people that built to keep, right, right. And you could, if you can see, they, that was their intention. And then they [00:28:00] ended up having to divest anyway. Then, you know, that they, they, they probably did, did a little bit more work on the technology side.

Which

Allen Hall: one’s more successful? Build to sell or build to keep

Lene Hellstern: build, to keep

Allen Hall: built, to keep has better power production, more revenue,

Lene Hellstern: less uh, downtime.

Allen Hall: Less downtime. Yeah. Because they’ve done their work upfront and many

Lene Hellstern: of them Yes. Have have done it. Yeah.

Allen Hall: Mm-hmm.

Lene Hellstern: So, but, but developers can still do, uh, build to sell.

Sure. But then they need someone with the technol technological glasses to come in and help.

Allen Hall: Sure, sure. But that’s where PEAK wind comes in, because. You carry those people on your staff, you, your PEAK wind’s full of experts.

Lene Hellstern: We would love to, yes.

Allen Hall: So that you can immediately tap the group of experts about the different aspects of this new development.

Yeah. From training to warranties to technology to just generally how an OEM performs and Yeah, but it’s

Lene Hellstern: also, it’s the technology [00:29:00] commercial finance, right? Bingo, finance. Yeah. They go, they go together. Right, right. It’s not a. Enough to have a brilliant gearbox that can last a hundred years if you only need it for 35.

Right. That’s true. And you paid a fortune. Right. That true. That’s just not a good business case.

Allen Hall: Right. And there are turbine manufacturers that have that model that do do that still. Yeah. Yeah. This is fascinating and I, I appreciate your time. Every time we talk, I just get more in depth of what is happening and, and where we can get better as an industry.

Yeah. And that’s what PEAK wind is all about. Yes,

Lene Hellstern: but we are really good already. We just need to get, we are good. Better. Yeah. Yeah.

Allen Hall: We do need to get better. And we do, I think we do need to take a pause.

Lene Hellstern: Yeah.

Allen Hall: So how do people get a hold of PEAK wind and to tap your expertise and attack, to bring in the expertise of your team?

Lene Hellstern: Well, we have a, a webpage, uh, where you can contact us through, or, uh, LinkedIn. I am on LinkedIn, so feel free to send me a, a message. Um. [00:30:00] So, and reach out to us and we would love to help. We also have a, we have offices in Boston and uh, uh, Texas. Uh, we also have Oh, around the world. Yeah. Canada. So Taipei, yes.

Yes. Re and

Allen Hall: congratulations. I think you just won a, was it in Taiwan? Uh, an offshore site Yes. That you’re gonna be operating or managing Meow.

Lene Hellstern: Yeah.

Allen Hall: Yes. Congratulations on that. Thank you. That’s very exciting. That’s

Lene Hellstern: my lovely C in asset management. Yeah.

Allen Hall: Very nice. Yes. So Lene, thank you so much for being back on the podcast and we have to have you back on again ’cause there’s so much to talk about and win.

And it’s great to talk to someone who has been around and has seen it and has done it. Uh, it’s, thank you for having, it’s such a tremendous learning experience.

Lene Hellstern: It was a pleasure. Thanks.

https://weatherguardwind.com/peak-wind-site-turbine/

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EchoBolt’s BoltWave Makes Bolt Inspections Easy

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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.

EchoBolt’s BoltWave Makes Bolt Inspections Easy

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Renewable Energy

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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Renewable Energy

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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