Weather Guard Lightning Tech

TPI Composites Bankruptcy, Vestas Buys Mexico Factories
Allen, Joel, and Yolanda examine TPI Composites’ Chapter 11 proceedings, including the Oaktree Capital secured debt controversy and Vestas’ acquisition of two Mexican factories. With remaining assets heading to auction in January, they discuss what operators should consider as blade supply uncertainty grows.
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The Uptime Wind Energy Podcast brought to you by Strike Tape, protecting thousands of wind turbines from lightning damage worldwide. Visit strike tape.com. And now your hosts, Allen Hall, Rosemary Barnes, Joel Saxum and Yolanda Padron. Welcome to the Uptime Wind Energy
Allen Hall: Podcast. I’m your host, Allen Hall. I’m here with Yolanda Padron and Joel Saxum.
Rosemary Barnes is on holiday. We’re here to talk about the TPI composites, uh, bankruptcy hearings, and there’s been so much happening there behind the scenes. It’s hard to keep track of, but we’ve done a deep dive and wanted to give everybody at least a highlight of what has happened over the last couple of months.
So, uh, if you do own vessels or GE turbines, you understand what the situation is. As we all know, TPI composites, gee, was the world’s largest independent of wind blade manufacturing. Uh, they [00:01:00] were, it, they built blades for renova, Vestas, Nordex. They built blades for almost everybody, uh, names that basically power the global energy transition.
And then, uh, if, and a lot of people don’t know this, but back in December of 2023, uh, TPI struck a deal that is drawing some fire. Right now, TPI swapped $436 million in preferred stock for. $393 million in secure debt held by Oak Tree Capital and by August of last year, just a couple of months ago, TPI filed for Chapter 11.
Now the Blade Makers assets are being carved up and sold, and two of wind energy’s biggest players are stepping in to keep production running while the bankruptcy plays out. Now, Joel and Yolanda, I, I think the bankruptcy of. TPI sort of came to the industry as a little bit of a shock. Obviously [00:02:00] the, the price had fallen quite a bit.
Uh, if you’ve watched the stock price of TPI composites had been dropping for a while and didn’t have a lot of of market value. However, uh, GE and Vestas both have manufacturing facilities basically with uh, TPI composites and, and needs them to produce those blades. So the filing of the bankruptcy, I’m sure was a nervous point for Vestus and GE being really the, the two main ones.
Joel Saxum: Well, I think we talked about this a little bit off air. Is it, it shouldn’t just be Vestus and GE nervous about this now. It should be every operator that’s in either in development or still has blades under warranty. Uh, so, and this is a not a US problem, this is a global problem. ’cause TPI is a global company that serves, uh, global industry all over the place, right?
We know that a large percentage of their throughput was GE and Vestas, but also Siemens ESAs in there, you name it, right? The, any major operator’s gonna have some blades built [00:03:00] by TPI or op major, OEM. So. There isn’t gonna be much of a, uh, dark corner of the wind industry that this issue doesn’t touch. So I think they, the, one of the issues here is, um, we’ve, we’ve, we’ve heard about some issues going on with TPI, but it was almost like a, ah, they’re not, they’ll, they’ll be okay.
They, so, so something will happen. I mean, Yolanda, you had said. What was it that you said ear earlier? Like, uh, the kind of the, the, the feeling about it.
Yolanda Padron: They’ll take care of it. You know, OEMs will take care of it and we’ll be fine.
Joel Saxum: Someone’s gonna support this thing.
Yolanda Padron: Yeah. I, I think teams, you’re, you’re definitely right.
Teams really do need to at least think of a, of a plan B or a plan C to have when the dust settles so you’re not scrambling.
Allen Hall: Yeah. And it hasn’t really played out that way. Uh, Vestas has stepped in a little bit and GE has stepped in. Not in terms of acquiring any of the major assets, but I think the first question is what is Oaktree Capital’s, [00:04:00] uh, role in all this?
And that is being played out right now in front of the bankruptcy court. Uh, so when you go to bankruptcy, there’s obviously a lot of oversight that happens there, uh, and. When TPI composites entered bankruptcy, the accreditors committee had a bunch of questions about that transaction. Uh, they pointed to a December, 2023 refin refinancing deal with Oaktree and in which creditors were really suspicious of basically saying that TPI was already insolvent in 2023 and Oaktree exchanged equity for secure debt jumping ahead of everybody else in line to get paid.
So because they Oaktree has secured debt, they’re first in line to get paid. If, uh, weather Guard was involved selling parts to TPI, which thank goodness we weren’t, we would be unsecured. They wouldn’t have to pay us. So Oaktree would get paid first and everybody else is unsecured, gets paid [00:05:00] later. Uh, that’s okay.
I mean, that’s the way they, uh, they structured it. But this has led to a problem, right? So that oak tree. Uh, was supposed to release about $20 million in funding to keep the factories open, and that, that happened just a couple of weeks ago, and Oaktree refused to do it. So the amount of cash flow to keep the factories open was a real issue.
TPI was in front of the court saying, we’re in trouble. We’re gonna become insolvent. We don’t have cash flow to keep the doors open. So the blade factories nearly shut down a couple of weeks ago. However, there was a, the settlement, uh, just after that, uh, in regards to Oaktree about when the payouts happen, what Oaktree will receive, and which basically it’s, most of whatever’s gonna happen here.
So whatever, uh, TPI decides to sell or can sell, Oaktree is gonna be the recipient of those funds for most of it. I think the
Joel Saxum: difficult thing here for. The [00:06:00] general listener, me included, is understanding that this is a very complicated legal process that’s governed and it’s global, right? So it’s governed in certain court systems in different places.
And because there is also the idea of like say in the, in the United States, the SEC Securities Exchanges Commission, that kind of regulates these. Publicly traded companies. There’s a lot of lights and there’s a lot of lawyers and there’s a lot of jargon involved in this thing. And, but basically what what we’re saying is, is the way the process works when you have a, uh, a bankruptcy and insolvency, if a company has debt to certain people, there may be a list of a hundred people.
There may be a list of two, doesn’t matter. There’s certain classes of debt, right? And Oaktree has secured debt, which means. If they get paid first, if there’s anything, right? If this bankruptcy goes and, and gets, sell this, sell that, sell this, whatever’s left, goes to the secured debt and then it goes to unsecured debt.
And [00:07:00] there’s sometimes there can be different classes of unsecured debt as well. And, but if there’s not, some of it just goes by like date or value or everybody gets a percentage, it just kind of all depends on how it works out in the specific court system that the stuff takes care of. But that person.
That is the top. Um, in this case, Oaktree Capital, right? Based out of la but offices all over the world, they got about $200 billion in real estate equity and debt assets or, uh, I guess valuation. I wouldn’t say assets. Um, they are the debtor in possession, so they’re the one that’s kind of like top of the heap.
They’re kind of controlling how the. The restructuring and or sale goes alongside the court system.
Allen Hall: And the trouble is, is that when you have unsecured and secured debt, everybody that’s unsecured wants to get paid. So any material supplier that has been for in selling product to TPI over the years [00:08:00] usually has a 30, 60, 90, maybe 120 days of, of after they deliver the product to they get paid.
In that timeframe, if bankruptcy happens, all that product that’s sitting on the floor at TPI, you sort of lost it. You know, you can’t get it back and you’re not gonna get paid for it for if, if, if ever, what do you do? And so you start, you know, you start filing claims, but those, those claims most likely will never get paid.
Or if they will, they’re going to get pennies on the dollar.
Joel Saxum: Yeah. And I would imagine like, so, you know, when we, when we sit here and say from the weather guard hat, right? We put a. They go to a client, net 15, net 30, we expect to get paid in that amount of time. That’s kind of how our, basically US forwarding credit to someone else.
That’s how it works. And if you work within the wind industry, you know that the OEMs, because they are the OEMs, they have a heavier hand. Sometimes they’re net 90, net one 20. Um, once they, once they’re cool with your invoice. So you could see that some of these people that have, [00:09:00] uh, and TPI falls within that OEM category, right?
Um, you can see that they more than likely will have had longer, more favorable terms for themselves with some of these sub-suppliers. And the sub-suppliers are, think about TPI blades. It is composites, it is fabric, it’s resins, it’s all of those supply companies. Um, and you know, there may be, uh, some other.
Dead in there that you’re not, we’re not sure of. We saw some stuff with some OEMs, maybe they have some exchange agreements you paid up front for some blades or something of that sort. You didn’t get ’em. I don’t know. But there is also, and this is the one that kind of hits home to some of our listeners, um, not only some of our listeners are those supply chain companies that support them, um, but a lot of them are ISPs.
Right? So we were just talking to someone who, you know, just a couple weeks ago that had done some inspection work, uh, for, for TPI that. They’re not gonna get paid for it. Um, we have seen on the creditors list of some ISPs that we know they’re not gonna get paid, and those are people out [00:10:00] doing warranty repairs and those kind of things over a course of time.
And they may have had a net 30, net 60, net 90 days payment, but I’m sure that stuff is well and long gone. They probably have invoices due for a year now. Uh, but it, this, the, the, this downfall of TPI, what’s going on with them, it affects a lot of people in the wind industry. Um. Be being, having been on the short end once in my career of an unsecured debt, uh, when a, when the client or the, uh, um, purchaser of services, but went into bankruptcy and losing a whole bunch of cash, and there’s nothing you can do about it, um, except for.
Be mad and stew over it and learn from your mistakes. Uh, that’s a tough place to be.
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Allen Hall: the problem. With TPI has been keeping the doors open and they went in front of the court and said, we have a liquidity problem.
Uh, Vestus bought those two factories, those two LLCs for $10 million each. That was the agreement During that transaction, TPI asked for another $55 million, uh, and it’s in the transcripts. You can go listen to this dental, listen to it, but obviously the vest representatives were. No [00:12:00] way. We’re not doing that.
We are in good faith. De decided to buy, uh, these two pieces. So 10 million bucks a, a factory is. Pretty decent price, but they are still in a liquidity challenge. So GE Renova and Vestus, uh, don’t want the Blades manufacturing to stop. They have customers who need blades and so they need these TPI factories to keep running.
GE Renova is providing emergency financing. Uh, through what the court calls, uh, Erna, G-E-R-N-A, it’s a liquidity agreement. Uh, they also signed a long lead materials agreement to keep raw materials moving into the plants. Vestas provided cash advances to keep production going at the Mexico facilities also.
So for now, everything continues to be running, but essentially GE and Vestas are pro paying for the materials. To keep the production line going and there’s this, there’s on the back end of this TPI is essentially. Gonna charge, um, [00:13:00] GE vest less for the blades when they roll off the line because they advanced some those funds.
So, TPI as an organization is still trying to continue to produce blades and trying to honor their commitments as much as they can, but they need cash and the, the place they’re going to go get it or have been getting it from as Vestas in GE Renova. So you
Joel Saxum: one would expect that either Vestas or GE Renova would eventually just say like, we’ve got to buy you.
Is that a reality? Because it doesn’t seem like it from the court documents and stuff. It seems like they’re, they’re kind of, they don’t want to get their hands into back or back into, in GEs case, this blade manufacturing, uh, faculties, right? They’re okay right now providing cash for you guys to keep your operation running and providing us with the things we need.
But we don’t actually want to take it over. That’s what it feels
Allen Hall: like. Uh, well, Vestus did, right? So Vestus took over two factories in Mexico. GE has not done [00:14:00] that yet, and there’s no indication from the proceedings that I read on all the documents that GE has made any move to do that. Vestus definitely stepped in and wants to keep the two factories running, uh, with the issues with ge, Renova and LM at the minute, and there was a lot of layoffs at LM just before the new year.
It’s a question of what GE will do, and it doesn’t seem like as of right now, GE is going to buy factories. Now that being said, uh, TPI composites has deadlines to meet and some auctions to run. Uh, the remaining assets, the non vestus. Portion and the, the Turkish operations, which were sold way earlier, uh, all of the remaining assets go up for bid on January 26th.
And if no outside buyer steps in, which is very possible, Oak Tree Capital can use its debt as currency to take ownership of from what is called a credit bid. [00:15:00] From there, uh, the secure lender could convert that debt into equity and, and so basically what happens is Oak Tree Capital. Would be the holder of the company for whatever remains.
But you would think that GE Viva, uh, would want to have some piece of this to keep the blade factories running, but there’s no indication of that. No one from GE has said anything. None of the filings indicate that GE wants to go ahead and or ge. Viva wants to go ahead and buy the factories. Nothing like that has happened.
So there may be, uh, some more financial transactions at play here, but as of right now, everything that remains for TPI composites is gonna be in the auction block. Someone could walk up and for several million dollars, obviously, uh, acquire it and
Joel Saxum: in theory run it. So, I mean, Alan, you and I talked about this this morning a little bit.
We have seen more [00:16:00] layoffs at lm. Right. We saw more people depart and it sounds like that building is basically a ghost town over in Denmark. GE is basically scuttling LM down to nothing, and they will more than likely either sell off whatever LM has or discontinue whatever that business model is, if that’s where they’re going, blade wise, wind wise.
At the same time, they’ve also said, we’re not building any more g offshore turbines.
Allen Hall: What are they
Joel Saxum: doing? I don’t see them having the, the, the, the thirst to go scoop up or put any money into TPI, but it’s like a catch 22. ’cause they need them to fulfill the orders and stuff that they have. Right now what we’re staring at is basically oak tree composites.
Allen Hall: There’s no chance of that. The oak tree doesn’t know how to run that business. They’re gonna have to hire somebody to go do that. Even if they did, you still got factories in Iowa, a bunch in Mexico, other [00:17:00] places. You have all these assets kind of spread all over the place. It’s not like running an automotive dealership on the corner, you’re, you’re running a major operation with thousands of employees and producing these massively complex blades.
There’s only a handful of companies that would be even possible that we could acquire that and run it with any competency at all right now.
Joel Saxum: So does oak tree being, being that oak tree is the debtor in possession and if, if possible with, or if possible, if it, if it rolls this way with the plan toggle, right.
Where they would basically, the cell would convert them into equity holdings and they would own it. Are they the gatekeepers to who can bid? Like do they control ge? You can bid vest as you can bid? Or does the court control that?
Allen Hall: The court controls all of that. So it’s all part of the chapter 11 proceedings.
Anybody can walk up and put a bid in. And now whether it qualifies or not is, is a good question, but anybody can walk up and, [00:18:00] and make a claim for what remains. There’s, there is a process that will happen there, but who else would it be? Nordex? I don’t think so. Is is Vesta gonna buy more? I don’t think so.
So the concern is obviously for TPI, what is it gonna look like going forward? If you have purchased Vestus turbines or GE Renova turbines, are you gonna have the blades that you have purchased in time? Great questions to ask. I think on the other side is if you do own GE Renova or Vestus turbines and they’re made by TPI, where the technical aspects lie, what do you do where, what should you be thinking about if you’re a large operator of some of these turbines?
How I should be planning for the future here? What are you thinking about?
Joel Saxum: So let’s divide it into two categories. One of them is turbine blades on order supply chain, supply [00:19:00] chain, and the other one’s being turbine blades already in production or received order.
Yolanda Padron: I’m not sure that we can fully look at them separately though, right?
Because if you have them, if, if they’re yours and they’re under a service agreement or something. Eventually you might be in the queue for a replacement that you need, right? That your OEM would be on the hook for.
Joel Saxum: That raises another question there then does. I don’t, ’cause I don’t know this. Maybe you do.
Alan does a bankruptcy qualify as a force majeure event?
Allen Hall: Not in terms of like lightning would be, but, but in terms, yeah, sure.
Joel Saxum: Yeah. But can they claim force majeure and be like, uh, out of our control? So now the turbine supply agreements are, you know, basically have to be rewritten. Timelines have to be rewritten.
Yolanda, to your point, if we have a blade that we need for production, am I not responsible for LDS anymore because the blade manufacturer went into, uh, bankruptcy?
Yolanda Padron: I think it’d be more of [00:20:00] either Now you’re not just. In the queue for TPI Blades. But you’re in the queue for whatever we can retrofit there, right?
That they could put in.
Joel Saxum: Yeah. The alternative is you need a whole set though, right? So if we say like, I need a blade from TPI, or I need an entire set of LM blades, now you’re triple the cost. Who has to pay for that?
Yolanda Padron: I really would hope that it, they wouldn’t go this route, but I think some OEMs would just hit liquidated damages.
And stop.
Allen Hall: That’s what I think too. I mean, we’ve seen that happen with some of the OEMs. Is that the, uh, LDS and that’s it. There is nothing going forward. They’re, they’re fine doing that. That’s the only play that they have. I, I am deeply concerned what GE Renova is about to do in the wind business because of their gas turbine and everything else are so profitable.
And they just announced that the wind business in 2026 is not likely to make any. Positive cash flow. [00:21:00] It, the, the discussion inside of GE Renova, at least at the sort of the boardroom level, must be really tense because in, in theory, they could buy TPIs assets in the factories and run them, but they just went through essentially a liquidation process with lm.
Do they want to run another company, especially when they’re bleeding cash in that particular business? I think the answer GE historically has been no. If we’re not number one or number two, we’re getting the heck outta that business. That was the Jack Welsh of running ge, and anybody that worked for GE knew that loud and clear because they said it all the time.
Those same people that grew up in that GE culture are now in the boardroom, and what are they likely to do? They’re likely to follow that advice. Because it’s just what they know. It’s, it’s, it’s, it’s the school they went to. Are they gonna change their mind and say, A longer term play is wind [00:22:00] and we wanna stay in it and we’re willing to lose a couple hundred million dollars a year for the next couple of years, and now we’re gonna run a Blade Factory with several thousand employees down in Mexico.
I just don’t see it. Uh, not that I could be totally wrong about that. Probably am. Uh, today, sitting at the beginning of January of 2026, I don’t think GE Renova wants to be in the blade manufacturing business if they can at all avoid it.
Yolanda Padron: I think it’s important for owners to start thinking a lot more about educating their internal teams on what they can.
So if it’s through, if you know people within your OEM that you can trust and that can help you. Learn how to self-service some of your blades. That would be great if it’s through ISPs that you can trust. If it’s a hodgepodge of items. I think it’s really important for owners right now to start building that up because it will take a while.
I. And, and the risk [00:23:00] is there.
Allen Hall: That wraps up another episode of the Uptime Wind Energy Podcast, and if today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn and don’t forget to subscribe so you never miss an episode. And if you found value in today’s conversation, please leave us overview.
It really helps other wind energy professionals discover the show. And we will catch you here next week on the Uptime Wind Energy Podcast.
Renewable Energy
Biggest Threat to Human Civilization
Until Donald Trump rose to power, I probably would have said climate change.
Now, I would say it’s world fascism, as the world’s power powerful nation, at least at this point, is no longer a democracy in any meaningful sense of the word.
The planet is faced with rule by sociopathic dictators with absolute authority.
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.
Renewable Energy
Carbon Capture and Synthetic Fuels
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.
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