Weather Guard Lightning Tech

Updates from ACP 2024, Thoughts on Vestas Q1 Financial Loss
Allen, Joel, and Phil record their thoughts on the show floor of American Clean Power 2024 in Minneapolis, Minnesota. Which companies are in attendance? What seems to be the industry direction? And they also discuss Vestas’ Q1 financial results which show a loss.
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Intelstor – https://www.intelstor.com
Allen Hall: Welcome to the special edition of the Uptime Wind Energy Podcast. I’m your host, Allen Hall, and I’m here with Phil Totaro, the CEO of IntelStor and Joel Saxum, the chief commercial officer of Weather Guard. And we are in Minneapolis today for the opening of American Clean Power 2024. And we wanted to get everybody’s thoughts on what we have seen today, what the feeling is, what the number of people we’ve seen bouncing around, what the business atmosphere has been like, and, give everybody an update who couldn’t be here.
Obviously there’s a number of people out in the field fixing wind turbines right now. the people actually keeping wind turbines operating. give us a sense of what’s happening with some of the new technology we’ve seen today and what to expect on the remainder of the week. And Joel, I know early on this morning, it seemed like it was going to be pretty busy.
Joel Saxum: Yeah, absolutely. So I walked in here, the agenda said 10 30, they opened. I walked in at 10 31 and it was already. Packed in here. I tried to get a cup of coffee. There’s 200 people in line. so I know Phil, you were saying that you, were the only one of us able to actually take a lap so far today around the show floor and saw a ton of people.
Alan and I have been basically in conversations back to back since we got here with whether it’s talking about podcast stuff or strike tape or fixing any other kinds of problems with everybody from the insurance industry, asset owners, ISPs all the above. So it has been swamped here at our booth.
Philip Totaro: Unfortunately, I got here late. I arrived because of some weather in Denver, at about 2. o’clock this afternoon. And so I’ve been here about, two hours now, three hours now as we record this, and I think I’ve already closed about three deals. So this is probably the, most productive I’ve seen an ACP event in, a long time.
which I guess is, good news. but just based on my walking around, I’d conservatively say there’s at least about 10, 000, if not maybe 12, 000 here, at this event. So it’s got a much better tenor to it, much better mood. people are, really quite engaged. so it’s, overall, I, think, better, better than everybody might have expected.
Joel Saxum: Yeah, Minneapolis, the Minneapolis Convention Center, that’s where we’re at. The weather’s great right now. but the Minneapolis Convention Center is huge. I’ve been in this, when I was a kid, we were, we’d come down here for sports shows and they’d have this whole thing full of boats and all kinds of stuff.
I remember it as a kid, I don’t remember it being this big. but it is, from end to end, we talked with Armando from Earthwind, our friend, and he’s Dude, we walked up and down every aisle basically just to check everything out. And it took them almost four hours. Yeah. There’s
Allen Hall: a lot of vendors here.
It’s a lot. And I think some of the feeling I got just talking to people who walked up to the booth and running into people we’ve had on the podcast is there’s more activity. the operators are focused. On getting their assets up and running and to, get to the solutions and the ones that I had talked to specifically have been trying different solutions, evaluating them over the last couple of years and are ready to start moving.
It’s no longer trial phases. We want to get going and deploy useful ideas, useful solutions fleet wide.
Joel Saxum: Yeah, absolutely. Absolutely. And, Not only is it the asset owners that are looking at these things, the ISPs are asking, right? So what that means to me is that their clients, the asset owners, have been telling them, Find us a solution, or we’re looking for this solution.
I had an ISP come up and just say We’ve been tasked by our clients to find things to solve problems. When we came to this show, I said, you’re talking to the right people, lightning wise. that, I think is a, It’s real and it’s moving, right? People want to get their assets up and running and they want them to be running smoothly.
and they’re willing to spend money right now that people are allocating budgets to, to get things done and you can feel it.
Allen Hall: Yeah. Excited. I think the feeling on the OEM side and GE Vernova is here, but I haven’t seen Vestas. not to me, they haven’t been here, but I haven’t seen them and I haven’t seen, Siemens Gamesa.
Joel Saxum: No, I heard, of some people having meetings with people from Siemens Gamesa, but they don’t have a booth. Okay. Yeah. So I know there’s definitely representation here, but, not necessarily in a booth. I haven’t seen any Vestas. what do you call these things? Badges? I haven’t seen any Vestas badges walking around though.
Allen Hall: So that, that’s an interesting point because Vestas announced their first quarter results and they came to a loss of about 75 million, right? Which in the bigger scheme of things is, a small drop in the bucket. I think the bigger story there is the number of sales that they had is down.
And I attribute that, Phil, to the increase in prices. everybody’s talking about the OEMs increasing prices and looking to recover the money they lost over the last couple of years. that necessarily, I would assume, is going to drop the quantity of megawatts purchased, right?
Philip Totaro: to an extent, yes. there’s a couple of things at play here.
Number one, Vestas normally has a down first quarter anyway. but that’s something that a lot of equity analysts already price in and that sort of thing. so that’s been a part of it. Obviously, there’s year to year fluctuations. The other thing is, yes, to an extent, raising prices theoretically means less, demand.
But it’s, there’s been a consolidation in the U. S. market to an extent because Siemens Gamesa is not really offering turbans for sale, which is why any of the folks from Siemens Gamesa that are here are probably service, and the Nordex, while they’re, they’ve obviously got a presence in the U.
S. market with the N149, and now they’re trying to get the N163 product in here, and we have these, hints about, The fact that they’re going to be launching, probably a lower power rated version of the N163 to compete with the, Vestas V163, later this summer. that’s, reason to, be interested for them.
But I, I think it, it really has to do with interconnection cues. if I go, if I point the, indicator anywhere, it’s interconnection cues. Piling up are causing a slowdown in deal closures. That is then having a result of an impact on Vestas, not being able to, close deals and recognize as much revenue in, quarter by quarter as they, they otherwise would.
Allen Hall: So why is solar going so heavy right now? They’re in the same interconnection queues, right?
Philip Totaro: Yeah. And, that’s a great point because they’re actually taking up more space in the queue with a lot of projects that are never going to get built. than wind. However, the projects that are getting built, it’s still more capacity than what wind is doing.
and so for an IPP, for every dollar that they can spend on solar or storage, it’s one less dollar they have to spend on wind. grand scheme, I think this is not emblematic of a, industry wide issue. Or anything Vestas specific to be concerned about. Again, I think it’s one bad quarter that it’s not really that concerning.
If it starts showing, another quarter and by the third quarter, if it’s also down, then we worry that raising prices has resulted in lower sales. But for one quarter, I’m not that concerned about it.
Allen Hall: But Vestas, as seen by a lot of operators at the moment, is the number one choice. So if, Vestas is having a decrease in sales in Q1, I would assume GE and then Siemens Gamesa, who knows, but it’s going to be a pinch on GE, right?
Philip Totaro: to be honest with our order tracking that we’re doing at Intel store, it’s, that’s not necessarily the case there. So keep in mind that Vestas only receives revenue when projects go COD. And it’s commissioned and it’s, they’re online and operating, or at least the bulk of what they get paid.
there’s usually an upfront and et cetera, et cetera. Based on orders right now, Vestas didn’t have such a great quarter, but GE actually did in the U. S. Nordex also got a few orders, that they’ve closed in, the U. S. as well in the first quarter. But, it’s, everybody’s having to accept a higher price because even the Project CapEx cost is going up, which means the cost of finance is up, interest rates are still high, so everybody’s paying more.
And, especially when an OEM’s gotta pass on the cost of raw materials and increased, labor and overhead rates and all these other things that they have to incur, that’s necessarily gonna push the prices up for everybody.
Allen Hall: So is that a marker now that we need to focus on in terms of what to expect the remainder of this year?
If GE is starting to see a little bit of a, if GE is starting to see a little bit of a turnaround, which they have to, they have to be profitable this year. And Investus is obviously going to be profitable. I think by the end of the year, the full four quarters, they’ll be going to be profitable.
But GE is making
Joel Saxum: moves outside of sales efforts to be profitable. Yes, they are. They’re making a lot of internal changes. process changes, they’re, dumbing down their order or their order capability book and some other things as well, let alone getting rid of people.
Allen Hall: So does that then foretell of profitable GE by third quarter?
Joel Saxum: I think so. I think if you, I think GE’s, GE, the GE Vernova split right now looks great. If you watch the stock trackers and you want to listen to the street, again, of course now that, Wall Street is not always, a direct indicator of how the health of a company, right? But they, see it as we want to put money in here.
We want to invest in here because they looking good for the future. So since they split, it looks great.
Philip Totaro: and to be blunt, even Siemens energy, which is the parent of Siemens Gamesa, they’re even had, a great quarter in, the first quarter, but Siemens Gamesa is obviously still suffering.
So overall the power generation industry is doing well. Wind. Has been a bit impacted, but again, I don’t think it’s a long term problem. I think, even, with Vernova and the aerospace split, aerospace is now doing very well. And Vernova is actually also doing very well outside of the wind business, which they still have some work to do.
The onshore business is okay. Not as healthy as they want it to be. The offshore business, we’ve talked about ad nauseum on the show and, that needs to improve, but should happen if we can get, more of these, projects through a consenting and interconnection queue, which really comes down to market efficiency, companies signing corporate PPAs, utilities signing PPAs and transmission availability.
If we can get those things resolved, that’s going to start opening up more of the queue. More companies like GE, Vestas, Siemens, and Nordex are going to start closing deals and we’re going to see a much more, robust and healthy market. I think it hinges on transmission availability.
Allen Hall: But the DOE just announced a week ago about making that process faster to get the turnaround and get rid of some regulatory pieces there to turn it on.
But I’m not sure That is a short term fix, right? In a
Philip Totaro: year and a half when that happens, I’ll be excited about it.
Allen Hall: Okay, so from, I haven’t heard anybody mention that today. Or this week even, that hey, they’re going to open up the transmission lines and boom, here we go. That’s not the, that’s not the feeling.
But the feeling I’m getting, I talk to a lot of operators today, is we’re trying to produce the power we were asked to produce. How do we do that? Efficiently, yeah. It has really changed from, I would say, two years ago, where it was, we don’t really need to get too deep into some of these solutions that are out there today.
I think they have a lot of blade issues and turbine issues. They have bearing issues. They have blade issues.
Joel Saxum: Let’s think about one of the, what could be a macro reason for this. IRA Bill went through, two years ago now? Two years, year and a half. Two years ago in August, right? So that extended PTC credit.
So a lot of these wind farms are being PTC repowered. There’s been a lot of repowers go on in the last few years. Now that we’ve done those repowers and they’re finished, those farms are quote unquote new, right? they’re at that one, two years since COD of, repower. So now is the time when you want to spend money on upgrades and things like that for the life of that turbine, because it doesn’t make sense.
If you’re going to repower that thing at the end, at year eight to go, Strike tape on or something like that. Like you’re just going to read, but now all of those IRA bill driven PTC or, PTC fund repowers are fresh and there’s more of them coming down the pipeline. So at this point in time, maybe when you want to put some money into that wind farm, some capex to make sure that it’s running smoothly,
Allen Hall: but they’re not going for little percentage gains.
They’re going for big wins. Have you noticed that? if you mentioned we can make an a one or 2 percent increase in AEP, everybody’s just sloughs it off like. Yeah, we’re looking for 20 percent today because of bearing issues, because of blade issues, because of the operational issues that
Joel Saxum: they don’t Less AEP percentage gain and more just uptime availability.
Availability.
Philip Totaro: and I’ll tell you what too, based on the data that we’ve got at Intel Store, where we analyzed the delta between the old site and the repowered site, on average for the 105 or so sites that have been repowered in the U. S. so far, It’s only about a 3. 6 percent increase in AEP. Whoa. and there are actually some sites that have gone down.
Because they’ve had issues with the new turbines that they repowered the site with.
Joel Saxum: Yeah,
Philip Totaro: And teething issues. So the reality is, you’re right Joel, they’re not getting the AEP that they need necessarily out of the repower. The PTC is driving the repower. And availability. With that PTC is what they want because they want to eke out as much revenue as they can.
That’s going to have this extra 26 or 26. 80 or whatever it’s indexed to now. I forget. but that’s what they want. They want the PTC revenue. So availability and PTC farming is, the, industry we’re in. I coined that term, I think about a year and a half ago that we’re not wind farmers anymore.
We’re PTC farmers.
Allen Hall: You can
Philip Totaro: hear
Allen Hall: it. Phil, now you say it, it was clearly identified today to me by multiple operators that it’s availability. And it used to be AEP. Two, three years ago it was AEP. If we get another percent or two out of the turbines we have, it’s certainly fine.
Joel Saxum: With these newer, some of these newer turbine models that they’re running, like we talked with one operator today, we know what their wind farms are and what they run.
And they’re, six of their seven wind farms in the United States are the exact same wind turbine model. And that wind turbine model has specific issues to it. So they’re looking, so if you are having issues with that model, it’s not affecting one of your wind farms for those guys. It’s affecting every single wind farm they have.
So they need the solutions because it’s a plaguing issue that’s fleet wide.
Allen Hall: That opens up a number of doors here. What are those top three items that they’re going to be looking for this week? I think one of the big items that’s going to happen this week is the 3S lift climb auto system. because The adoption rate, from what I can understand, is increasing rapidly.
It improves availability, right? Getting a technician up and down is an availability answer. the CLI model system, boom, easy one, right? Leading edge erosion, I think people today were asking about leading edge erosion, what’s out there, and there’s a lot of different applications. We talked to Bergelin, obviously, but there’s others that, they think leading edge protection is the way to keep my availability up.
Then it comes to lightning, right? It comes to the lightning issue. Hey, we have turbines down because we have holes in our blades. So we gotta fix the holes before we can turn the turbine on. Again, back to Phil’s point, availability. If we’re in that availability mode, then who are the winners this week?
Who are gonna be the losers?
Philip Totaro: We’re actually, happen to be sitting next to one of the winners, potentially, which is, NextAir is actually here exhibiting at an ACP event. which for those of you who’ve been in the industry a long time, that’s pretty rare. They sponsor and, are usually a, title sponsor, but they almost never exhibit.
And what they’re doing is they’re actually offering their asset management platform now, for sale to other asset owners. they took their data analytics platform where they’re doing a lot of, analysis on, as least for O& M, on that side of the business, the work order prioritization, they also have, energy trading, tools built into this capability.
it’s actually quite impressive and, quite robust. And given, the, pedigree that they have as a company, that’s, definitely one. to, maybe answer a broader question, there’s, the, asset owners that are here that are in need of solution providers, it’s really matchmaking those, those companies together.
It’s, there are plenty of people that would be capable of providing, an asset owner better availability, depending on what they have. there are some asset owners that are dependent on. an OEM service contract and they’re not getting the OEM to fulfill their obligations under the contract.
is there a way that they can potentially supplement that OEM arrangement with, something else? and whether that’s an independent service provider, whether that’s a data analytics company, anybody that’s got information, data answers on, and Joel, you’ve brought this up before on the show, just tell me what to do.
Like, how do I run my asset? Those are the people that have answers to those questions. They’re the ones that are going to be winners. Alan. So the next era
Joel Saxum: three 60 platform that we’re, right next to them. I’m staring at their booth right now. The real winner here, to be honest with you is all of the other IPPs
Philip Totaro: who benefit, who
Joel Saxum: can benefit from that solution.
Because we’ve talked to Alan, you and I personally talked to people that are trying to develop some stuff like that. Like we’ve got to figure out a more efficient way to manage our assets better. Here you go. It’s in a box now next year. We’ll give it to you after the learnings from there. What are they?
12, 000 turbines or something like that?
Philip Totaro: Oh yeah. It’s, 20 gigawatts of wind. I forget precisely how much solar and the amount of energy storage that they’re deploying is insane because even if they’re going to just operate it on behalf of a financial focused asset owner, those asset owners that want energy storage, particularly in either Southwest Power Pool or air cot.
To take advantage of the arbitrage play with energy trading, it’s insane. California, Texas, they’re, they are seeing a significant amount of interest in deployment. And, again, it’s, next there is one company, and as I said, with the pedigree they’ve got, that’s gonna, attract a lot of interest and attention, I’m sure.
But really anybody that, we’ve talked on the show about, Onyx Insight, we’ve talked about Windesco, we’ve talked about, any number of companies that actually have that type of, asset management platform capability. Power Factors is still out there, Spark Cognition, et cetera, et cetera, just to name, a few.
Allen Hall: Okay, so that, that’s really interesting, because we have not really seen that until now. So even a next era, the next era thing is fascinating in multiple levels, right? Next era doesn’t need to sell any product. They have a pretty good system set up internally. They’re profitable. They have a lot of projects.
They know how to run their business. But now they’re offering to help others run their business. So like we saw this week with Elite, right? Elite is possibly being sold or maybe in the process of being sold. There’s a lot of regulatory hurdles there. We’ll Is that indicative of, hey, outside money coming in saying, Elite runs a pretty tight ship from what I’ve seen, operationally.
It’s looking at CPP as an investor,
Joel Saxum: right?
They’re just, cash. Yeah, but then why would they go
Allen Hall: after an asset like Elite?
Joel Saxum: Because it’s run well.
Allen Hall: Exactly. And,
Philip Totaro: and, GIP too, keep in mind, because they, both of them, okay, let’s talk about the, CPP investment board. They are invested in assets globally now, not just in, Canada where they’re, headquartered, but, this is potentially if this, deal for elite gets approved, this expands their, footprint in the U.
S. They’ve got assets in Brazil. They’ve got assets over in Europe. They set up a whole platform, to go invest in projects just for Scandinavia. so they’ve got a huge interest in. asset ownership while they may not have the requisite expertise in operations. That’s the play is they do want something that they can get hold of.
And, we even did some, on the spot analysis when this deal was announced Monday afternoon or morning, where, they’ve spent elite spent just on their wind portfolio, about three, a little over 3 billion, in CapEx. And the deal that was announced was, I think, for about 2. 2, 2.
3 billion, to acquire it. taking into account the, the depreciation of those assets and the, operating revenue. but they’ve got a fleet that, I, I wanna say something like 52%, operates at or above, a P50 energy yield. Based on, again, the Intel store analysis of the, IPP provided data to, FERC and the Energy Information Administration.
Thank you. they’ve got a pretty robust and healthy portfolio. Even their net profit per megawatt installed is 877, 000 per megawatt. So that’s right there at about the industry average. So if you were controlling the purse strings at CPP, that’s a good investment? Yeah, it’s a solid, it’s not Above average, but it is at least average.
And it’s also giving them access to a fleet that has an average, asset age of, something just below 10 years, which means that for the projects that are already 10 years, they gotta be looking at repowering. And for the ones that are six, seven, eight years, they’re in the queue to, to be repowered.
I
Joel Saxum: know they do
Philip Totaro: have
Joel Saxum: some, ripe for the repower opportunities where they will take the towers down because they’ve got some Zond Z 50s and stuff down in like Bentonville. So they’ll there’s definitely room for growth within that as well
Philip Totaro: yeah, and it’s well just one one thing on this is Companies like I mean look CPP investment board and GIP as Examples of infrastructure companies we and we’ve talked ad nauseum about that on the show as well that they’re plowing money into renewables at this point But the It’s funny because they’re not even necessarily looking at, this is so PTC driven, they’re not even necessarily looking at the financial performance and health and operational performance of the elite portfolio.
yeah, obviously they did their due diligence and that was a factor, but the fact that they can just get their hands on an asset portfolio that they can repower and capture PTC revenue from, that is the most lucrative thing right now. And so if you’re looking to sell a project, you’re going to have a pretty easy time of it.
Or if you’re a company that’s going to sell your company or sell a portfolio of projects, there are buyers out there. There are people that want that because the we’re finally Joel, to your point earlier, we’re finally seeing the impact of the IRA bill in this PTC extension that again, we’ve got 10 years worth of certainty on the PTC at this point.
the industry is starting to open the spigot.
Allen Hall: So what does GE Vernova do and Vestas do to fill that void?
Philip Totaro: They gotta get their game together with their factories and make sure that they don’t have more than, an 18 to 24 month order backlog. Which means factories, which means jobs, which is good.
But it also means partnerships and contract manufacturing opportunities. Which frankly might be good for LM Wind Power. and it’s definitely going to be good for TPI. and certainly other companies that are, supply chain companies to both GE Vernova and, and Vestas. The other thing it potentially does is, and again, this is why it’s so concerning for Siemens Gamesa not to be, offering a product for sale at this point.
I really wish they would Announce what they’re going to do and when they’re going to do it. Nordex will benefit. And here’s the real question. Is there another player who feels that now is the right time to plow some money into re establishing or reinvigorating or creating a presence in the U. S.
market? As An alternative to GE Investus.
Allen Hall: It can’t be a Chinese manufacturer. That just is not happening. The political atmosphere right now is going to be the worst time to do it. Okay, so there’s more to hear about during ACP 2024. We’re going to continue to check out all the vendors and all the new technology here this week and when we get back to our regular studio offices, we’re going to inform everybody about what’s happening and keep you up to date.
Thanks for joining the Uptime Wind Energy podcast. We appreciate all the listeners. Our numbers have been extraordinarily high the last couple of weeks and we appreciate all the new listeners to the program. So we’ll see everybody next week.
https://weatherguardwind.com/updates-from-acp-2024-thoughts-on-vestas-q1-financial-loss/
Renewable Energy
EchoBolt’s BoltWave Makes Bolt Inspections Easy
Weather Guard Lightning Tech

EchoBolt’s BoltWave Makes Bolt Inspections Easy
Pete Andrews from EchoBolt joins to discuss ultrasonic bolt inspection, the Bolt Wave device, and blade stud defect detection.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Welcome to Uptime Spotlight, shining light on wind. Energy’s brightest innovators. This is the Progress Powering tomorrow.
Pete Andrews: Pete, welcome to the program. Good to be back. Yeah. See you face to face. Yeah. Yes. This is wonderful. It’s a really great event to catch it with loads of the. UK innovation that are happening in the supply chain. So it’s, yeah, really nice to be here.
Allen Hall: This is really good to meet in person because we have seen a lot of bolt issues in the us, Canada, Australia, yeah.
Uh, all around the world and every time bolt problems come up, I say, have you called Pete Andrews and Echo Bolt and gotten the kit to detect bolt issues? And then who’s Pete? Give me Pete’s phone number. Okay, sure. Uh, but now that we’re here in person, a lot has changed since we first talked to you probably two years ago.[00:01:00]
You’re a bootstrap company based in the UK that has global presence, and I, I think it’s a good start to explain what the technology is and why Echo Bolt matters so much in today’s world.
Pete Andrews: Yeah, absolutely. So, um, as you said, we’re a uk, um, SME, there’s a team of 13 of us based here in the uk. Yeah. But we do deliver our services internationally, but really focused on Northern Europe.
Yeah. But increasingly we’ve done more in the US and North America, a little bit in Canada. Um, but our big offering really is to help wind turbine operators and owners reduce the need to routinely retire in bulks. So we have a quick and simple inspection technology that people can deploy, find out the status of their bolt connections, and then.
Reti them if necessary, but the vast majority of the time we find that they’re static and absolutely fine and can be left [00:02:00] alone. So it’s a real big efficiency boost for wind operators.
Joel Saxum: Well, you’re doing things by prescription now, right? Instead of just blanket cover, we’re gonna do all of this. It’s like, let’s work on the ones that actually need to be worked on.
Let’s do the, the work that we actually need to, and instead of lugging, like we’re looking at the kit right here, and I can, you can hold the case in one hand, let alone the tools in a couple of fingers. As opposed to torque tensioning tools that are this big, they weigh a hundred kilos, and those come with all of their own problems.
So I know that you guys said you’re, you’re focused here. You do a lot of work, um, in the offshore wind world as well. Yeah. I mean, offshore wind is where you add a zero right? To zeros. Yeah. Everything else is that much more complicated. It costs that much more. It’s you’re transitioning people offshore to the transition pieces.
Like there’s so much more HSE risk, dollar risk, all of these different spend things. So. The Echo Bolt systems, these different tools that you have being developed and utilized here first make absolute sense, but now you guys are starting to go to onshore as well.
Pete Andrews: Yeah, that’s right. So I mean, as as you said, that there’s really [00:03:00] three main benefit areas we focus on.
The first one is the health and safety of technicians, right? As you said, some of the fasteners used offshore now are up to MA hundred. So a hundred millimeter diameter bolts,
Joel Saxum: four inches for our American friends. Yeah, absolutely.
Pete Andrews: And they probably weigh. 30 kilos plus per bolt. Yeah. Um, so just the physical manual handling of that sort of equipment and the tightening equipment for those bolts is a huge risk for people.
If you think 150 bolts lifting or maneuvering, the tooling around on on its own can cause all the problems. So as well as the inherent risk of the hydraulic kit failing. So occasionally we see catastrophic tool failure. Is, which have really high potential severity, you know, sort of tensioner heads ejecting or crush injuries from Tor.
So that is really a key focus for our customers, just to [00:04:00] keep their teams safe, but also you have to be the cost effective and the the major cost benefit we allow is that we don’t have to revisit every bolt and every turbine like you’d have to do if you were retyping. So we believe there’s something of the order of a million pounds per installed gigawatt saving.
By moving from a routine REIT uh, maintenance strategy to a focused condition based inspection, you significantly reduce the amount of intervention you make and keep your turbines running more and reduce the boots on the ground on the turbine. So three real kind of, um, key. Benefits for people adopting our technology
Allen Hall: because we routinely see tower bolts being reworked or retention depending on who the manufacturer is.
And I’m watching this go on. I’m like, why are [00:05:00] we doing this? It seems, or the 10% rule, we’re tighten 10% this year, and they’ll come back and see how it’s going. That’s a little insane, right, because you’re just kind of. Tensioning bolts up to see if one of them has a problem and then you just do more of them and we’re wasting so much time because echo bolts figured this out years ago.
You don’t need to do that. You can tell what the tension is in a bolt ultrasonically, which was the original technology, the first gen I’ll call it, uh, that you could tell the length of the bolt. If the length of the bolt is correct within certain parameters, you know that it is tension properly. If it’s shrunk, that probably means it’s not tensioned properly.
That’s a huge advantage because you can’t physically see it. And I know I’ve seen technicians go, oh, I could take a hammer and I can tell you which ones are not tensioned properly wrong. Wrong. And I think that’s where equitable comes in because you’re actually applying a a lot of science simply [00:06:00] to a complex problem because the numbers are so big.
Pete Andrews: Yeah, I mean that, that, that’s been the real. Driving force between our offering is to simplify it. So ultimately we’re based on a non-destructive testing technique. It’s an ultrasonic thickness checking technique, but when from the non-destructive testing background, it’s crack detection, people have time, they can be, it’s a very precision measurement.
People have to be trained in the wind industry. We’re trying to inspect. A thousand, 2000 bolts a day at scale. It’s a completely different, um, ask of the technology and the way the technology has been developed historically has required too much technician expertise, too much configuration and set up time, and hasn’t delivered on the, on the speed that’s needed to be efficient in wind.
And that’s where our bolt wave [00:07:00] unit we’ve, that we’ve developed over the last. 18 months, let’s say, where all of our focus has gone to make it as slick and as easy for a client technician to pick up with minimal training. It’s through an iOS interface. Everyone understands it intuitively. Um, it’s a bit like using the camera app on your phone.
You know, you’re just hitting measure, measure, measure, measure, measure 10 seconds a bolt as you move the, um, ultrasonic transducer across, and then the data gets moved. Automatically to the cloud, to our bolt platform. And customers can view it in near real time. The engineer in the office can see the inspections happened.
They can see if there are any anomalous bolts, and then there can be communication there and then whether an intervention is necessary. So it’s sort of really changed the way our customers think about managing their, um. They’re bolted joints.
Joel Saxum: Well, I think these are, these are the kind of innovations that we love to see, right?
Because [00:08:00] we regularly talk about a shortage of technicians, and this isn’t, I was just learning this this week too, like this is not a wind problem. This is a everywhere problem. No matter what industry you’re in. Use are short of technicians. But we’re seeing like a tool like this is developed to be able to scale that workforce as well.
Right. You don’t need to be an NDT level three expert to go and do these things. ’cause there’s a very few of those people out there. Right? Right. We know the NDT people, a lot of NDT people, and that’s a hard skillset to come by. Yeah. This can be put in the hands of any technician. Yeah, a quick training course.
Just, Hey, this is how you use your iPhone. You can check Instagram, right? Yeah. Okay. You can off figure. Yeah, have fun. See you at lunch. Um, but they can, they can make this happen, right? They can go do these inspections and you’re getting that, that, uh, data collected in the field. Centralized back to an SME that’s looking at it and you don’t have to put that SME in the field and try to scale their ability to go and travel and do all these things.
They can be in the office making sure that the, the QA, QC is done correctly. I love it. I think that that’s the way we need to go with a lot of things. [00:09:00]Uh, and you’re making it happen.
Pete Andrews: Yeah. And it’s a real kind of. F change in mindset for us. So originally when we started Ebot, we were using third party hardware.
Yeah. Which required a bit of that specialism. Yeah. A bit of care about the setup of the project, getting multiple parameters configured before you got going. And it wasn’t really something we could put in the hands of a customer.
Joel Saxum: Yeah.
Pete Andrews: Which meant Ebot scale was limited to what our own team could go and do, and regionally as well.
You know, so we’re UK based. Probably 60% of our customers are uk, but now we have this Northern Europe offshore wind is obviously on our doorstep, but then increasingly we’ve done more and more in North America, so we’ve probably been to five or six sites now in North America and expect that to be a growth market because we can, we can now ship the devices over there, give some virtual training help.
Uh, [00:10:00] people set themselves up and then that opens up that market, you know, so it’s been a real change in strategy for us, but has allowed us to have far more impact than we otherwise would just try to be a pure service.
Allen Hall: Well, let’s talk about the big problem in the states of a minute, which are the root bushing or inserts that are loose in some blades.
When you lose that pushing, you also lose the tension on the bolt that can be measured. Is that something you’re getting involved with quite a bit now because of just trying to determine how many bolts are affected and, and where we are on the safety scale of can we run this turbine or not? Is that something that EE bolt’s been looking into?
Pete Andrews: Yeah, absolutely. So I, I’d say there’s sort of two halves of what we do. There’s the, there’s the bulk wholesale monitoring of. Typically static connections to eliminate this routine retitling where it’s not needed typically, typically. But then we have these edge cases of certain [00:11:00] connections and certain platforms that have known bolt integrity problems, and we are working with clients to really, um, manage those integrity risks.
Blade stud is an absolute classic, you know, sort of, I think almost every turbine OEM on some, if not all of their platforms has got. Embedded risk into their blades, pitch bearing connections. Um, so yeah, exactly as you said, our customers are using the technology for two things really. One is to ensure the bolts have been tightened to the preload that was specified or the target window.
And quite often we find there is an opportunity to increase the preload and therefore increase the resistance to fatigue failure. So. You know, particularly on older sites where the bolts perhaps not in the condition they were on day one. Well, they definitely won’t be. Um, when people have gone and retti them, they haven’t got back to where they, they should be.[00:12:00]
So we can prove that and increase a bit of that resilience, but then also start to look for the segments around the joint where, um, the bolt might start loosening or failures are occurring, and find areas where they can really hone in. And actively manage risk. And that sort of leads to what we’ve decided to do for the next year, particularly with Blade Stud in mind, is evolve this technology.
So whilst it’s also measuring the elongation, we will do a defect scan at the same time. So you’ll monitor your blade stu, um, connection and we’re hoping that we can set the device to flag to you there and then. We believe this bulk has got a defect while you’re here, get it changed out before it fails and, and all the knock on problems, um, from there.
Joel Saxum: So what you’re just pointing to there is a, is a workflow, right? So to me that is typical [00:13:00] of some of the amazing, innovative companies in the UK that I’ve run into throughout my career. And that is, you’re a group of SMEs, you know, bolted connections. That’s what you do, right? But then you’re like, hey. If there’s a tool, we could make a tool that would make our lives a bit easier, then it’s like, well, we could make the entire industry’s lives a little bit easier as well.
So let’s iterate on that. And now you’re able to send these kits around the world to look at these things. Hey, you have a problem with this specific model. We can help you with this because we know the failure mode and we know how to look for it. Let’s do that for you. Also here, you’re doing bolt bulk measurements.
We got that for you. But it all kind of flows back to the fact that Echo Bolt is a team. A bolted connection, SMEs that are making tools and being able to also provide consulting if need be. Yeah. Right. Um, to, to an entire industry. And I think that, um, this is my take on it, right? Wind is stop number one. I think you guys are gonna do a fantastic year, but there’s a lot of, uh, opportunity out there in bolted [00:14:00] connections as well.
Allen Hall: A tremendous amount blade bolts being broken from defects in the crystalline structure. What appears to be a more. Rapidly developing issue across fleets that I’ve seen. I went to a farm this summer and the number of blade bolts that were there on the table that were broken on the conference room table was And the whiteboard office.
Yeah. Yeah. This one,
Joel Saxum: this one.
Allen Hall: Your hard head is not gonna protect you from this one. It’s, it’s, it was this, um, I couldn’t imagine the amount of time they were spending hunting these things down. And of course, the only way they were finding ’em was they were broken. You like to catch ’em before they break because it becomes
Joel Saxum: a safety risk.
Just not too long ago we saw an insurance case where there’s an RCA going on and it is pointing at an entire tower came down. Right. And it is pointing at a mid, mid tower section bolted connection. How often do you guys run into those problems? Or are you contacted by insurance companies or anything like that to, to take a peek at those?
Pete Andrews: We haven’t done anything directly for insurance [00:15:00]companies, but we have been engaged by. Engineering consultancies that are doing RCA type activities. Okay. Um, things like at the end of defect liability periods mm-hmm. A customer has, has seen, they’ve had a lot of, uh, issues from an OEM, maybe an OE EM has offered a modification or an upgrade, assessing whether that upgrade is actually solved the problem or not.
We’ve got involved in, um, but the tower. Issue specifically. It’s actually very rare we find, um, problems with tower connections, but where we do is often where they haven’t achieved good flange flatness, ah, during installation or the bolts have been, let’s say, left out in the elements for a period and lubrication has been, has deteriorated before the bolt’s been installed.
So there are cases out there, but what I would say is. [00:16:00] To think about your whole life cycle, so ensure the bolt’s installed correctly and we can help with that with a QA to say, yes, this torque or tightening method has got you to the load that you want. Do some through life monitoring, but often if you install it correctly, it will it’s operational life.
You will have very little concern. But then in the UK market, we’re increasingly getting involved again at the end of life, right? Life extension where life extension turbines are 20, 25 years old. How does an operator make a decision to carry on running without replacing all bots? Um, and that’s where increasingly we being asked to use the technologist just to say, actually the joint is fine.
The bolts have run in a good, um, operational envelope. Run them on. Don’t replace a hundred percent of them like you might have been recommended to from your, um, yeah. Turbine supplier side. [00:17:00]
Allen Hall: So Pete, if someone’s doing a repower where they’re basically putting a new one in the cell on an existing tower, they’re making a lot of assumptions about all the bolts from the ground up that they’re gonna be okay.
And I know we’re talking about that. We’re in a lot of installations where. If the turbine has gone through a repowered or two. So now those bolts are 20 years old. Yeah. And trying to get ’em to
Joel Saxum: 30 35. 35
Allen Hall: 40. Yeah. I don’t know what they’re doing. By those bolted connections. Are they just like replacing the bolts?
Are they hitting ’em with a hammer again? Is that the, yeah,
Pete Andrews: I mean, they might replace ’em, but you’ve got a problem with the foundation bolts. ’cause they’re obviously often anchor bolts set into concrete, so you have to reuse them and. With the projects, both in wind and in process power industry with the chimney stacks to try and ascertain whether foundation bolts that are set into concrete are still suitable for operations.
So look for corrosion losses, look for [00:18:00] defects. Um, so yeah, they’re all things that need thinking about before you just make the snap decision to repower. But I think
Joel Saxum: a lot of that, uh, going back to a couple minutes ago, you were talking about at the commissioning phase, making sure that you have proper qa, QC of how these things were installed day one, and then making sure that before commissioning of a turbine, they’re checked.
I think that’s really important. We’re starting to see that in the blade world now too, where we’ve been talking about it for a long time, and now when you talk to operators, they’re like, we’re getting inspections done on the blades before they’re hung. Or at the factory before they’re hung. After they’re hung.
Like they want a good foundation baseline. Are you seeing that in the bolted connection world too?
Pete Andrews: Yes. Sort of. It’s just emerging for us. What we’ve found is, so most of our customers are in the operational phase ’cause they are the ones feeling the pain. Yeah. Of the routine retitling work. When they do major components, they sometimes engage us to come and say, can you check [00:19:00] before and after the blade was removed?
What was it? Before we took it off from a a bolt load perspective, what is it afterwards? Can you then recheck after 500 hours When we retalk it? And what we’ve seen there often is the initial install hasn’t got them to where they needed to be and they’ve had to go and do the break in maintenance or the 500 hour REIT to get the bolts to the right load.
So one of the questions that we have is whether. Some of the defects are actually being initiated very early on in that initial running in period and whether if, if actually you’d taken the time at, at the point of assembly to make sure you were correct, whether that avoids some of the knock on integrity concerns.
So yeah, it’s interesting area.
Allen Hall: Well, bolts are what hold wind turbines together and you better know you have the right. Tension and [00:20:00] torque on your bolts to get to the lifetime of the wind turbine and to, and to check it once in a while. And I know there’s a lot of operators I can think of right now in the United States that are sort of doing that job somewhat.
I I think they have missed out on opportunities to save a lot of money and to call it echo bolt. How do people get ahold of you? Because that’s one thing I run into all the time. Like, Hey, hey, you gotta talk to Ebol, call Ebol. How do they get ahold of you?
Pete Andrews: So the easiest ways are via our website. Which is echo bolt.com.
Um, LinkedIn, you’ll find us at Echo Bolt on LinkedIn. Reach out. Our email would be info@cobolt.com. So any of those route and you’ll, uh, reach me and the team and more than happy to speak to you about any of your faulting concerns or problems. We are, uh, yeah, we’re passionate about your problems.
Allen Hall: Pete, thank you so much for being on this podcast.
I, it is great to actually see you in person and see the bolt wave technology. It’s really [00:21:00] impressive. So anybody out there that needs bolt tensioning to checking tools, you need to get ahold of Pete at Echo Bolt and get started today. Thank you Pete. Thanks guys. It’s great to be here.
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