Success Stories

Operators of Siemens Gamesa SWT-3.6 wind turbines have long faced a persistent and costly issue: hub-to-main shaft misalignment caused by uneven fastener preload. Over time, this misalignment can progress to bolt loosening, joint instability, and ultimately unplanned corrective maintenance or component failure requiring jack up vessel deployment.

Blade stud failures are one of the most common bolting issues seen across wind turbines throughout the industry. When failure occurs, the consequences can be significant — increased structural risk, secondary component damage, extended turbine downtime, and costly repair operations. Identifying stud defects before failure is therefore essential to maintaining both turbine reliability and overall operational safety.

BoltWave has been designed as an intuitive bolt inspection tool allowing customers to easily adopt the technology. Equinor is the first customer to implement the technology across their offshore wind fleet.

EchoBolt's BoltWatch platform has been successfully implemented by RWE across five offshore wind assets in the UK and Germany.

A significant part of replacing wind turbine drive train components is ensuring high quality, efficient tightening of critical bolted connections.

As wind assets approach design life, the opportunity to continue safe and efficient operation is a key value lever for wind turbine operators.

EchoBolt has supported RWE with a long-term monitoring and inspection campaign for offshore wind monopile foundations.

In partnership with GE Renewable Energy and ORE Catapult we have completed the assessment of bolt preloads in wind turbine tower connections to help eliminate hydraulic check-tightening

Wind turbine blade connections are notoriously challenging to manage with regular integrity problems and difficult maintenance access.

Large, bolted connections across industries may be subject to fatigue and ultimate failure. Phased array ultrasonics is state of the art technology for non-destructive defect investigation of these bolts.

Phased array ultrasonics is a game-changer for bolt inspection, especially in the wind turbine industry. This cutting-edge technology allows for faster, more accurate, and more efficient inspection of bolts, making it an essential tool for integrity management in the wind energy sector.

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