Project Overview
A UK offshore wind operator managing 48 turbines needed to replace 3 separate monitoring systems (SCADA data, ...
Technology Stack
Compliance & Standards
The Challenge
A UK offshore wind operator managing 48 turbines needed to replace 3 separate monitoring systems (SCADA data, maintenance records, and environmental reporting) with a single platform. UK GDPR for employee and contractor data, Environment Agency reporting requirements, and HSE offshore safety obligations were the compliance requirements. Real-time turbine performance analytics, predictive maintenance alerts, and carbon performance reporting (for CfD contract obligations) were the business requirements. Budget: £110,000.
Our Approach
SCADA Data Integration
OPC-
UA protocol bridge
- SCADA systems use OPC-UA (industrial standard) — ClickMasters built a Node.js OPC-UA client polling turbine metrics (output power, wind speed, rotor RPM, gearbox temperature, pitch angle) at 1-minute intervals.
- AWS IoT Core for cloud ingestion, TimescaleDB for time-series storage (1.2M data points per day for 48 turbines).
Predictive Maintenance ML
Python scikit-learn anomaly detection: gearbox temperature deviation from baseline (turbine-specific models — each gearbox has different baseline characteristics), bearing vibration pattern analysis, and power curve deviation (actual output vs theoretical output at measured wind speed).
Alert threshold
2.5 standard deviations from 30-day rolling baseline triggers maintenance recommendation.
Environment Agency Reporting
CfD (Contract for Difference) carbon reporting: automated monthly carbon output calculation per turbine (kWh × grid emissions factor), aggregated annual report in Environment Agency prescribed format.
Marine licence compliance
vessel movement logs automatically populated from AIS data (automatic identification system) for maintenance vessel tracking in protected marine area.
HSE Offshore Safety Compliance
- Permit to Work (PTW) digital system: offshore maintenance jobs require PTW issuance, isolation confirmation, and sign-off before work commences.
- PTW audit trail satisfies HSE offshore safety obligations.
Contractor competency tracking
offshore workers must have valid BOSIET (Basic Offshore Safety Induction), GWO (Global Wind Organisation), and medical certificates — all tracked with expiry alerts.
The Results
Platform live at 16 weeks, £103,000 — under budget.
Predictive maintenance alerts: 4 gearbox anomalies detected 3–6 weeks before failure (estimated cost saving: £1.2M avoided repair costs).
CfD reporting: Environment Agency commended automated reporting system in compliance audit.
HSE inspection: PTW system praised as best practice for offshore maintenance safety.
Turbine availability improvement: 98.2% → 99.1% (predictive maintenance reduces unplanned downtime).
“Four gearbox anomalies caught before failure — that's a £1.2M saving from a £103,000 investment. The predictive maintenance ML paid for itself in the first three months of operation. The Environment Agency commend on the automated CfD reporting was genuinely unexpected." — Asset Manager, UK Offshore Wind Operator (name withheld)”
Project Details
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