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The Uptime Wind Energy Podcast

Allen Hall, Rosemary Barnes, Yolanda Padron & Matthew Stead
The Uptime Wind Energy Podcast
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  • The Uptime Wind Energy Podcast

    Offshore Turbine Prices Jump, Data Centers Squeeze US Grids

    2026/05/12 | 21 mins.
    Rystad reports offshore turbine prices have jumped 45% since 2020, plus data centers squeeze US grids, Fortescue chases real zero by 2030, and GE Vernova battles Vineyard Wind in court.

    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!

    The Uptime Wind Energy Podcast, brought to you by StrikeTape, protecting thousands of wind turbines from lightning damage worldwide. Visit striketape.com. And now, your hosts. 

    Allen Hall 2025: Welcome to the Uptime Wind Energy Podcast. I’m your host, Allen Hall, and I’m here with Rosemary Barnes, who’s been busy in Australia up in Sydney at a energy conference.

    Rosemary, what happened this past week? 

    Rosemary Barnes: Oh, yeah. I’ve been up in Sydney for the Smart Energy Conference and Exhibition. It’s a big… I don’t know if it’s the biggest. I think they get about 12,000 people or something through the doors. So yeah, it’s, it’s one of the big, maybe the biggest, um, energy conference in Australia.

    It’s really focused on distributed energy households. So in the past, it was, like, nearly all solar, um, like rooftop solar. There used to be lots of installers that were there and, yeah, there’s heaps of solar [00:01:00] panels around in the exhibition hall. And over the last few years it’s been a mix of batteries and solar, and then now this year it was basically 99% batteries, 1% EV chargers, and almost not a solar panel to be seen.

    I didn’t actually spend that much time in the exhibition this year. I mostly was, um, attending sessions. Andrew Forrest from Fortescue headlined, and that was really good. I haven’t seen him speak live before. Y- you know, he, he told about all the, like, good plans that Fortescue’s doing to get to real zero by 2030.

    So he’s on a real rampage at the moment to try and get rid of the diesel rebate that we pay at the moment. We pay diesel users a, a, yeah, a fuel, fuel rebate. It was just cool to hear about y- you know, all of Fortescue’s plans, why they’ve got this big green grid that they’re building out in the Pilbara.

    Um, I really liked when he said, you know, it’s not, it’s not magic, it’s, um, it’s just, what did he say? Like, maths, physics, engineering, and [00:02:00]economics, and a bit of courageous leadership. That’s what you need to make a green, a green electricity grid. So I really like that the, you know, engineering was mentioned, was mentioned there.

    I did actually get the chance to ask him a question, too. Wanted to know, um, you know, like, Fortescue is, is really one of the most interesting things about the company is that they are using brand-new technologies or even not quite there yet technologies. I asked, uh, Andrew Forrest, I asked him, you know, like, how you make these bold, bold decisions, does it ever, you know, worry you that it’s not gonna work out?

    And I was assuming he would say, “It doesn’t worry me,” um, because, you know, he has that kind of brash, confident personality. So I, you know, my follow-up was, what, what steps do you take so that you aren’t worried by it? And he said it does worry him, and he s- stays awake every night worrying, worrying about if these technologies aren’t going to work.

    And that, uh, basically they try and have a really, really solid plan B that isn’t a [00:03:00] brand-new technology. So, um, you can, you know, infer from that, that if the– I mean, first of all, he said, “We don’t invest in the technology until they have demons- demonstrated with a good prototype that it’s likely to work.”

    Um, but I guess that, you know, assuming that they’ve ran into problems in the rollout of all of these Naberebo towers, that, um, they have a backup of some conventional towers. 

    Speaker 2: Yeah, uh, the, the Fortescue people, when we talked to them about, pfoof, probably six months ago, maybe a little bit longer, we were helping to build a farm out in Western Australia.

    It was a small team, much smaller than anything you would see in the US, and it does sort of align with the Australian approach to it, is that you don’t need a massive team of people to do these projects. You just need to know what you’re doing, and that was really remarkable. So e- I’m not surprised that Fortescue is continuing on in, in different aspects.

    It does seem like they’re pretty bold about their engineering approach and taking on massive projects that otherwise wouldn’t be [00:04:00] done and- 

    Rosemary Barnes: It, it’s also really cool to hear, uh, Andrew Forrest or anyone from Fortescue talk because they’re talking about things that they’ve done. You know, like we have so much when you’re at these, uh, events and, you know, everyone’s doing these inspiring talks, it’s always about, “Oh, this is the possibility for the future.”

    But Fortescue has actually, has actually done it. Yeah, there was a lot of, like, actual progress discussed at this conference. It wasn’t, “This is what we could do if we all joined hands and sang Kumbaya.” It wasn’t like that, you know? It’s like, this is what’s happening when the engineering is there, the economics are there, and the government isn’t standing in the way.

    Um, y- you know, you can make a lot of, a lot of progress. And you know what? Like now we’ve got so much distributed energy in Australia. It’s the rooftop solar that we’ve been building for, you know, 20 years by now. Um, and it’s the, the batteries especially. Like it is a- starting to have a noticeable impact on electricity prices, and co- coal and gas are both reducing in the grid.

    I think the last quarter of gas use in Australia was the lowest it’s [00:05:00] been since 1999. Like, um, yeah, so it’s, yeah, it’s, it, it’s dropping, you know? And so I think that that’s a really unique story for Australia is that households can actually really change the dial. 

    Speaker 2: Well, can I ask you about that? Because the data center issue is popping up again in the United States, and one of the things about data centers is they feel like you, you’re gonna need a good amount of batteries to support if the grid hops on or turns off, that they wanna be able to support this data center, so having a buffer and batteries would make a lot of sense.

    However, there’s not a lot of battery storage in the US at the minute versus a place like Australia where there’s a lot of it. Doesn’t it make a lot of sense to start putting data centers in Australia? I still don’t understand Why that hasn’t been done? Because electricity prices are cheaper, the land is available, the infrastructure’s there.

    It’s going [00:06:00] to be, you would think, easier to build in Australia than it would be in the United States. What’s the dilemma there? 

    Rosemary Barnes: I think certainly there are plenty of plans to build big data centers in Australia. Um, and now I’m gonna go, like, move a little bit outside my expertise, but I think that one of the issues is that at the moment, a lot of the data centers need to be quite close to where the work is happening.

    So I mean, you’re always gonna need data centers close to any big city where people are, are using the internet. Um, but aside from that, you know, like, the tech sector in the US is much bigger, so the people actually developing, um, you know, training, um, uh, yeah, training AI models, um, are more likely to be sitting in the US and, you know, need a large amount…

    Not all of their compute needs to happen nearby, but a fair chunk of it. And so I think that that is one reason why so far that’s where it is. Um, but it also doesn’t mean… I mean, there’s [00:07:00] plenty of smart, um smart computer types in Australia as well as the US, so you could start to see more companies moving, um, moving to where electricity is cheap.

    I think that– And grid connections are fast. 

    Speaker 2: The one thing you notice about using any of the AI platforms today is, like, there’s a built-in delay. Unlike when you’re on Amazon or any other s- active site, when you click, you want something to happen immediately. With AI, they, they build in a little wait process, which means you can have a data center anywhere, because you’re not expecting an instantaneous response from it.

    That means, in a sense, they’re setting it up to be a global industry. There is more of a delay now than there was a month ago. And I assume that has to do with usage, and they’re trying to manage all the data usage, right? So electricity is one of the limitations in the United States. That’s evident right now.

    The amount of data centers is a problem, so they’re trying to spread out the usage, and they are definitely… At least Anthropic is slowing it down. [00:08:00] I’d imagine all the other ones are doing the same thing. So it does open up the world to cheaper electricity. 

    Rosemary Barnes: There’s heaps of really interesting work happening in trying to get, um, AI and data centers to be better grid citizens, not probably primarily out of the goodness of their heart, but because of two things.

    One, grid connections are really slow, and so there’s a strong incentive that you can save, in some places, years off your development time if you can just bring in enough batteries, enough smart tech to make sure that you’re never going to, um, you know, add to peak, peak load in the grid, then you can- You know, change how things go.

    It’s also a matter of, like, social license as well, because at the moment it’s probably not too bad. People don’t realize too much. But if people’s electricity prices start going up because, you know, grid had to be built out because of da- data centers, they’re gonna start getting pissed as soon as they realize what that is.

    So I think [00:09:00] that, um, you know, these big companies, what do they call them? Hyperscalers. I think that they’re aware that that is gonna come and that that is a really strong incentive to do the right thing before they are made to do the right thing. Because, you know, like, if people got really upset then, um, you could easily have the rug pulled out from underneath a project that you thought was all set to go ahead, you know, could very easily be delayed indefinitely.

    I mean, we’ve definitely seen in the US that- 

    Speaker 2: Right. In 30 states in the US have already put prohibitions or limitations on data centers. That means there’s only 20 states left. Alaska is probably not a prime choice, Hawaii is not either, so you even have fewer. It does seem odd that when these limitations pop up that the discussion doesn’t move to other countries.

    Australia being an easy one, because electricity there is practically free. It seems like a smart move, but they haven’t made it yet. 

    Rosemary Barnes: Yeah, I mean, it’s not, it’s not [00:10:00] practically free in Australia yet, but I think that the, um, horizon, um, like the, you know, the outlook is it’s, it’s getting cheap. We… And we are finally seeing wholesale prices actually start to come down.

    But there’s this really awkward middle period though, you know, like, because, um, at the moment we’ve still got all of the… nearly all of the coal generation there, nearly all of the gas generation is there, and you need to have it there until you build out the other stuff. But it’s like prices drop and drop and drop when you’ve got this oversupply problem.

    But you’re gonna have the oversupply problem until you’ve got enough to start turning off, you know, gigawatt, two gigawatt, um, thermal generators. So it is a really weird middle, um, mid- mid-transition, I think is the term for it. You need planning. You know, you need… You actually do need… At some point you need a plan, and you need to execute it and expect that, like, every step you take is not gonna be better.

    Y- you know, like [00:11:00] some steps you’re gonna take that are gonna make it, um, economically worse for the short term. But, you know, like, if you’ve got a mountain range in between you and your destination, then yeah, like it’s, it’s really hard going for a while. But you’ve gotta climb that mountain if you wanna get to the other side and, um, you, and you, you can’t do that without a plan.

    Speaker 2: Well, what other place on the planet has or will have shortly unused gigawatts of old generation? I don’t think I know of one. It, it’s gonna be Australia So th-those gigawatt plants that were thermal plants that won’t be needed ’cause the price of electricity is so low, it does seem like a smart person would put a data center right next door to it.

    Rosemary Barnes: No, but we wanna turn ’em off. I 

    Speaker 2: don’t think you’re gonna be able to, Rosemary. I’m just saying, the world needs, uh, AI and it’s coming. 

    Rosemary Barnes: We’ll see. I think that, um, you know, I did get quite energized by the event, the, um, SSE event that I was at this week because it’s like there are a few things that [00:12:00] Australia, um, you know, really has, like, an opportunity to be world leaders in.

    And when you get to be the leader, then it means that the technologies that you invent to solve the problems that, you know, the early adopters have, you have the headstart on that. And, you know, as other countries follow in your footsteps, you have the opportunity to lead, lead those technologies. 

    Speaker 2: As wind energy professionals, staying informed is crucial, and let’s face it, difficult.

    That’s why “The Uptime Podcast” recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future. Whether you’re an industry veteran or new to wind, PES Wind has the high-quality content you need. Don’t miss out.

    Visit peswind.com today. So if you want to build an offshore wind farm in Europe right now, you had better be ready to pay. A new analysis from Rystad Energy shows that the turbine selling prices have jumped between 40% and 45% [00:13:00] since 2020. And here’s the thing, manufacturing costs only went up about 20% to 25% over the same period.

    The difference is pure pricing power. And with GE Vernova out of the new offshore order book and only Siemens Gamesa and Vestas left to supply Western markets, developers are facing a seller’s market in the most critical of components. Nacelles and blades are where the bottleneck hits hardest, and there is no quick fix in sight.

    So Rosemary, Siemens Gamesa and Vestas are leveraging the, the lack of com- competition, particularly from China at the moment, to gather market share and to raise prices, which I think everybody would agree if you’re on the engineering side of wind turbines, the prices needed to come up because there’s some work that needs to be done, and the engineering side has been pretty thin.

    To make these turbines more resilient, [00:14:00] you’re gonna need more engineering, it can be a little bit more on the manufacturing side. That takes money So prices had to come up 

    Rosemary Barnes: Yeah, I mean, I, I, I agree. It’s definitely n- not the case that everyone would agree. Anybody who has a spreadsheet and they’re trying to get the number, number right so that they can develop a new project is gonna say that it’s a bad thing, and it will also probably slow down development a little bit.

    Although, I guess if there was a supply constraint, then that was already a natural, um, handbrake, so maybe there’s no difference. But I do think that, um, you know, and I’ve said it a lot of times, like, you know, wind power reduced, it had a really steep cost reduction curve through the 20-teens, and I think that it was just artificial.

    You know, like it was driven by competition rather than true cost reductions in the technology. I think we undershot the price level that it needed to go for, and there just wasn’t enough money to do proper engineering, and, you know, w- we see that. Y- you know, you and I work in O&M, and we deal ev- every day with, with things where it’s like how did, [00:15:00] uh, how, how did they think that this technology was ready when they went and sold thousands of turbines with it?

    And I know that the answer is not that, um, engineers were lazy or stupid or just didn’t s- see the problems coming up. It was just too, too fast a pace of technology, um, rollout, like new technologies combined with just relentless focus on, on cost. You know, like all of my projects, it’s just like you just have to reduce cost and reduce it and reduce it and reduce it and, you know, to the point where you’re making changes that you don’t have time to fully check.

    Um, and, you know, then you have quality problems in the field. 

    Speaker 2: What’s the effect of an Indian manufacturing company in Europe on the offshore marketplace? If like an Adani or one of the other, Suzlon, one of the, one of the big manufacturers in India decides to make offshore wind turbines at scale, [00:16:00] wouldn’t that dramatically shift the marketplace in Europe?

    Rosemary Barnes: Yeah, I guess if you’ve got a new player, it’s always gonna shift things a bit. I don’t think it matters specifically that it’s Indian. Um, but a new player is gonna wanna be making sales and probably, you know, setting their price at the point that, that they need to, to, um, get those sales, maybe not initially worried so much about profits.

    If we were talking about Chinese manufacturers in Europe, and we have in the past, if we’re talking about that, then I think that that is a bit more relevant which, which country it is because China, you know, has just like essentially infinite money to put behind it and can keep on going long enough. You know, like they don’t need to make a, a profit every single year or every single five-year period even.

    They can think longer term. I, I, as far as I know, India is not quite the same as that, so I would expect it to be a bit more short-lived, but that’s always the risk that, you know, someone comes in and [00:17:00] undercuts, um, undercuts for long enough that it- causes the local local, uh, manufacturers to not be able to compete and shut down 

    Speaker 2: Well, just knowing some of the operators that were doing offshore wind projects and their desire to bring in a alternative to keep prices to the level that they could accept, with Mingyang being shut out at the minute, they’re gonna have to look somewhere else.

    So I think the only place they can find an alternative lower price competitor is gonna be India. Although the turbines aren’t at scale yet, I, I think you’ll see somebody make noise about it in the next six months on the operations side. 

    Rosemary Barnes: I think the European manufacturer is a probably better place to just scale up.

    Speaker 2: Well, let’s talk about GE Vernova for a minute, because the legal fight over America’s first large off-scale wind farm just got more complicated because Vineyard Wind reached commercial operations on April 24th, about a week or [00:18:00] two ago, and activated its purchase power agreement. Well, uh, now GE Vernova is using those very milestones against Vineyard Wind in court.

    GE Vernova filed an emergency motion arguing that the activation of those contracts undermines Vineyard Wind’s claims of irreparable harm. But Vineyard Wind’s attorney says the project is generating at less than half of its 806 megawatts capacity, and GE Vernova’s work is still needed to get it there.

    The next court hearing is set for this week. This little battle continues, and it’s– Although it seems fairly quiet, you don’t hear a lot of news reports about it in, uh, particularly the mainstream press, not too much about it, it– this has huge ramifications because as we talked about offshore wind over in Europe, if, if GE is truly getting out, and particularly if they’re in a fight with one of their largest purchasers of turbines, it’s gonna [00:19:00] disincentivize Europeans from even considering GE.

    In my opinion, I don’t know how you would think that GE would be one of the options. Although you would like to have three competitors bidding on every project in Europe, I think GE’s taken itself out of the marketplace because of this, this lawsuit. 

    Rosemary Barnes: Mm. You know what it reminds me of? It, um, it reminds me of the Justin Baldoni versus Blake Lively lawsuit that’s ongoing at the moment, where it’s just, like, mutually assured destruction.

    Speaker 2: But at least they settled, Rosemary. They’re, they’re not fighting anymore. 

    Rosemary Barnes: They settled, but they didn’t settle all aspects of it. 

    Speaker 2: The only reason I know about that is because you keep mentioning it. So when I see it pop up, I would normally just let it go. But I figured Rosemary’s focused on this, I should probably at least dabble in it briefly.

    That wraps up another episode of the Uptime Wind Energy podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you Reach out to us [00:20:00] 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 a review.

    It helps other wind energy professionals follow the show. For Rosie, I’m Allen Hall, and we’ll see you next week on the Uptime Wind Energy Podcast.
  • The Uptime Wind Energy Podcast

    Pentagon Stalls 30 GW US Wind, New York Defends Sunrise

    2026/05/11 | 2 mins.
    Allen covers the Pentagon stalling 165 US wind projects on private land, New York stepping in to defend Sunrise Wind, New Mexico approving a 212 MW wind farm, Octopus Energy’s €584M European buying spree, and Europe’s tightening offshore turbine market.

    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!

    Good morning, everyone. Here is a number for you. One hundred and sixty-five. That is how many onshore wind projects the Pentagon is now holding up across the United States. One hundred and sixty-five projects… on private land. Thirty gigawatts of generating capacity… frozen.

    The American Clean Power Association says the delays began last August. Canceled meetings. Applications no longer being processed. Then in April… letters went out. The Pentagon said it was reviewing how it evaluates the national security impact of energy projects. That review has no deadline. This is the same justification used against offshore wind… the one courts have already struck down. And the administration has already paid nearly two billion dollars in taxpayer money to buy out offshore leases… paying developers not to build. Thirty gigawatts… enough to power millions of American homes… sitting in a stack of unprocessed paperwork.

    But here is the thing about wind. It does not wait for permission.

    In a federal courtroom in Washington… New York State just stepped up to fight. Attorney General Letitia James filed a motion to intervene on behalf of Ørsted’s Sunrise Wind project. A Rhode Island nonprofit called Green Oceans sued the Bureau of Ocean Energy Management back in March… trying to overturn the project’s federal permits. New York is not having it.

    Sunrise Wind is a nine hundred and twenty-four megawatt project. Already under construction. Expected online next year. NYSERDA says the project carries eight hundred and seventy-five million dollars in economic benefits for the state… including nearly one hundred and seventy million dollars for the Town of Brookhaven alone. If it gets canceled… New York says those benefits vanish… tax credits expire… and replacement power would cost ratepayers far more. So the state is putting its name on the line… in open court.

    Meanwhile… out in New Mexico… a different kind of wind story. Ten thousand acres of state land in Torrance County just got approved for a new wind farm. Two hundred and twelve megawatts. Enough to power sixty thousand homes. It will become the second-largest wind farm on state land. And it is projected to send nearly ninety-nine million dollars to New Mexico public schools over the life of the lease.

    Now… across the Atlantic. Britain’s Octopus Energy just went on a shopping spree. Five hundred and eighty-four million euros… for seventeen onshore wind farms. Three hundred and twenty-one megawatts spread across France, Germany, and Poland. Ten farms in France. Four in Germany. Three in Poland. Combined… enough power for a quarter million European homes. Octopus now manages sixty-seven onshore wind farms across Europe. Zoisa North-Bond, Octopus Energy Generation’s CEO, said Europe has exceptional wind resources… but needs to move faster. Faster. There is that word again.

    And then there is the supply side of the equation. Rystad Energy reports that Europe’s offshore wind market is running into a structural supply constraint. With GE Vernova having paused new offshore wind orders… the Western turbine market is now essentially a two-player game. Siemens Gamesa and Vestas. Turbine selling prices are up forty to forty-five percent since twenty twenty. Manufacturing costs? Up only twenty to twenty-five percent. The OEMs are recovering their margins… and developers are absorbing the difference. That is the new reality for European offshore wind.

    So let us step back. In America… the federal government blocks thirty gigawatts of wind on private land. New York goes to court to protect a project already under construction. New Mexico approves a wind farm that will fund schools for a generation. In Europe… a British company spends more than half a billion euros on wind farms in three countries. And OEMs finally have the pricing power they have been chasing for years.

    The push… and the pull. Washington pulls back. But everywhere else… the industry pushes forward.

    And that’s the state of the wind industry for the 11th of May 2026.

    Join us for the Uptime Wind Energy Podcast tomorrow.
  • The Uptime Wind Energy Podcast

    CNC Onsite Cuts Repair Costs With Uptower Machining

    2026/05/07 | 20 mins.
    Søren Kellenberger, CEO of CNC Onsite, joins to discuss uptower yaw gear repairs, flat tower flanges, and replacing 1,000 blade root bushings across 26 turbines.

    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!

    Allen Hall 2025: Soren, welcome back to the podcast. 

    Søren Kellenberger: Thank you, Allen, and, uh, nice doing it, uh, face-to-face- Yes, it’s great … and not as a team, uh, call. Right. That’s 

    Allen Hall 2025: true. Yeah. You’ve been doing a good bit of traveling, and you’re the new head of CNC Onsite. 

    Søren Kellenberger: I am, yes. 

    Allen Hall 2025: So congratulations on that. 

    Søren Kellenberger: Thank you very much. 

    Allen Hall 2025: And all the exciting new things that CNC Onsite [00:01:00] is doing, plus all the things you have developed and are now out in the field implementing, the, the list goes on and on and on.

    I’m alwa- every time I talk to you, “Oh, we got a new-” Yeah … “machine to do something uptower.” So it’s all uptower, which is the, the beauty of CNC Onsite. You’re thinking about the operator and the cost to pull the blades off and do lifting the cell off and all those things. If we can do it uptower, we can save 30, 40, 50% of the cost of a repair.

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: That’s where CNC Onsite is just really killing it. You guys are doing great. Thank 

    Søren Kellenberger: you. Of course, we like what we do, but, uh, thank you. 

    Allen Hall 2025: Yeah. Yeah. Yeah, yeah. No, it’s good, it’s good. And, and so w- let’s talk about the things that I know about, and we’ll start there, and then we’ll go to all the new things you’re doing.

    So the one that I see a lot of operators asking about is yaw tooth. Yeah. 

    Søren Kellenberger: Uh, 

    Allen Hall 2025: deformations, broken teeth on the yaw gear. That’s a big problem. And when I talk to [00:02:00] technicians, and I have them texting me about this, like, “Oh, well, I just weld on the gear back on, weld the tooth back on.” That’s a short-term solution.

    That’s not gonna be long-term. The long-term solution is the CNC Onsite. Can you explain what you do to permanently fix these yaw gear problems? 

    Søren Kellenberger: Yeah. So what we do is actually we start by getting information about the, uh, original yaw ring, so the dimension of the teeth, and we get some load data. And, uh, then we start designing a replacement segment.

    Uh, so what we ac- the process is actually that we bring a CNC controlled machine uptower, mount it on the yaw ring, and then we mill away that worn area, uh, creating a small pocket. And then those, uh, segments that we have designed, they are prefabricated. We bring them up and mount them in, in that, uh, pocket and bring the- The yaw ring back to where it’s, you can say, original design, uh, [00:03:00] that way.

    Yeah 

    Allen Hall 2025: It’s better than the original design, ’cause you’re actually putting in better teeth than the, the manufacturer did originally. 

    Søren Kellenberger: True. Yeah, yeah. 

    Allen Hall 2025: So that happens, so you’re, you’re machining out those old teeth, broken teeth, putting the new set of teeth in th- and that all bolts in, and that’s it. That’s it.

    But the, the difficulty is getting the machinery uptower to do that. That’s where a lot of your, your technology comes from, is getting this very accurate, uh, well-defined machine uptower and doing very controlled grinding and milling. Yes. So can you explain what that system looks like? If I’m gonna grind off those yaw, broken yaw teeth, how big is that kit?

    Søren Kellenberger: It… Obviously, it depends a little bit on the turbine size. Sure, okay. Yeah. So, uh, it, so the, the newer five, six, uh, 10 megawatt turbines have larger teeth, so yeah, there you need a, a larger machine. 

    Allen Hall 2025: Okay. 

    Søren Kellenberger: But let’s say for, uh, Vestas three megawatt, the, the [00:04:00] complete machine weighs about 250 kilos. That’s it? So yeah.

    So it, it comes up in smaller components. We just use, uh, the, the internal crane in, in the nacelle, and, uh, then we can lift the components to the yaw ring, assemble the machine, and then we are basically good to go. So it take, takes less than a day to get everything up and, uh, get set and be ready to, to machine.

    Allen Hall 2025: So if you wanna fix a yaw gear problem, how long does it take from start to finish to get that done? 

    Søren Kellenberger: It typically, it takes one day to get everything up and get ready, and then per six teeth, which is a typical segment, it takes about a day to machine that. Okay. So, uh, let’s say you have, uh, somewhere between 10 and 15 teeth, it’s, uh, two to three segments.

    So we do that in a week. Um- 

    Allen Hall 2025: Wow … and- ‘Cause the alternative is call a crane, have them lifting the cell off. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: Take the yaw gear off, put a yaw gear on, if you can find a yaw gear. Yes. Put the nacelle back on. [00:05:00] Well, and I guess obviously the rotors are coming down too, so- Yeah. You’re talking about- Yes

    hundreds of thousands of dollars in downtime. Yeah. It’s a big ordeal. The CNC Onsite method is so much easier. 

    Søren Kellenberger: We will just put our equipment in the back of our truck- … and then, uh, we’ll, we are ready to mobilize in a few days. So yeah, we can significantly, uh, bring down the downtime and, and as you said, the crane cost is of course extremely high.

    And then you can add all the project management. You know, con- do I actually have my access roads, uh, still available? Right. Is the crane pad intact? And all of that stuff you need to organize. You can just forget about that and, uh- And 

    Allen Hall 2025: get it done … 

    Søren Kellenberger: get it done. Yeah. 

    Allen Hall 2025: Yeah. There’s, there’s a lot of owners, we, everybody knows who the machines are that have the, the, the yaw tooth problem.

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: So if you’re one of those owner operators, you better get ahold of CNC Onsite. Now, flanges on tower sections. It’s become a, a really critical issue. You hear a lot of, of [00:06:00] operators, OEMs talking about, “I’m putting together these tower sections and those flanges don’t really meet up quite right.” 

    Søren Kellenberger: Yep.

    Allen Hall 2025: “I’m creating uneven torque patterns, bolt pat- my bolt tightening is not quite right.” 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: And it never really seats right, so you have this mechanical, built-in mechanical problem. CNC Onsite is now fixing that so those flanges are actually really flat. Really flat, yes. ‘Cause that’s what you need. 

    Søren Kellenberger: Yeah.

    Allen Hall 2025: Yeah. They’re highly loaded. 

    Søren Kellenberger: If, if you want, uh… If you want your joints to be, uh, basically maintenance free, uh, we can, uh, achieve that with machining the flanges. And then, of course, you need to be in control with your bolt tightening process. Sure. But if you do those two things, you can have maintenance free bolted connections, and there’s so much money to be saved in the operations.

    Um, and of course, when you have these bolts that end up fatiguing, some of them don’t get caught in time and you end up ha- having a catastrophic failure on the turbine. Uh- We’ve [00:07:00] seen that … because you have that zipper effect. Once a bolt starts breaking, the neighboring ones take that extra load and it accelerates really quickly.

    Uh, yeah. Sure does. 

    Allen Hall 2025: Yeah. It’s a very serious situation, but it starts with this very simple solution which is just make the flange flat. 

    Søren Kellenberger: Yeah. But I think it’s some… a part of the issue is that those buying the towers aren’t necessarily responsible for the operational cost of maintaining that bolted connection.

    So they might save a little bit of money when they buy the tower sections with rougher tolerances, but you will spend the money 10 times in the operations. Uh, and, and that’s, I think that’s where some of the operations, uh, re- the, the, those responsible for operational costs should, uh, get a little bit more CapEx spend, uh- Oh, sure.

    Yeah. And, and then, uh, actually save a lot of money and, and reduce risk. Uh, it’s a huge, huge risk 

    Allen Hall 2025: It’s, it’s one of those lessons learned. You [00:08:00] don’t know that they should be flat. You shouldn’t know… You don’t know your flanges should be flat until you experience the problems, and then you want all your flanges flat from here on out.

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: But there’s only one way to do that really, and that’s to call CNC Onsite to come in and to make them flat. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: Because it’s a difficult thing to do. You really need to have the machining prowess and the tight tolerances that CNC Onsite’s gonna deliver in a tool that can actually be adapted to that tower ring and make those surfaces flat.

    It’s complicated. Exactly. 

    Søren Kellenberger: It is. Uh, but that is what we do every day, so, uh- Yes, I’ve noticed … yeah, so 

    Allen Hall 2025: so- You take on those challenges 

    Søren Kellenberger: So we are optimizing our machines to be not only fit for one-offs, but actually to go into a manufacturing, uh, process. So we have op- optimized our machines a lot with, uh, automatic alignment and, uh, stuff like that to, to really make that process, uh, easier.

    Because it has been considered that when you had to machine a flange, you weren’t in [00:09:00] control with your production, uh, processes. But I think that is, um, a bit of a misinterpretation. It’s, it’s a little bit like saying when I have a casted component, I cannot get a bearing fit, uh, in my cast process. That’s not because your cast process is wrong, there’s just some limitations to what you can do.

    Sure. And it’s basically the same here. Yes. And, and if you apply that con- uh, planned machining, you can gain some real benefits, uh, later on and the cost will, of course, drop dra- dramatically if you plan it, rather than call for one, uh, every time you have one that is out of tolerances and, and you can even narrow those tolerances down and get the benefits from maintenance-free bowler connections.

    Allen Hall 2025: Right. 

    Søren Kellenberger: Uh- 

    Allen Hall 2025: Right, ’cause you’re gonna pay for it for the next 20, 30 years. Yeah. Yeah. That’s absolutely right. Now, you’re getting involved in some of the safety aspects of operating a turbine. Uh, some of the pins and the lockouts on the low-speed gearboxes get a little worn over time, so the hole [00:10:00] you put the pin in gets worn.

    There’s a lot of loads on that and- Yeah … it starts to oblong out and eventually, if you’re trying to work on that gearbox, you’re trying to keep that and your technicians safe, which is what you’re doing- Yeah … that lockout pin doesn’t quite fit in the hole and it creates a little bit of a safety risk.

    Yeah. So now CNC on-site’s coming in and saying, “Hey, wait a minute. We can realign that, clean that hole up, make that safe again.” 

    Søren Kellenberger: Yes. 

    Allen Hall 2025: Explain what that looks like and what that process is to do that. 

    Søren Kellenberger: Yeah. So again, it’s the same thought like with the, with the O-ring, uh, that instead of bringing a component down and trying to fix it, we have designed some machinery we can bring uptower and then make that repair.

    So basically what we do is that, that we mill that hole a little bit larger and then we bring a bushing, uh, that we, uh, freeze into that hole- Okay … and to recreate that tight fit again with a, with a locking pin. Uh, so it’s, it’s not that [00:11:00] complicated, but you still need to know, of course, what you are doing.

    So finding the center of the original hole is one of the critical things because you want the center of the new ring to be in that same position- Sure … to make sure it fits with the pin 

    Allen Hall 2025: right. So- Right. You can’t just take a drill up there and try to clean out that hole. No, no. That is not the way to do that

    That, 

    Søren Kellenberger: that 

    Allen Hall 2025: won’t work. No, no . I’m sure it’s been tried, but- Yeah … no, you wanna have accurate mach- actual, uh, tight tolerance machinery up there to, to align that hole, drill it properly, put that insert back into that spot- Yeah … which is gonna be a hardened insert so it’ll last longer, right? 

    Søren Kellenberger: Yeah, yeah. 

    Allen Hall 2025: So once you do that, y- it’s a permanent fix to a otherwise nagging problem.

    That’s wonderful. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: So, th- again, that kit just goes right uptower, right up the, the lift, right up the cl- crane- Exactly … and bang, you’re done. Yeah. Okay. 

    Søren Kellenberger: So all our machines are designed to be able to be lifted with the internal crane- 

    Allen Hall 2025: Yeah … 

    Søren Kellenberger: of that specific nacelle. 

    Allen Hall 2025: Okay. 

    Søren Kellenberger: So obviously as the cells go bigger, they have more load cap- uh- Me too

    load capacity. Yeah. So for the smaller [00:12:00] turbines, the machines come in, in a bit smaller parts- Okay … so that we are sure we stay within that 250 or 500 kilogram or even whatever the limit is of, of that- Yeah, yeah, yeah … crane. And then we can, uh, reassemble everything uptower and still do tolerances within a few hundredths of a millimeter.

    And, and I think that is, that is really the core of, of what we do that, that we can achieve those workshop tolerances on site, um- 

    Allen Hall 2025: It’s crazy when I tell people that. I say, “Well, you know, CNC on-site, they can’t… I mean, those, those tolerances can’t be that tight.” And I say, “No, no, no, no. They’re talking about, you know, fractions of a millimeter,” which in, in American terms means fractions of a mil.

    Yeah. That’s 1/1000th of an inch. That’s the tolerance you’re doing. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: Uh, and that means quality at the end of the day. If you can machine things that tight, that means what you’re getting is gonna be right for that job. Yeah. It’s gonna fix that, fix that problem permanently, which is the goal. Yes. Don’t recreate the problem.

    Just fix it once and be done. Now, blade root [00:13:00] inserts, huge issue. CNC on-site has been developing tooling to drill out those existing inserts and, and put in new inserts, and you’re having success with that. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: That’s a… it seems like a complicated process, but you have owned that quite well. Talk about what that machinery looks like today, how you’re doing that process, and what have you learned from doing some, uh, field work.

    Søren Kellenberger: It’s, uh… we actually, we’ve, we’ve developed two different machines now. Okay. So we, we have, we have one that is, uh, fully CNC controlled, uh, when you need to do a lot of bushings. Yeah. Um, that one takes a bit more, uh, time to set up, but, but, uh, each drilling process is, is really fast. Uh, and then we have developed a semi-automatic machine as well, uh, which is a little bit easier to mount, mounts directly on the blade.

    And it’s, uh, really perfect when you only have smaller areas of the, the blade root where you don’t need to replace all bushings- But maybe typically it’s, it’s in the high load [00:14:00] area, which is 15 to 20 bushings maybe. Right. Something like that, right? Yes. 

    Allen Hall 2025: Yeah. 

    Søren Kellenberger: So, so there we can just mount it directly on the blade and, and then drill from, uh, from there.

    Um, and it works really well. We completed, uh, the first large scale, uh, commercial, uh, project, uh, together with our good friends from, uh, We4C. Uh- Right. 

    Allen Hall 2025: Yes. 

    Søren Kellenberger: And, uh, and now we are producing, uh, two more drilling machines- Oh … uh, for, for new upcoming, uh, projects also together with, uh, the guys from, from We4C.

    Allen Hall 2025: Wow. 

    Søren Kellenberger: So now it’s, it’s starting to, uh, to pick up. Um, it’s been a relatively long process, and I guess no one really wants to be the first mover on, uh, on new technology, right? Right. So we’ve had a lot of questions. Oh, that… And that looks interesting, but how many, uh, turbines, uh, or how many blades have you repaired?

    And it’s been up until now, well, it’s only tested in the lab. Uh, but now we have the first, uh, large scale commercial, uh, project with, uh, 26, uh, turbines, [00:15:00] uh, repaired and, uh, and 1,000 bushings, uh, that were replaced, uh, across those, uh, 26 turbines. So- 

    Allen Hall 2025: Wow … 

    Søren Kellenberger: so I guess that is now large scale. Uh- 

    Allen Hall 2025: That’s large scale.

    Yeah. Yeah. I would consider 1,000 a large scale test. Yeah. Yeah. Yes. And that brings all those turbines back to life. 

    Søren Kellenberger: Absolutely. They are up running, uh, full power again, so, uh, that is, uh- 

    Allen Hall 2025: That’s huge … 

    Søren Kellenberger: really nice. 

    Allen Hall 2025: For the operator, I’m sure they love that. 

    Søren Kellenberger: Yeah. And, and of course, uh, there’s, there’s been a lot of discussions about blades and, uh, bla- the, the waste, uh, issue you have on, on worn- Oh

    out blades. Sure. So by being able to fix them instead of replacing them, not only is the, the cost for fixing a blade a lot lower than buying new ones, uh, but, but also from a, an environmental perspective. The not having to scrap them and create that waste is, uh, is also a nice, uh, 

    Allen Hall 2025: thing. Yeah, it’s one of the things that pops up more recently about replacing blades, and I think the [00:16:00] industry and the operators are pushing back on that.

    Uh, because a lot of times the OEM wants to replace a blade, it’s just easier for them to do. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: But the reality is, is that yeah, you’re creating this additional problem. What are you gonna do with the disposal of this blade? Do we really need to do that? Is it so far gone that I can’t recover it? I think a lot of times, especially with fiberglass blades- Yeah

    you can bring them back to life. 

    Søren Kellenberger: Yeah. 

    Allen Hall 2025: Just with a little bit of engineering, uh, prowess and some good machinery- Yeah. You can, you can make magic happen, and that’s what CNC OnSite is doing. So that, that’s really amazing that, uh, you’re starting to get more adoption of that on, on the blade root inserts. I know across the United States there’s all kinds of issues, and you’re proving it out.

    I think the adoption rate in America and all over is gonna really step up. Now, uh, you always have some cool new project, sort of top secret. What are you working on that the world needs to know about? 

    Søren Kellenberger: Yeah. W- I mean, we are constantly, uh, [00:17:00]expanding our, our line of services. Uh, so- Sure … so we are just out there trying to listen to what kind of issues do we see in, in the industry- 

    Allen Hall 2025: Yeah

    Søren Kellenberger: and how can that be fixed, uh, uptower. So, so some of the, the latest, uh, innovations we’ve been doing is a, a new machine on, um… to, to do shaft milling. Uh, so that c- that can be on generator shafts, uh, for instance. There are some machines out there, but we’ve decided to go, uh, against CNC control- Okay

    because it gives us a lot of, uh, opportunities both on, on speed, uh, of the process. It’s a more safe, uh, way to, uh, to do it. 

    Allen Hall 2025: Sure. 

    Søren Kellenberger: And we can actually also do different, uh, shapes on the shaft, so, so we can do more advanced, uh, repairs. Okay. We, we don’t need to stick to a certain diameter all the way. Now we can, we can mo- make grooves, and we can do, uh- Really?

    all sort of sorts of stuff, uh- Oh … along that process because it’s CNC controlled. 

    Allen Hall 2025: Oh, sure. Okay. Um, and- Boy, okay. That makes a lot of sense. So you can actually take a, a, a basic, [00:18:00] basic, basic design of a shaft and make modifications to it- Yeah … to extend the lifetime and make it work better. 

    Søren Kellenberger: Yes. So typically we would mill down, uh, the shaft and- Sure

    install a sleeve- Sure … to recreate a, a bearing fit, for instance. 

    Allen Hall 2025: Right. Yeah. 

    Søren Kellenberger: But we have possibilities to, uh, to create, um, grooves or anything that would do a stress relief or whatever you need, lubrication, or if you, if you want to do something, uh, afterwards, we, we can do that with, uh, with our machines.

    Uh- Yeah. So yeah, we, we have some new machines for, for hollow shaft, uh, machining, so we can do stuff, uh, inside the main shaft, for instance. We can do stuff on the, the outside, as I mentioned on, on the generator shaft, but that could be on the gearbox as well. So- Sure … sometimes we see issues on the main shaft to, to gearbox, uh, connection.

    Allen Hall 2025: Yeah. 

    Søren Kellenberger: We are able to, to fix, uh, those, uh, things uptower. Wow. And, uh, so yeah, lot of new, uh, stuff being, uh, developed. 

    Allen Hall 2025: That’s, that’s awesome. 

    Søren Kellenberger: [00:19:00] Yeah. 

    Allen Hall 2025: And I, I know you guys are busy, but- If somebody wants to get ahold of CNC Onsite and get work done this year, they better be making phone calls to you- … quickly. So I, I know your order book is filling up and you’re, you’re having to devote crews and machinery and time.

    Yeah. How do people get ahold of you and get on that contact list and can start working the process? 

    Søren Kellenberger: I would say go into, uh, cnconsite.dk and, uh, there we have all our, our contacts. Uh, so just reach out. There’s a, yeah, formula you can, uh, fill in, uh, or you can find our direct contacts in our webpage, and, uh, then we can start looking at it.

    So we are quite busy, but we are always- Yeah … open for, uh, discussions and, uh, yeah. That, 

    Allen Hall 2025: that’s a problem with being successful, is you’re just always busy running around trying to take care of problems, and that’s the thing, is that everybody I talk to that’s used CNC Onsite loves it- 

    Søren Kellenberger: Yeah … 

    Allen Hall 2025: and loves the process and loves the work you do.

    So there’s gonna be a lot more phone calls and a lot more orders coming your way, and that’s- Yeah … that’s awesome. [00:20:00] Soren- Yeah … it’s so good to see you again and it’s so good to see you in person. Yeah. And congratulations on the promotion and everything that’s happening at CNC Onsite. 

    Søren Kellenberger: Thank you, Allen. It’s a pleasure.
  • The Uptime Wind Energy Podcast

    Vineyard Wind’s $69.50 PPA, Two Offshore Lease Exits

    2026/05/05 | 33 mins.
    Rosemary reports back on her visit to multiple Chinese renewable energy companies, Vineyard Wind activates a $69.50/MWh PPA with Massachusetts utilities, and Bronze Age jewelry halts a German wind project.

    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!

    [00:00:00] 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 2025: Welcome to the Uptime Wind Energy Podcast. I’m your host, Allen Hall. I’m here with Yolanda Padron in Austin, Texas, who is back from the massive wedding event. Everybody’s super happy about that, and Rosemary Barnes had her own adventures. She just got back from China and Rosemary. You visited a a lot of different places inside of China.

    Saw some cool factories. What all happened? 

    Rosemary Barnes: Yeah, it was really cool. I went over for an influencer event. So if you are maybe, you know, in the middle of your career, not, not particularly attractive or anything you might have thought influencer was ruled out for you as a career. No one, no one needs engineering influencers in their [00:01:00] forties.

    It’s incorrect. It turns out that’s, that’s where, that’s where I, I found myself. It was pretty cool. I, I did get the red carpet rolled out for me. Many gifts. I had to buy a second bag to bring home the gifts, and when I say I had to buy a second bag, I had to mention. Oh, I have so many gifts, I’m gonna need another bag.

    And then there was a new bag presented to me about half an hour later. But, so yeah, what did I do? I got to, um, as I was over there for a Sun Grow event. Huge, huge event. They, um, it’s for, it’s for their staff a lot, but it’s also, they also bring over partners. They also bring over international experts to talk about topics that are relevant to them.

    Yeah. They gave everybody factory tours in, um, yeah, in, in shifts. Um, I got to see a module assembly factory, so where they take cells, which are like, I don’t know, the size of a small cereal box, um, and assemble them into a whole module. Then the warehouse, warehouse was [00:02:00] gigantic. It, um, was, yeah, 1.8 gigawatt hours worth of cells that couldn’t hold in that one building.

    They’re totally obsessed with fire safety there in everything related to batterie, like in the design of the product, but also in, in the warehouse. And they do, yeah, fire drills all the, all the time. Some of them quite big and impressive. Um, I saw inverter manufacturing facility that was really cool.

    Heaps of robots. Sw incredibly fast. Saw a test facility. 

    Allen Hall 2025: So was most of the manufacturing, robotics, or humans? 

    Rosemary Barnes: Yeah. So at the factory it was like anything that needed to be done really fast or with really good quality was done by robots. So they had, um, you know, pick and place machines putting in. Um, you know, components in the circuit board, like just insane, insane rate.

    I’m sure it’s quite, quite normal, but, um, just very fast. Everything lined up in a row. Most of their quality control is done by robots. Um, so it does well it’s done by ai, I should say. [00:03:00] Taking photos of, of things and then, um, AI’s interpreting that. Repairs, I think were done by humans. There were humans doing, um, like custom components as well.

    Like not every product is exactly the same. So the custom stuff was done by humans. 

    Allen H: So that’s the Sun Grove facility, right? You, but you went to a couple of different places within China? 

    Rosemary Barnes: Yeah, I went to another, a factory, a solar panel, a factory, um, from Longie. That was really cool too. I got to see a bit more probably of the, um, interesting, interesting stuff there, like, uh, a bit more.

    Um, yeah, I don’t, I dunno, processes that aren’t, aren’t so obvious. Not just assembly, but um, you know, like printing on, um, bus bars and, you know, all of the different connections and yeah, it was a bit, a bit more to it in what I saw. Um, so that was, but it, it’s the same, you know, as humans are only involved when it’s a little bit out of the.

    Norm or, um, where they’re doing repairs, actual actually re [00:04:00]repairing. You know, the robots or the AI is identifying which components don’t meet the standard and then they’ll go somewhere where a human will come and, um, fix them. 

    Allen H: Being the engineer there. Did you notice where the robots are made? Was everything made in China that was inside the factory or were they bringing in outside?

    Technology. 

    Rosemary Barnes: I didn’t think to look for that, but I would assume that it was Chinese made, also 

    Allen H: all built in country 

    Rosemary Barnes: 20 years ago that wouldn’t have been the case, but I think that China has had a long, a long time to, to learn that. Again, it’s not like, it’s not, it’s not rocket science. These are, these are pick and place machines, you know, like I remember working on a project very early in my career, so.

    Literally 20 years ago, um, I was working with pick and place machines. It’s the same, it’s the same thing. Um, some of them are bigger ’cause they’re, you know, hauling whole, um, battery packs around. It’s just the, um, the way that it’s set up, but then also the scale that they can achieve. You just, you can’t make things that cheap if you don’t have the [00:05:00] scale to utilize everything.

    A hundred percent. Like I said, wind turbine towers is a really good example. ’cause anyone, any steel fabricating 

    Allen H: shop 

    Rosemary Barnes: could make a wind turbine tower. Right? They, they could, they could do that. You know, the Chinese, um, wind turbine tower factories have the exact right machine. They don’t have a welder that they also use for welding bits of bridges or whatever.

    Uh, they have the one that does the exact kind of world that they need, um, for the tower. They, you know, they do that precisely. Robotically, uh, exactly the same. And, you know, a, a tower section comes on, they weld it, it moves off to the next thing, and then a new one comes on. They’re not trying to move things around to then do another weld in the same machine.

    You know, like they’re, um, but the exact right. Super expensive machine for the job costs a whole bunch to set up a factory. And then you need to be making multiple towers every single day out of that factory to be able to recoup on your cost. And so that is [00:06:00] the. The, um, bar that is just incredibly hard slash impossible for, um, other countries to clear.

    Allen H: Can I ask you about that? Because I was watching a YouTube video about Tesla early on Tesla, where they wanted to bring in a lot of robotics to make vehicles and that they felt like that was the wrong thing to do. In fact, they, they, they kinda locked robots in and realized that this is not the right way to do it.

    We need to change the whole process. It was a big deal to kind of pull those. Specialized piece of equipment, robots out and to put something else in its place in that they learned, you know, the first time, instead of deciding on a process, putting it in place and then trying to turn it on, see if it works, was to sort of gradually do it.

    But don’t bolt anything down. Don’t lock it in place such that it doesn’t feel like it’s permanent. So you engineer can think about removing it if it’s not working. But it sounds like this is sort of the opposite approach of. A highly specialized [00:07:00] machine set in place permanently to produce. Infinite amounts of this particular product, does that then restrict future changes and what they can make or, I, I, how do they see that?

    Did, did you talk about that? Because I think that’s one of an interesting approaches. 

    Rosemary Barnes: I didn’t actually get as much chances I would’ve liked to speak to engineers. Um, I was talking mostly to salespeople and installers. Um, so they know a lot, but I couldn’t, um, like in the factory tours, I was asking questions.

    Um. That kind of question and, and they could answer all, all that. Um, but outside of that, and I couldn’t record in the factory obviously. Um, but I did, I did take notes, but what I would say is that they would have a separate facility where they would be working out the details of new products and new manufacturing processes and testing them out thoroughly before they went and, you know, um, installed everything correctly.

    But what I do hear is that, you know, especially with solar power. Maybe to [00:08:00] batteries to a lesser extent. You, you know, you like, you have these kind of waves of technology. Um, so you know, like everyone’s making whatever certain type of solar cell and then five years later, um, there’s a new more efficient configuration and everybody’s making that.

    And I know that there are a lot of factories that kind of get scrapped. Um, and the way that China’s set up their, like, you know, their economy around all this sort of thing is set up is that it’s not that, like every company doesn’t succeed. Right. They SGO was a big exception because they’ve been going since 1997, I think it was.

    It was started by a professor quid his job and hired a room across the, across the road from his old university and, you know, built his first inverter and, um, you know, ’cause he, he could see that. Uh, the grid was gonna have to change to incorporate all of the solar power that was coming, which to be honest, in 1997, that was like pretty, pretty farsighted.

    That was not obvious to me when I started working in solar in mid two thousands. And it was not obvious to me that this was a winner. 

    Allen H: Well, has sun grow evolved then quite a bit? ’cause if you’re [00:09:00] saying that they’ve minimized the cost to produce any of their products by the use of robotics, they have been through an evolutionary process.

    You didn’t see any of the previous generations of. Factories. You, you were just seeing the most modern factory that that’s actually producing parts today. So is that a, is that a, is that just a cost mindset that’s going on in China? Like, we’re just gonna produce the lowest cost thing as fast as we can, or is it a market penetration approach?

    What are, what were, were the engineers in management saying about that? 

    Rosemary Barnes: I think there’s a few different aspects to that, like within China. So Sun Grow is the big company with a long track record and they’re not making the cheapest product out of China. So I think that they are still trying to make the cheapest product, but they’re not thinking about it just in the purchase price.

    Right. They’re thinking more in terms of the long, long term. You know, they’ve been around for 30 years and probably expect to be around for another 30 years. They don’t wanna be having [00:10:00] recalls of their products and you know, like having to, um. Installers in particular are probably working with them because they know that they won’t have to go back and do rework and the support is good and all that sort of thing.

    So they’re spending so much money on testing and you know, just getting everything exactly right. But I don’t think that that’s the only way that China is doing it. There’s, you know, dozens, probably hundreds of companies. Um. Doing similar stuff between Yeah, like solar panels and associated stuff like inverters and, and batteries.

    So many companies and all of them won’t succeed. You know, sun Girls Facility in, I was in her and it’s huge, you know, it’s like a, a medium sized country town. Just their, um, their campus there, they’re not, they’re not scrapping that and moving to a new site, you know, they’re gonna be. Rejiggering and I would expect that, you know, like everything’s set up exactly the way it needs to be, but it’s not like gigantic machines.[00:11:00]

    It’s not like setting up a wind turbine blade factory where it’s hard if you designed it for 40 meter blades, you can’t suddenly start making 120 meter blades. Like it’s, they will be able to be sliding machines in and out as they need to. Um, so I, I, yeah, I guess that it’s some, some flexibility. But not at the cost of making the product correctly.

    Allen H: Did you see wind turbines while you were in China? 

    Rosemary Barnes: I, the only winter I saw, I actually, I saw, because I caught the train from Shanghai, I actually caught the fast train from Shanghai to, which is about, it depends which one you get between like an hour 40 or three hours if it stops everywhere. Um, and I did see a couple of wind turbines on the way there, out the window, just randomly like a wind turbine in the middle of a, a town.

    Um, so that was a bit, a bit interesting. But then in the plane, on the way back, the plane from Shanghai to Hong Kong, I, at the window I saw a cooling tower of some sort. So either like a, yeah, some kind of thermal [00:12:00] power plant. And then. Around all around, well, wind turbines, so onshore wind turbines. So I don’t know.

    Um, yeah, I, I don’t know the story behind that, but it’s also not a particularly windy area, right? Like most of the wind in China is, um, to the west where, uh, I wasn’t 

    Allen H: as wind energy professionals, staying informed is crucial, and let’s face it. That’s why the Uptime podcast recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future.

    Whether you’re an industry veteran or new to wind, PES Wind has the high quality content you need. Don’t miss out. Visit PS win.com today. So there are two stories out of the US at the minute that really paint a picture of the industry. It was just being pulled in opposite directions. The Department of Interior announced agreements to terminate two more.

    Offshore wind leases, uh, [00:13:00] Bluepoint wind and Golden State wind have agreed to walk away from their projects. Global Infrastructure Partners, which is part of BlackRock, will invest up to $765 million in a liquified natural gas facility instead of developing blue point wind. Ah. And Golden State Wind will recover approximately $120 million in lease fees after redirecting investment to oil and gas projects along the Gulf Coast, and both companies say they will not pursue further offshore wind development in the United States.

    Well, we’ll see how that plays out. Right? Meanwhile. In Massachusetts Vineyard Wind, which has been fighting with GE Renova recently has activated its long awaited power purchase agreement with three utilities. The contract set a fixed electricity price of drum roll please. [00:14:00] $69 and 50 cents per megawatt hour for the first year and a two and a half percent annual increase.

    Uh, state officials say the agreements will save rate payers $1.4 billion over 20 years. So $69 and 50 cents per megawatt hour is a really low PPA price for offshore wind. A lot of the New York projects that. Renegotiated we’re somewhere in the realm of 120 to $130 a megawatt hour, and there’s been a lot of discussion in Congress about the, the usefulness of offshore wind.

    It’s intermittent blahdi, blahdi, blah. Uh, but the, the big driver is what costs too much. In fact, it doesn’t cost too much. And because it’s consistent, particularly in the wintertime, uh, electricity prices in Massachusetts in the surrounding area are really high. ’cause of the demand and ’cause how cold it is that this offshore wind project, vineyard wind would be a huge rate saving.

    And [00:15:00] actually the math works out the math. Math everybody. Do you think this is, when we go back five years from now, look back at this. This vineyard wind project really makes sense for Massachusetts. 

    Yolanda Padron: I think it really makes sense for Massachusetts. I’m really interested to know what the asset managers are thinking on the vineyard wind side, um, and if they’re scared at all to take this on.

    I mean, it’s great and I’m sure they can absolutely deliver. Like generation I don’t think should be an issue. Um. I just don’t know. It’s, it sounds like they’re leaving a lot of money on the table. 

    Allen H: I would say so, yeah. But remember, the vineyard win was one of the early, uh, agreements made when things were, this is pre Ukraine war, pre Iran conflict on a lot of other, a lot of other things.

    It was pre, so I remember at the time when this was going on that. P. PA prices were higher than obviously a lot of other [00:16:00] things. Onshore solar, onshore wind, it would, offshore is always more expensive, but I don’t remember $69 popping up anywhere in any filing that I remember seeing. So even if they had said $69 five years ago, I think that would’ve still been like, wow, that’s pretty good for an offshore wind project.

    And now it looks fantastic for the state of Massachusetts 

    Yolanda Padron: because I know that there’s sometimes, and we’ve talked about this in the past, right? There are sometimes projects where, you know, you think you, you’ve got a really good price and you’re really excited about it, and then it goes into operation and then like a couple years down the road, prices increase quite a bit and it’s not the worst thing in the world.

    But you do just kind of think a little bit like, I wish I could. Renegotiate this or you know, just to get, to get our team a bit of a better deal or to get a bit more money in operations and everything. 

    Allen H: Does this play into Vineyard wind claiming $850 [00:17:00] million in dispute with GE Renova that at $69 PPA, there’s not a lot of profit at the end of this and need to get the money out of GE Renova right now, and maybe why GE Renova wants to get out of this because they realize.

    The conflict that is coming that they need to separate the, the themselves from this project. It’s, it’s very, as an asset manager, Yoland, as you have done this in the past, would you be concerned about the viability of the project going forward, or is all the upfront costs. Pretty much done in that operationally year to year.

    It’s, it’s not that big of a deal. 

    Yolanda Padron: As an asset manager taking this on, I’d probably have started preparation on this project a lot earlier than other of my projects like I do. I know that usually there’s, you know, we’ve talked about the different teams, right, throughout the stages of the project until it goes into operations, [00:18:00] but.

    And usually you don’t have a lot of time to prepare to, to make sure all of your i’s are dotted and t’s are crossed, um, by the time you take the project and operations from a commercial standpoint. But this project, I think would absolutely, like you, you would need to make sure that a lot of the, of the things that you’re, that might be issues for some of your projects like aren’t issues for this project.

    Just to make sure at least the first few years you can. You can avoid a lot of, a lot of turmoil that the pricing and the disputes and the technical issues are gonna cause you, because I feel like it’s just, there’s, there’s just so many things that just keep this side, just keeps on getting hit, you know?

    Allen H: Well, I, I guess the question is from my side, Yolanda, is obviously inflation, when this project started was pretty consistent, like one point half, 2%. It was very flat for a long time. And interest rates, if you remember when this project started, were very, very low. Almost [00:19:00] nonexistent, some interest rates.

    Now that’s hugely different. How does a contract get set up where a vineyard can’t raise prices? It would just seem to me like you would have to tie some of the price increase to whatever the inflation rate is for the country, maybe even locally, so that if there were a, a war in Ukraine or some conflict in the Middle East.

    That you, you would at least be able to, to generate some revenue out of this project because at some point it becomes untenable, right? You just can’t afford to operate it anymore. And, 

    Yolanda Padron: and I think, um, I, I haven’t, I obviously haven’t read the, the contracts themselves, but I know that there’s sometimes there, it’s pretty common for a PPA to have some sort of step up year by year.

    And it’s usually, it can be tied to, um, the CPI for. Like the, the change in CPI for the year to year. So you’re [00:20:00] absolutely like, right, like maybe, I mean, hopefully they’re, they’re not just tied to the fixed 69 bucks per megawatt hour. Um, but, but yeah, to, to your point like that, that price increase could, could really save them.

    Now that we’re, we’re talking the, the increase in, in inflation right now and foreseeable future, 

    Allen H: if you think about what electricity rates are up in the northeast. I think I was paying 30 cents a kilowatt hour, which is 300. Does that sound right? $300 a megawatt hour. Delivered at the house, something like that.

    Right? So 

    Yolanda Padron: prices in the northeast are crazy to me, 

    Allen H: right? They’re like double what they are in North Carolina. Yeah.

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    Yolanda Padron: you millions.

    Allen H: Well, sometimes building a wind farm turns out more than expected construction workers at a 19 turbine wind project in lower Saxony Germany under Earth. What experts call the largest Bronze age Amber Horde ever found? The region, the very first scoop of an excavator brought up bronze and amber artifacts that stopped construction and brought archeologists back to the site.

    Uh, the hoard has been dated between [00:22:00] 1500 and 1300 DCE and is believed to have belonged to at least three. Status women possibly buried as a religious offering. Now as we push further and further across Germany with wind turbines and solar panels for, for that matter, uh, we’re coming across older sites, uh, older pieces of ground that haven’t been touched in a long time and we’re, we’re gonna find more and more, uh, historically significant things buried in the soil.

    What is the obligation? Of the constructor of this project and maybe across Europe. I, I would assume in the United States too, if we came across something that old and America’s just not that old to, to have anything of, of that kind of, um, maybe value or historically significant. What is the process here?

    Rosemary Barnes: I assume that they’ve gotta stop, stop work. Um, yeah, that’s my, my understanding and I don’t think, do you have [00:23:00] grand designs in America? 

    Allen H: I don’t know what that is. Yes. 

    Rosemary Barnes: So missing out by not having that chat. It’s a TV show about people who are building houses or doing, um, ambitious renovations, and it just, it follows, it follows them.

    You can learn a lot about project management or. The consequences if you decide that you don’t need to, project management isn’t a thing that you need to do. Um, anyway. I’m sure that in some of those ones I’ve seen they have had work stop because in their excavation they found a, um, yeah, some, some kind of relic, um, from the, from the past.

    So based on that very well-credentialed experience that I have, I can confidently say that they would be stopping stopping work on that site. I mean, it’s so bad, bad for the developer, I guess, but it’s cool, right? That they’re, you know, uncovering, uh, new archeology and we can learn more about, you know, people that lived thousands of years ago.

    Allen H: It, it does seem [00:24:00] like, obviously. Do push into places where humans have lived for thousands of years. We’re going to stumble across these things. Does that mean from a project standpoint, there’s, there’s some sort of financial consequence, like does the lower Saxony government contribute to the wind turbine fund to to pay the workers for a while?

    ’cause it seems like if they’re gonna do an archeological dig. That that’s gonna take months at a minimum, may, maybe not, but it usually, having watched these things go on it, it’s. It’s long. 

    Rosemary Barnes: But wouldn’t that be something that you’d have insurance for? 

    Allen H: Oh, maybe that’s it. 

    Rosemary Barnes: You know, it seems to me like an insurable, an insurable thing, like not so hard to, it would’ve affected plenty of other, like any project that involves excavation in Europe would come with a risk of, um, finding Yeah.

    An archeological find. And having work stopped, I would assume. 

    Allen H: Yolanda, how does that work in the United States do, is there some insurance policy towards finding [00:25:00] a. Ancient burial ground and what happens to your project? 

    Yolanda Padron: I don’t know. I, um, the most I’ve heard has been, it’s just talking to like the government and like the local government and making sure that you have all your permits in place and making sure, you know, you might need to, to have certain studies so you know, you might not have to get rid of the whole wind farm or remove the hole wind farm, but at least a section.

    Of it has to be displaced from what you originally had thought. I don’t know. I know it happens a lot in Mexico where you get a lot of changes to construction plans because you find historical artifacts or obviously not everybody does this, but like. Tales of construction workers who will like, find, they’re so jaded from finding historical artifacts that they just kind of like take and then dump them to the next plot over to not deal with it right now.

    Not that it’s anything ethical, uh, or done by everybody, [00:26:00] uh, but it’s, but, but it’s a common occurrence, a relatively common occurrence. 

    Allen H: You would think it where a lot of wind turbines are in the United States, which is mostly Texas and kind of that. Midwest, uh, wind corridor that they would’ve stumbled across something somewhere.

    But I did just a quick search. I really hadn’t found anything that there wasn’t like a Native American burial ground or something of that sort, which they previously knew. For the most part. It’s, so, it’s rare that, that you find something significant besides, well, maybe used some woolly mammoths tusks or something of that sort.

    Uh, in the Midwest, it’s, it’s, so, it’s an odd thing, but is there a. A finder’s fee? Like do does the wind company get to take some of the proceeds of, of this? Trove of jewelry. 

    Rosemary Barnes: I, I would be highly surprised. 

    Allen H: Well, how does that work then? Rosemary? 

    Rosemary Barnes: I’d be highly surprised if that’s the case in Europe. I bet it would happen like that in America.

    Allen H: Sounds like pirate bounty in a sense. 

    Rosemary Barnes: In, in Australia it wouldn’t be like that because [00:27:00]you, when you own land, you don’t actually. You, you own the right to do things from surface level and above, basically. I don’t know how excavation works. So you don’t generally have a a right to anything you find like that?

    I mean, you shouldn’t either. It’s not, it’s not yours. It’s a, it belongs to the, I don’t know, the people that, that were buried. When you then to the, the land, like, I guess. The government in some way. I mean, in Australia it’s, um, like we don’t have so many archeological fines that you would find from digging.

    I mean, it’s not that there’s none, but there’s not so many like that. But it is pretty common that, you know, there are special trees, um, you know, some old trees that predate, uh, white people arriving in Australia. And, um, you know, that have been used for, you know, like it might have a, a shield that’s been, um.

    Carved out of it. Or, uh, hunting. Hunting things, ceremonial things, baskets, canoes, canoe like things, stuff like that. They call ’em a scar [00:28:00] tree ’cause they would cut it out of a living, living tree. And you know, so when you see a tree with those scars and that’s got, um, cultural significance. There’s also, you know, just trees that were, um.

    That that was significant for cultural reasons and so you wouldn’t be able to cut down those trees if you were building any, doing any kind of development in Australia and a wind farm would be no different. I know that they are, there are guidelines for, if you do come across any kind of thing like that or you find any anything of cultural significance, then you have to report it and hopefully you don’t just move it onto the neighboring property.

    Allen H: I know one of the things about watching, um. Some crazy Canadian shows is that. Uh, you have to have a Treasure Hunter’s license in Canada. So if you’re involved in that process, like you can’t dig, you can’t shovel things, only certain people can shovel. ’cause if they were to find something of value, you.

    You’ll get taxed on it. So there’s just a lot of rules [00:29:00] about it. Even in Canada, 

    Rosemary Barnes: if I was an indigenous Australian and you know, some Europe person of European descent came and found some artifacts, uh, aboriginal. Artifacts. I would be pissed if they just took it and sold it. Like that’s just clearly inappropriate right.

    To, to do that. So you, I don’t think it should be a free for all. If you find artifacts of cultural significance and you just, it’s, you find its keepers that, that doesn’t sound right to me at all. 

    Allen H: Can we talk about King Charles II’s visit to the United States for a brief moment?

    Uh, he is a really good ambassador, just like, uh, the queen was forever. He’s, he does take it very seriously and the way that he interacted with the US delegation was remarkable at times in, in terms of knowing how to deal with somebody that there’s a war going on right now. So there’s a lot [00:30:00] happening in the United States that, uh, not only could it be.

    Uh, respecting both sides of the UK and the United States’ position in a, in a number of different areas, but at the same time being humorous, trying to build bridges. Uh, king Charles, uh, had the scotch whiskey tariffs removed just by negotiating with President Trump, and sometimes that’s what it takes.

    It’s a little bit of, uh. Being a good ambassador. 

    Allen H: Yeah. The very polished you would expect that. Right? But this is the first visit of. The king to the United States, I believe. ’cause he, he’s been obviously as a prince many, many, many times to the United States. [00:31:00]But this time as, as a, the representative of the country, the former representative or head of the country, which was unique.

    I think he did a really good job. And I wish he, they would’ve talked about offshore wind. Maybe he could’ve calmed down the administration on offshore wind. 

    Rosemary Barnes: I bet that’s one of the, the goals. I mean, that’s an industry that’s important to. So 

    Allen H: I wonder if that happened actually. ’cause that’s not gonna be reported in, in the news, but how the UK is going on its own way in terms of electrification and I guarantee offshore wind had to come up it.

    Although I have been not seen any article about it, I, I find it hard to believe that King Charles being the environmentalist that he is, and a proponent of offshore wind for a long time. Didn’t bring it up and try to mend some fences. 

    Rosemary Barnes: Maybe he’s playing the long game though. I mean, Trump is pretty, he’s transactional, but he also, you know, he has people that he really likes and you know, will act in their interests.

    So maybe it’s enough to just be [00:32:00] really liked by Trump, and then that’s the smartest way you can go about it.

    Allen H: Did you see the gift that King Charles presented to, uh, the US this past week?

    It was a be from, uh, world War II submarine, which was the British, I dunno what the British called their submarines, but it was, the name of it was Trump. So they had the bell from. The submarine when it had been commissioned and they, they gave that to the United States, or give to the president. It goes to the United States.

    The president doesn’t get to keep those things, but it was such a smart, it’s a great president. It’s such a smart gift, and somebody had to think about it and the king had to deliver it in a way that got rid of all the noise between the United States and the uk. Brought it back to, Hey, we have a lot in common [00:33:00] here.

    We shouldn’t be bickering as much as we are. And I thought that was a really smart, tactful, sensible way to try to men some fences. That was really good. That wraps up another episode of the Uptime Wind Energy Podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn.

    Don’t forget to subscribe, so you never miss this episode. And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show. For Rosie and Yolanda, I’m Allen Hall and we with. See you’re here next week on the Uptime Wind Energy Podcast.
  • The Uptime Wind Energy Podcast

    CIP Buys Ørsted EU Onshore Wind

    2026/05/04 | 1 mins.
    Allen covers CIP’s €1.44 billion buyout of Ørsted’s European onshore wind, the new Perigus Energy name, and Vestas paying €506 million for its stake in the firm.

    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!

    In Denmark, there is an old expression. “What goes around comes around.” The founders of Copenhagen Infrastructure Partners — known in the industry simply as CIP — know exactly what that means.

    Back in 2012, four executives were fired from DONG Energy, the Danish energy giant that would later rebrand itself as Ørsted. Their offense? Their paychecks were considered too large. So large that DONG Energy’s own CEO was forced out as well. Four men shown the door were. A year later, a woman joined them from that same company. The Danish press had a name for these five. They called them “the golden birds.”

    With six billion Danish krone from the pension fund PensionDanmark, they launched what is now one of the world’s largest clean energy fund managers.

    In 2020, turbine maker Vestas purchased a 25 percent stake in CIP. The deal included a performance-based earn-out arrangement. This week, the books revealed the size of that windfall.

    The five partners have now collected a combined 1.8 billion Danish krone — roughly 240 million euros. Vestas expects to make one final payment of 71 million euros this year. Including interest, Vestas will have paid 506 million euros for its stake in CIP. Not a bad return for a group of people who were shown the door.

    And. This week, CIP completed its acquisition of Ørsted’s European onshore wind business for 1.44 billion euros. They renamed it Perigus Energy. The new company holds 826 megawatts of wind and solar capacity, operating in Ireland, Germany, the United Kingdom, and Spain.

    Let that circle close. The executives fired from DONG Energy — the company that became Ørsted — just bought Ørsted’s business.

    Meanwhile, CIP’s annual report for 2025 tells the story of a company in transition. Profit for the year came in at 561 million Danish krone, down from 683 million the year before. The employee count fell by nearly a fifth, to 441 people. And yet, their CI Five fund closed this year at 12.3 billion euros — the largest greenfield renewable infrastructure fund ever raised. Looking ahead, CIP expects profit of 600 to 800 million Danish krone in 2026 as new fund closings take shape.

    So the picture this week is this. The men and women once considered overpaid, at a company that no longer carries the same name, have built the world’s largest greenfield renewable energy fund. And they now own a piece of the legacy that fired them.

    The golden birds are still flying.

    And that is the wind energy news for the fourth of May, 2026. Join us for more on the Uptime Wind Energy Podcast.

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About The Uptime Wind Energy Podcast

Uptime is a renewable energy podcast focused on wind energy and energy storage technologies. Experts Allen Hall, Rosemary Barnes, Yolanda Padron, and Matthew Stead break down the latest research, tech, and policy.
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