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  • The Uptime Wind Energy Podcast

    PowerCurve Recovers India AEP, Silent Edge Cuts Noise

    2026/07/02 | 26 mins.
    Nicholas Gaudern, CTO at PowerCurve, joins to discuss India AEP gains, DragonScale VGs, and Silent Edge noise reduction.

    Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

    Welcome to Uptime Spotlight, shining light on wind energy’s brightest innovators. This is the progress powering tomorrow

    Allen Hall: Nicholas, welcome back to the podcast. 

    Nicholas Gaudern: Thanks, Allen. Great to be back. 

    Allen Hall: So there’s a lot going on at Power Curve, and I saw some news online about Power Curve in India. 

    Nicholas Gaudern: Yes. 

    Allen Hall: Which is a new development. 

    Nicholas Gaudern: Yeah, so we’ve been working in India for, for some years now, and we have, uh, more than 100 turbines out there with our equipment on, primarily vortex generators so far.

    And what we’re seeing in India is some of the highest AEP gains we’ve ever recorded with our vortex generators And I think a lot of this is being driven by the fact that in certain parts of India, there’s some very unique, uh, environmental conditions, climatic conditions, and there’s parts of the year, like the dry season up in [00:01:00] the north of India, where you’re getting this very sticky dirt accumulating on the blades.

    And it’s really quite dramatic when you see the photographs, but that means that the blades are actually starting to, to stall, have flow separation on them. 

    Allen Hall: I’ve seen pictures of that. Yeah. I was really shocked at the time, uh, ’cause I didn’t know it was just kind of a black, gooey- Yeah … kind of tar-like substance- Yeah, yeah

    on the blades, and, uh, it, it was only on there a limited time. As soon as the monsoons come through and the rains hit, it would wash, eventually wash it off. Yes. But while it’s there, you could see the airflow over the blade surfaces. You, you could definitely see separation happening really early on those blades.

    Dramatic. 

    Nicholas Gaudern: Yeah, absolutely, and I think the, um… Like you say, it’s not all year. No. But it doesn’t have to be all year to have a huge impact on, on how many, you know, megawatt hours you’re getting out the other end. So there’s a few months of the year where this problem is particularly severe, maybe sort of December through to February, something like that.

    And what we’re finding is that when you see, uh, the power curves for these [00:02:00] turbines, some of them aren’t even hitting rated power. They’re not able to hit rated power because there’s so much flow separation on the blades. 

    Allen Hall: Wow. 

    Nicholas Gaudern: And that, I mean, just imagine that. You’ve got a two megawatt turbine, for example.

    Maybe it doesn’t cast- get past 1.5 megawatts for this, uh, time of the year. I mean, that’s crazy. 

    Allen Hall: Does the turbine try to adjust itself when that happens? Because the pictures I s- have seen indicates, like, the turbine is pitching the blades to, ’cause it knows- It can- … 

    Nicholas Gaudern: what the wind 

    Allen Hall: speed is- I mean, yeah … and it knows what it should be putting out, and it’s not putting that out.

    Nicholas Gaudern: It’s very turbine specific, kind of controller logic specific, but what we see is even the turbines that try to do something, they’re very limited in how much pitch authority they have from the controller. They might be able to just do a little bit, a degree. Okay. Two degrees. You know, very, very small pitch adjustments.

    And when you have this kind of dirt on the leading edges, a degree of pitch ain’t gonna save you really. Um- N- 

    Allen Hall: no. And I think that’s what we’re seeing. And it’s not gonna get that power back. No, no. 

    Nicholas Gaudern: No. 

    Allen Hall: But does it add extra load onto the blade structurally over [00:03:00] time when you do that? 

    Nicholas Gaudern: In terms of the pitching, or- 

    Allen Hall: Yeah, in terms of the pitching, where you’re trying to be more aggressive on the angle of attack to get the power out of the turbine.

    Potentially. And the winds are still pretty strong, you just, the blades are inefficient. 

    Nicholas Gaudern: I think it’s one of those things where there’s, there’s so many interconnected items with the dirt and the controller and the structure. It’s actually pretty difficult, I think, to say with confidence how much life impact you would have from that.

    But what I would say is the more that you might end up trying to pitch, if that’s what’s going on on some machines, that obviously puts wear on the pitch bearings themselves. But yeah, I think at the moment we’re kind of at the beginning of really trying to understand how some of these turbines do deal with this phenomenon.

    But what we’re trying to do is get to a point where the turbine doesn’t really have to deal with it. Because if you fix the problem at the source, which is stop the flow separating, then the controller doesn’t really have to, to worry. It doesn’t have to try to, to fix it itself. 

    Allen Hall: Yeah. That makes a lot more sense.

    Just the number of images I’ve seen over the last couple years from India- 

    Nicholas Gaudern: [00:04:00] Yep … 

    Allen Hall: you realize how difficult it is to operate a wind turbine there. 

    Nicholas Gaudern: So even when we, um, have this issue for a few months that we’re resolving with the VGs, we can still be seeing over the whole year more than 5% increases in annual energy production.

    Because those months are really important. Um ‘

    Allen Hall: Cause that’s when they need the 

    Nicholas Gaudern: power. Yeah, yeah, yeah. Exactly. For sure. And this is primarily coming from the vortex generators towards the tips of the blades. So that’s where you’re having this, uh, heavy contamination issue, and that’s where all the power would be produced.

    So kind of the outer third of a blade is 50, maybe 60% of the power production of a turbine, maybe closer to 50. So that means that if you have a problem out there, it’s, it’s a big problem in terms of your annual energy production. So- 

    Allen Hall: Right … 

    Nicholas Gaudern: the VGs are, what they’re doing is they are, they’re injecting energy back into the flow.

    Allen Hall: Redirecting the flow, in a 

    Nicholas Gaudern: sense. So, so basically you have all this contamination on the leading edge. It’s generating more turbulence. The flow isn’t able to retain, uh, remain attached [00:05:00] across the entire chord length. So the VGs are putting energy back into the flow and allowing it to remain attached all the way to, uh, to the trailing edge.

    Allen Hall: So even with the blades are dirty- 

    Nicholas Gaudern: Yes … 

    Allen Hall: you get that power out- Exactly … put, that you really desire or- 

    Nicholas Gaudern: Yeah … 

    Allen Hall: are paying for. Yeah. You, you paid a lot of money for that turbine- Yeah, exactly … you need to get the power out of it. 

    Nicholas Gaudern: Yeah. 

    Allen Hall: And- 

    Nicholas Gaudern: So of course, you know, that suggests that if you had a, a super clean blade, you went and pressure washed it, uh, you would get, uh, an increase in power as well, and that’s true.

    You, you- That’s true … you will do. But that’s a one-time thing. Um, so- And 

    Allen Hall: it’s expensive to do- Yeah … and time-consuming. 

    Nicholas Gaudern: Exactly. Maybe a few days later, the dirt’s back. So- Sure … you know, it’s not really a sustainable thing for you to be going out washing these blades the whole time. And washing the blades may not be great for the surface of the blade either.

    So, you know, a VG is just sat there the whole time. It doesn’t matter if it’s dirt, bugs, erosion, frost, it’ll recover those losses that, that you’re seeing. 

    Allen Hall: Do the VG installations in a situation like that, [00:06:00] the actual location differ because of the contaminants that are present and the kind of, uh, leading edge effects that you’re seeing?

    Do you design it for that environment? Or- Yeah … is every- Oh, you do. So- Yeah, we 

    Nicholas Gaudern: do. I mean, typ- typically our, our VG arrays are turbine model specific. But in India, we’re finding we’re actually having to be more site specific as well. Oh, 

    Allen Hall: wow. 

    Nicholas Gaudern: Because some of this contamination is so severe, we’ve seen that we need to design the VG layout a little bit differently to make sure that we’re giving enough, uh, energy recovery potential when you have these really severe, uh, situations.

    Allen Hall: Are you using the AeroVista tool to do that? How do you, how do you quantify the contamination that’s happened on the leading edge at a particular moment or roughly on scale a- and then try to model that? That just seems like a difficult computation. 

    Nicholas Gaudern: It is. And, um, you know, we’re, we’re getting better all the time.

    AeroVista is definitely part of that. So AeroVista’s primary function really is to look at, um- [00:07:00] AEP losses due to structural damages, things like erosion. But actually, erosion behaves very similar to dirt when it comes to, like- It, right … aerodynamic behavior. Yeah. So we can actually use kind of the AeroVista engine to help us understand what is the loss from different levels of contamination.

    So we can add contamination levels into AeroVista, as well as, uh, erosion. And we can start to look at, well, what happens if the blade looks like this? What if it looks like this? And then this gets combined with our computational fluid dynamics, our CFD models that we’re running, three-dimensional, two-dimensional.

    We sometimes do some aeroelastic modeling as well. So we basically have a big toolbox, and like with any engineering problem, it’s about picking the best tool for the job. So we just go in, and we have all these great tools, and we, we put them together in a workflow that allows us to design the, the best solution for each site that we look at.

    Allen Hall: And it’s not India-specific in terms of leading-edge contamination. No. I’ve seen pictures from the US, Brazil, um, [00:08:00] Australia, a number of places where there’s just bugs. Yeah. Right? Those, especially in places where there’s large bugs- Yes. … you kind of get this splatter effect going on. Yeah. And you can have a really contaminated blade surface.

    In the US, in the middle of the US, you’ll have grasshopper season, and- 

    Nicholas Gaudern: Yeah, absolutely … 

    Allen Hall: tho- those grasshoppers are big, and they splatter. And they leave a disaster. We’ve seen 

    Nicholas Gaudern: that in, uh, in the Midwest, for sure. Oh, yeah. Some really, really severe contamination from bugs. 

    Allen Hall: And you, you don’t think about, as an engineer or a site supervisor, that- All right.

    This sort of, uh, grasshopper season that happens is affecting my AEP, but 100% it is. And that stuff is gooey, so if you ever drive through the Midwest in the summertime- … you run through, uh, any kind of insect swarm and try to get it off your vehicle. Yeah. It takes some scrubbing. 

    Nicholas Gaudern: Yeah. It re- it really does.

    And imagine when you’ve gotta go up there for, like, 100-meter diameter rotor. 

    Allen Hall: Right. ‘

    Nicholas Gaudern: Cause that’s quite a challenge. So I think, yeah, they have all these challenges, uh, in terms of environmental conditions, and a lot of people consider aerodynamic [00:09:00] behavior blades quite binary. Either the blade is clean or the blade is dir- Or it’s dirty

    or it’s dirty. Right. But it’s this entire spectrum. It’s everything in between, and I think that is kind of a little bit of a different way of thinking about the problem. And then it makes the argument around why to put VGs there kind of, uh, easy to, to answer, because the blade is never really truly clean.

    Allen Hall: No. I… Unless it’s right after a rainstorm- Yeah … I rarely see clean blades. Okay, so the … If VGs are going on, are you using the DragonScale VGs to solve some of the India problems, some of the contamination problems? 

    Nicholas Gaudern: So DragonScale’s not in India yet. That’s something that we’re looking at. So we, um, we got all the tooling finished for DragonScale some months ago now, and we’re shipping DragonScale kits.

    Uh- Oh, wow. Okay … not, not to India yet, but they are out in, in the field, and we’re gonna be having some more out just in the next couple of weeks, actually, which is quite exciting. We’re doing our first project, um, in Canada. 

    Allen Hall: Oh. 

    Nicholas Gaudern: So we’re starting to kinda come across the, the pond with the VGs now, [00:10:00] with the DragonScale VGs.

    Allen Hall: So the DragonScales, uh, uh, uh, thank you for bringing a, a sample here today, but the, the DragonScales are really interesting in terms of just the way the airfoil shapes are and how they’re s- kinda stacked and layered- Yeah … and there’s different depths to them, heights to them, to get the flow back where you want it to.

    Yeah. And it, I guess it depends on where you are on the blade. If you’re near the root, they’re gonna look something like this. Exactly. Yep. If you’re getting near the tip, they’re 

    Nicholas Gaudern: much 

    Allen Hall: smaller- Yeah, we have some smaller ones. Yep … scale, scale of this. So- This then, the Dragon Scales do require a little bit of computational knowledge of what’s going on- Yep

    with the blade. And as you say, they- You just can’t willy-nilly stick 

    Nicholas Gaudern: them on … they’re, they’re quite different. You know, they’re quite different from a standard triangle of VG. 

    Allen Hall: Right. 

    Nicholas Gaudern: And, you know, there’s lots of ways that you can create a vortex aerodynamically. And triangles- Sure … create a vortex, sure, but they, they really create one through a process of separation.

    Yeah. You have a flow hitting this, this plate that’s angled to the flow. It’s rolling over the top, and it’s tripping into a, into a vortex. But that’s quite a draggy way [00:11:00] of- It is … creating a vortex. Yes. Um, so VGs work. We’ve seen that. You know, we have more than 2,000 turbines now with VGs, so we, we know they work.

    Yeah. But Dragon Scale, the whole idea is not that we … This is still a VG. It’s still creating a vortex. Sure. But it’s doing it in a much more efficient manner, so we get the same lift recovery benefits, lift boosting benefits, but at a much lower drag. So we have a better drag ratio. ‘Cause it’s the drag, right?

    Allen Hall: It’s the drag. The little triangular- 

    Nicholas Gaudern: Yeah … 

    Allen Hall: vortex generators are draggy. 

    Nicholas Gaudern: So anything you stick on a blade, it, it has a drag. It has a parasitic drag component. Um, they have a huge benefit that outweighs that. That’s why we put them on. 

    Allen Hall: Yeah. 

    Nicholas Gaudern: But of course, you can always do better. And I think here we really try to take inspiration from, from lots of the aerodynamic developments we’ve seen over the past decades in aviation and motorsport and, and these other disciplines.

    Allen Hall: Right. I always say these look like a Formula One 

    Nicholas Gaudern: add-on. Yeah, yeah. Exactly. A bigger blade. Or maybe some front slats of a aircraft or some, uh, gas turbine cascading elements- Oh, sure. 

    Allen Hall: Yeah … 

    Nicholas Gaudern: these 

    Allen Hall: kind of things. Yeah. 

    Nicholas Gaudern: Yeah. 

    Allen Hall: Gas turbine people would easily recognize this. Yeah, [00:12:00] I 

    Nicholas Gaudern: think so. 

    Allen Hall: Uh, so the, the Dragon Scales then in terms of, uh, the location of them on the blade, would it differ than the triangular VGs in terms of generic location?

    A, a 

    Nicholas Gaudern: little bit, but broadly it’s the same because- Okay … you know, ultimately the fundamental physics of what we’re trying to do hasn’t changed. 

    Allen Hall: Sure. 

    Nicholas Gaudern: Um, so we’re kind of, we’re addressing the same areas of the blade. But the Dragon Scale gives us a bit more flexibility. We can have these three fin versions that create a very powerful vortex, so we find those down in the root, ’cause that’s where we just want as much lift as possible.

    Right. 

    Allen Hall: Yeah. Right. 

    Nicholas Gaudern: Uh, but out at the tip we actually have a two fin variant. Oh. Because there we’re, we’re more focused on L over D. We wanna maximize our lift-to-drag ratio. 

    Allen Hall: Sure. 

    Nicholas Gaudern: Because that’s where the drag really hurts you, out towards the tip. 

    Allen Hall: So are they in a strip form then? Yes. Very similar to the triangular VGs?

    Nicholas Gaudern: Yeah, exactly. So the, the smaller ones on the strip, just because they’re only, like, five millimeters high. 

    Allen Hall: Yeah. They wanna 

    Nicholas Gaudern: see more- So otherwise it’s, it’s kind of watchmaking if they’re individual- … little pieces, uh, going down on the blade. O- 

    Allen Hall: okay. Yeah. Well, that’s fascinating. All right. Uh, I wanna talk about [00:13:00] Silent Edge before I, I lose you today.

    The Silent Edge product has been out in the field- Mm-hmm … and there has been some noise testing done, which I always think is very interesting because I’ve- Yeah … I’ve watched videos from, mostly from DTU, explaining how they do this, where they got the microphones around. And like- Yes … wow, that’s a really complicated test to go pull off.

    But you just got through a series of these- 

    Nicholas Gaudern: We did … 

    Allen Hall: noise tests with Silent Edge. And you have the results back. 

    Nicholas Gaudern: We do, yeah. I mean, it was a really exciting, um, test program, and we were partnered together with, uh, Statkraft, who very kindly lent us a few of their wind turbines up in Sweden. Uh, and we are working with the Danish Technical University, DTU Wind, to help with the measurements and actually figure out what’s going out on the turbine.

    So this was a project that we were, um, able to secure some funding from, from the Danish, uh, EUDP. So that’s the Energi [00:14:00] Teknologisk Udviklings- og Demonstrationsprogram. 

    Allen Hall: Right. 

    Nicholas Gaudern: Yeah. Nothing to do with the EU. It’s a very, it’s a Danish thing. Danish, yeah. But there is EU in the name. Right. Um, so they supported this project with Statkraft and DTU, and what we found is that when we put a Silent Edge on a, uh, it was like a two, two and a half megawatt machine, it had no serrations before.

    Okay. 

    Allen Hall: So we measured- So just a out of the factory blade. 

    Nicholas Gaudern: Yeah, exactly, and it was in good condition. It had had a recent repair campaign, so the blade was in, in good shape. And then what we did, uh, or what DTU did, is they went out and they measured the noise of this turbine according to the IEC standard.

    So there’s an IEC standard on how you should measure noise and what microphones to use and how to post-process it, and then we installed the Silent Edge serrations. And firstly, before we’d even done any measurements, we had people out at site, and they, they live out there. They’re the technicians. They see these- Okay

    turbines every day, and they went, “What, what have you, what have you done to, to this turbine?” Because it sounded so different. It sounded much [00:15:00]quieter. The, the quality of the sound was very different, and they just, they just stepped out the car and went, “Wow.” “This is, this is really impressive.” Um- 

    Allen Hall: So what, give me a description of what the sound is.

    I know generally, when you come with a standard blade, it has that kind of shoop, shoop- 

    Nicholas Gaudern: Yeah, exactly … shoop. It basically just really brings down that perceived loudness of the sound, so it’s just a m- it’s a much quieter sound, and we’re also taking out quite a lot of low frequency component. 

    Allen Hall: Okay. 

    Nicholas Gaudern: That’s what- These serrations are really targeting the lower frequencies, so kind of around the kilohertz and, and under.

    Allen Hall: Mm. 

    Nicholas Gaudern: That’s where these things are really starting to bring down the, um, the decibels. 

    Allen Hall: This- So, okay. So Silent Edge is, uh, sort of a unique design, or is a unique design i- in terms of the- What you see on the typical trailing edge, which are a bunch of triangles or dino tails, right? Yes, dino tails. Yes, 

    Nicholas Gaudern: yeah.

    Allen Hall: Dino tails is, was the generic term for years, and they looked like dino tails, so, so it’s a good description- Yeah … of them. But these more, look more like a cathedral in 

    Nicholas Gaudern: a sense. Yeah, these, these are quite different though. So we have kind of this iron-shaped, uh, tooth fundamentally, [00:16:00] but we have three different tooth sizes, uh, and they’re asymmetric.

    Allen Hall: Mm. 

    Nicholas Gaudern: And I would love to come here and tell you that we know exactly how this works. Um, but I can’t unfortunately, and, and that’s just how it is sometimes with engineering. We cannot simulate this in the detail required to really understand exactly why each geometric feature does what it does. And if someone claims they can do that, then, then I may be a bit suspicious.

    Or, or I’d really like to talk to them, one of the two. Um, but that means that to develop this kind of product successfully, you have to go to the wind tunnel. Okay. Because the simulation is so demanding. So we go to the wind tunnel. We spent a lot of time in the Paul Ricard wind tunnel at DTU, so we can measure aerodynamics and acoustics at the same time And we went with lots of components and 3D prints, and we iterated through design paths, and we came up with this, I think it’s a really wonderful shape we’ve ended up with.

    And it was proven out in the field because the final result was we reduced the overall sound [00:17:00] pressure level of the turbine by five decibels. And that is- Whoa … that is huge. 

    Allen Hall: That’s a lot. 

    Nicholas Gaudern: So in terms of, like, perceived, uh, loudness of the sound, that’s like a 30% reduction. So this is why the, the technicians who st- stepped out the car heard such a difference, because it’s a massive reduction in, in what the turbine produces.

    So 

    Allen Hall: you’re lowering the decibels coming off the, the trailing edge. Yeah. But also moving around the frequencies so it’s a little less- 

    Nicholas Gaudern: Yeah, so a lot of that- … uh- That… So the- … 

    Allen Hall: noticeable 

    Nicholas Gaudern: also … the five decibels, that’s, that’s this OASP, or we call it overall sound pressure level. This is an integration of all of the reductions we see across the frequency spectrum.

    Oh, 

    Allen Hall: okay. 

    Nicholas Gaudern: All right. So we’re getting more reduction at lower frequencies. Right. Good. There’s also some high frequencies. But the lower frequencies matter more. So what we do when we’re doing acoustic measurement is we A-weight, we, we weight the, the noise because it relates to how the human ear perceives sound.

    Allen Hall: Sure. 

    Nicholas Gaudern: So it matters more to you, the one [00:18:00] kilohertz frequency than the 20 kilz- kilohertz frequency. 

    Allen Hall: Yeah. Can’t hear 

    Nicholas Gaudern: 20 kilohertz. E- exactly. So that’s right at the upper end. So we weight the results, and this is part of the ICE standard, to understand how the human ear perceives the sound. 

    Allen Hall: Oh, wow. Okay. 

    Nicholas Gaudern: Um, and this is where we get our, our five decibels 

    Allen Hall: from.

    So this, this was really an iterative process then- Yeah … in the DT laboratory. Yeah. Ooh, wow. I didn’t realize that. Mm-mm. I, I figured you had gotten relatively close by computational methods and then- We- … honed it a little bit … 

    Nicholas Gaudern: we, we come sort of computate… We do a lot of computation around the angle of the serrations, because the angle of the serration is really critical for, uh, lift generation and loads.

    Allen Hall: So when you’re speaking of angle, you’re talking about- E- 

    Nicholas Gaudern: exactly … this angle back here at the- You can see that angle there. Okay. 

    Allen Hall: Yeah, 

    Nicholas Gaudern: yeah. Because you don’t want to put a serration on a turbine and add 20% to the lift of the blade. Right. No. Because- 

    Allen Hall: That’s not- … 

    Nicholas Gaudern: lift means loads. Yeah. 

    Allen Hall: You know? Right. You’re adding load.

    Nicholas Gaudern: So you have to be very careful about how you design these products to make sure that you’re not gonna add extra load to the turbine. And, and on the flip side, you also don’t wanna reduce lift significantly, which then [00:19:00] there’ll be less power produced. So it’s a bit of a balancing act, and this is where the computation comes in.

    We do a lot of CFD on these to make sure that we’re, we’re handling the loads correctly. 

    Allen Hall: And how important is the material choice- Yeah … in terms of the noise quieting? Is there a little bit to it about, well, one, durability. Yeah. You, you want to put them on once and leave them forever, so there’s a lot of interactions between the air and these parts that are gonna flex and bend, and you got- I think there’s, you know-

    20 years of 

    Nicholas Gaudern: doing 

    Allen Hall: that … 

    Nicholas Gaudern: the, you’ve, you’ve s- you’ve hit the, hit the nail on the head there. The durability is critical. Yeah. It doesn’t matter if you put these products on the blade, and they perform beautifully for six months and then fall off or, or snap or whatever. 

    Allen Hall: Right. 

    Nicholas Gaudern: So no, we, we make these products out of the same material as our VGs, and this is a material, uh, it’s an ASA, uh, plastic.

    And we’ve had these out in the, in the field for a long time now, so we know- It’s- … this, this is great. 

    Allen Hall: It’s ex- it’s kind of a flexible material. 

    Nicholas Gaudern: Yeah, there’s 

    Allen Hall: a little b- It’s stiff but flexible. 

    Nicholas Gaudern: Yeah, exactly. There’s a bit of give in there- Yeah … uh, which is important, but it’s very impact-resistant. Uh, it doesn’t really suffer much in terms of [00:20:00] UV aging, which is obviously critical- Oh, wow.

    Yeah … when you’re, when you’re- Very critical, yes … out in the field. Yes. So yeah, we’re, um, we’re really happy with the material choice because we know from all our other campaigns with VGs that they last. It doesn’t matter whether it’s sun, rain, ice, snow. These products can survive out in the field for 20 years.

    Allen Hall: That’s one of the things I’ve noticed, uh, looking at a lot o- of blade photos with OEM trailing edge serrations. That the little triangles on the back edges break off. 

    Nicholas Gaudern: Yeah. And I think- There’s 

    Allen Hall: a lot of them. I was shocked on 

    Nicholas Gaudern: some sites. One thing you have to be very careful as well is, is lifting and handling as well.

    Oh. So, you know, sometimes if these products are installed in the factory, then how do you safely transport that blade and lift that blade? 

    Allen Hall: You really can’t. 

    Nicholas Gaudern: So in some ways it’d be better if you put them on at site, but obviously I, I know that’s not always possible. No. So we’re typically acting, um, as, you know, a retrofit.

    Mm-hmm. So in that sense we, we minimize a lot of that risk of the, the transport and handling that the OEMs may have to deal with. 

    Allen Hall: So [00:21:00] what’s next for Power Curve? What’s h- happening this summer? 

    Nicholas Gaudern: So we’re gonna be really pushing to get Silent Edge and Dragon Scale out in the field more. Yeah. Um, Dragon Scale is, is really exciting, and we’re gonna get our, our first, uh, turbines in different countries equipped with these products.

    And Silent Edge, uh, we’re currently putting some of the finishing touches on the, um, the tooling, the injection molding tooling. So the part we have in front of us, this is actually one that we had in the wind tunnel. So this one here is a 3D print. A very nice 3D print. Oh, yeah, it’s- Uh, it’s had vapor smoothing on it, so the surface- It is really smooth

    is, is super nice. And you can put these out in the field. So the, the trial with Statkraft was actually with 3D-printed components. If you wanna do a trial for a few months, it’s very possible to do it with 3D prints. Oh. And I, I think they’d actually last way, way longer than that, but, you know, the test was designed to put them on, measure them, take them off again.

    Yeah. And that’s what we did. 

    Allen Hall: Offshore. 

    Nicholas Gaudern: Mm. 

    Allen Hall: Uh, uh, w- we’ve had some people write into the podcast talking about offshore wind turbines. And in the States, offshore wind turbines are [00:22:00] usually 10, 15, 20 miles from the shore, but that’s not always the case. Over in Japan and some other areas, the turbines are pretty close to shore.

    Nicholas Gaudern: Yeah, def- They’re 

    Allen Hall: almost- 

    Nicholas Gaudern: They’re definitely near-shore … 

    Allen Hall: they’re almost- Yeah. Yeah, yeah … onshore turbines, but because they’re offshore, they get really big, right? So y- you can build a really big offshore turbine. And some of the comments we have received is, “Hey, these turbines are noisy.” 

    Nicholas Gaudern: Yeah. And, you know, the, the water surface can do some weird things- 

    Allen Hall: Well, that’s what I wanted to know

    acoustically. Okay. Yeah. That’s what I wanted to know- Yeah. Yeah … because if you have trees and hills that kind of block the noise- Yeah … that’s easy. But if you have a turbine and you live on the, essentially the beach- Yep … or real close to the shore- Yeah … that turbine is right there. In some cases in Japan, it’s not very far.

    Yeah. You can see it. 

    Nicholas Gaudern: Particularly on a still day, you know, when you have a very flat water surface, that can mean that sound is able to propagate a little bit further than maybe it otherwise would. 

    Allen Hall: So is there a, a real need then to pay attention to the acoustics and noise- Yeah … coming off of offshore wind turbines?

    Nicholas Gaudern: [00:23:00] I think, uh, c- certainly the near-shore, the things you’re describing now. Yeah. Offshore’s an interesting question because I think often, if I think about the UK and, and Denmark, they are quite offshore, and I think in that, in that sense, the noise is much less of a, a concern. And I think it may be more driven by regulatory r- requirements- Mm-hmm

    than actual, you know, neighbor complaints perhaps. So noise is interesting because people put serrations on for different reasons. Yeah. Some put them on because there’s a regulation. Yeah. Uh, some put them on because they want to be shown to being a good neighbor, you know, doing the best they can to reduce noise- We should 

    Allen Hall: try to-

    Nicholas Gaudern: which we should absolutely be doing … 

    Allen Hall: do that every time we can. 

    Nicholas Gaudern: And some are doing it because they have curtailment on their turbines. 

    Allen Hall: Yes. 

    Nicholas Gaudern: So in order to meet a regulation perhaps, they have to basically turn down the turbine, and it means that it spins slower. And if it spins slower, the noise is lower, sure.

    But the power output is also lower. And what we found is that on some turbines that are in noise modes, they’re losing 3, 4, 5% AEP- Ooh. Ouch … [00:24:00]every year because they’re having to turn down the turbine to meet a regulation or to, to satisfy, you know, uh, neighbor relationships. But just imagine what that means for finances if you put a serration on.

    You can turn the turbine up again, which you’re now addressing the noise at the source, so you don’t actually have to stop it spinning slower. You’re actually killing the noise where it’s being generated. 

    Allen Hall: So there’s a big financial incentive- Yes … to look at trailing edge and try to quiet them as much as you can, particularly onshore.

    I think that case has- Yeah … been well made over time. I’m always shocked that a lot of operators that, uh, even in the US Midwest, and we s- we drive around quite a bit in the Midwest, there’s a lot of turbines that are near homes. 

    Nicholas Gaudern: Yeah, 

    Allen Hall: absolutely. Y- you know, there’s one or two or three homes. This isn’t like there’s a suburb right there, but there are homes out there, and, and they would like to have enjoyment of their property.

    Yeah, of course. And if you can knock down the noise a little bit, it would make it 

    Nicholas Gaudern: a much more pleasant place. Well, if you take, you know, if you take 30-plus percent off the perceived loudness, that’s, you know- 

    Allen Hall: Oh, that’s very noticeable … that’s gonna, that’s gonna make a difference. Yeah, you’ll get a thank you letter- Yeah

    for [00:25:00] sure. So that’s exciting. The- Yeah … all this is exciting. It- It’s 

    Nicholas Gaudern: gonna be, it’s gonna be a really great summer, I think, to get more of these components out in the field. 

    Allen Hall: So if, uh, an operator or an asset manager wants to get ahold of Power Curve, understand what Silent Edge is, and how to get it installed or put some dragon scales on this season, how do they do that?

    Nicholas Gaudern: So you can check out our website, uh, powercurve.dk. That has all of our contact details on. Uh, you can find me on LinkedIn, uh, as well. I’m often around these, uh- … events that we find- Yeah … uh, in different countries. So no, look, look us up, reach out by email, phone, whatever, and we’d be very happy to talk to you.

    Allen Hall: Or reach out to the India office. 

    Nicholas Gaudern: Yes, that’s something that we’re hoping to have up and running, uh- So 

    Allen Hall: if you’re 

    Nicholas Gaudern: in India- … 

    Allen Hall: later this year. Yeah. Reach out. Yeah, that, that’s gonna be an exciting advancement. Yeah. Great. For 

    Nicholas Gaudern: sure. 

    Allen Hall: Nicholas, it’s great to have you on the podcast again. 

    Nicholas Gaudern: Nice talking to you, [00:26:00] Allen.
  • The Uptime Wind Energy Podcast

    Japan Backs Floating Wind, US Grid Sidelines Clean Energy

    2026/06/30 | 32 mins.
    Japan and the UK sign a $12 billion floating wind deal for 5.9 GW, Muehlhan buys Coverwind Solutions in Spain, and US grid reform stalls as MISO, PJM, and SPP fast-track fossil resources over wind.

    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: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Rosemary Barnes, just back from Japan, in Matthew’s stead. Yolanda Padron is on special assignment. Well, Rosemary, what happened in Japan? You, you spent a, a week touring the country and looking at, uh, some energy projects.

    What did you learn? 

    Rosemary Barnes: I was there for just five, five nights. I went over for an, um, an, a systems engineering conference by INCOSE. I was doing a keynote presentation there, and also spoke to some of their… They’ve got this program, an international programming for, like, upcoming leaders. Um, and yeah, it was funny, the topic that I chose for [00:01:00] that was how you can combine an online presence with a serious professional career.

    Uh, ’cause, you know, like, a lot of the advice that you see about building an online presence is, like, totally compat- incompatible with being taken seriously in a, uh, you know, in a, a job like engineering. So that was pretty fun. And then on the last day, I was able to arrange a tour of a community. Like, we went to this village near Fukushima, and they, a- after the Fukushima, uh, or the earthquake that led to the Fukushima, uh, shutdown, that town, some power lines came down, and that, that village was without power for three months.

    So in response to that, they’re like, “Community power for the win.” At this place, like, there was literally steam coming out of the ground just, you know, randomly. It’s an onsen town, so you know, like, it’s, um, it’s built around tourism for these hot baths. And so they put in a couple of geothermal power plants, small ones, and, um, also some hydropower.

    But the reason why I wanted to go there was ’cause, you know, ge- [00:02:00]geothermal is such an obvious solution for Japan, for the energy, but they only have… .3% of their electricity is generated by geothermal currently. And, um, the main reason is that the onsen community in Japan is really opposed to it. They’ve lobbied against it because they’re worried that, um, you know, the onsen community needs heat to come out, hot water to come out of the ground, and geothermal takes hot water out of the ground, so they’re just worried that they’re incompatible.

    Um, now I think the science says that that’s not really true, that the, there isn’t, they’re not the same resource and that one doesn’t affect the other. The wastewater from the geothermal is not really wastewater. It’s just water that is not as hot as it was when it came up. Um, that goes down then into the onsen because it’s a good temperature.

    And then some of the even cooler water, about 21, 23 degrees, they’re using that to raise shrimp. 

    Allen Hall: Well, just speaking of Japan, uh, the Japanese Prime Minister was just in the UK and a [00:03:00] big deal was signed between Japan and United Kingdom, £9 billion worth, which is about 12 billion US dollars, uh, to work together on 5.9 gigawatts of floating wind capacity in the UK, uh, across three different projects.

    W- And the goal is to get some Japanese partners working with, uh, the UK companies involved with it to suss out how to do offshore wind. And as we all know, Japan is gonna, is headed there right now and is going to need a little bit of a primer on how to do it. And, and, well, they should because, uh, there’s been some really successful efforts in the UK and up north, Northern Europe.

    Uh, so the, the goal of this is to, to get these projects underway and, and Japan’s committing all this money, which, uh, sure, it’s a nice boost to the UK at the moment. It gets a little turbulent over there if you’ve been watching the news. Rosemary [00:04:00] Tying back to your experience in Japan recently, is there a big push internally?

    Do you see that internally in Japan for offshore wind and even offshore floating wind in Japan, or are they really prepping for it in country? 

    Rosemary Barnes: Yeah, I’d say I went over there thinking that Japan was, like, oddly not bothered about wind energy of any flavor. Um, ’cause, you know, like onshore wind, they’ve got problems because the good ri- wind resource is right on the ridges, and they’re getting just hammered by lightning, and they’ve got some, like, really interesting responses to how they think that they should manage that, that in my opinion are just gonna kill…

    Like, you would never bother to have an onshore wind farm if these, um, regulations go ahead. So offshore they have got, um, a bit of a, an, a fixed bottom resource, and they’ve had several auction rounds geared towards that, but they’re, um, they haven’t gone well. I think that, like, people have promised… It, it’s a similar story to elsewhere in the world.

    Uh, people have, like, bid, like, [00:05:00] bid down to quite low prices and then not been able to deliver and pulled out. Mitsubishi just recently paid some, uh, some huge penalty for not going ahead with a, a project. There isn’t actually that much fixed bottom potential, um, for Japan. So, um, if they wanna have a significant amount of wind energy in their grid, which they should, because they’re, like, honestly it is probably the best or one of the couple of best options to provide big chunks of their electricity supply, then it needs to be floating.

    Um, and the government is actually pushing on that. I thought they weren’t doing too much, but I did talk to someone from this group, Flora. It is a group that is, um, that, that is trying to form partnerships with other countries, but also with manufacturers to try and set the framework up so that it can, like, l- lay the groundwork for commercialization to happen without being prescriptive.

    Flora is in there [00:06:00] to try and, you know, get the pieces in place to be able to allow, um, you know, uh, innovation and competition to happen much, much faster. 

    Allen Hall: What’s the most complicated piece technically that needs to be solved before Japan can really move forward? Is it the money piece? I mean, um, um, I said technically, but I feel like there’s always this money aspect to it, which is important, but on the technology side, i- is it, is there any technology that remains to be solved or is it just the will to do it?

    Rosemary Barnes: Basically in any engineering question, the answer is money, like, when you come down to it. So, like, it’s almost boring to say, yeah, it’s, it’s money. Floating offshore wind- Too hard, too niche for most people to consider it a mainstream thing, but it’s the legitimate, like, good contender for Japan. And you know what?

    That presents opportunity. It can actually be good to have to do something hard. Um, and Japan has the opportunity to be the [00:07:00] country where, you know, it’s the country where floating wind makes the most sense, so they can be the ones, if they’re smart about it, they can be the ones where the smart technologies evolve.

    There will at least be little niche things that they develop that will go on to succeed, and Japan really needs some new big manufacturing industry to… Like, their car industry is obviously, um, has been so important, the automotive manufacturing, and it’s declining now relative to China. Um, so I am also hopeful that they can, you know, build that up a bit more, but I don’t think that they’re going to, you know, topple China, so they are looking for new industries that will be the new…

    Yeah, do for them what the auto industry did from, yeah, from the ’70s onwards. Actually, you know, like, you can tie it back in a nice loop back to the oil crisis in the ’70s because that’s when the world was like, “Oh, actually small, efficient cars are, are quite a smart idea.” And Japan had those because it was so [00:08:00] constrained in terms of, you know, the oil that it could bring in was expensive.

    Not having their own fossil resources, they learned to conserve it, and then that turned out to be, you know, a big advantage for them. 

    Allen Hall: Using the 1970s gas price crisis and the movement towards Japanese cars in the United States, I mean, timing is everything. And Japan was in, uh, Honda in particular, was in the United States.

    I think Toyota was too, if I remember correctly. And when gas prices went through the roof, uh, yeah, they were very efficient cars, and not the most reliable at the moment, but obviously they’ve changed quite a bit and s- they are, particularly Honda and Toyota, are probably two of the more reliable blan- brands you can buy in the States today.

    So things change, right? You’re just getting your foot in the door. But that, that break point is, is coming pretty soon, I would say, in, in terms of timing. I- is it the right time for Japan to move into floating offshore? It’s gonna be within the next couple of years, don’t you think, Rosie? 

    Rosemary Barnes: Yeah, yeah, def- [00:09:00] definitely.

    Um, and yeah, I mean, I, it, it, it does frustrate me that any money is being spent on, um, hydrogen and ammonia imports. I, I would just rather that they just, just, just do the LNG until you figure out alternatives. 

    Allen Hall: That makes more sense. 

    Rosemary Barnes: Gas is better than… You know, like ammonia, for example, they’re locking in these coal power plants for additional years, making investments, um, you know, thinking that this is gonna be part of their future.

    They’re gonna end up burning coal, y- you know? At least gas is flexible enough to support renewables, and so it can, you know, like speed the rollout of, of wind. And they do have a fair bit of solar too in Japan. Floating solar, actually. They invented that there, and have actually got quite, quite a lot of it.

    Allen Hall: Gas is gonna be the answer short term. I think in the relationship between the United States and Japan has always been pretty solid since after World War II, that the United States would be willing partners to help Japan stand up any [00:10:00] technology, probably except for wind, which is just bizarre. 

    Rosemary Barnes: One of your maybe, um, unexpected legacies in Japan was, I say you, I mean the USA, they’ve got, um, not just the, like, silly American power plug design where you’ve got, like, the parallel pins that just fall out, so they’ve got that.

    But they also have 110 volts. Like, where else in the world is, is, thinks that’s a good idea? I had, um, my little travel steamer I’d taken over there, hairdryer, useless. Absolutely useless. 

    Allen Hall: That’s all you 

    Matthew Stead: need. 

    Rosemary Barnes: I blame you personally, Allen. I hold you personally responsible for my wrinkled clothing.

    Allen Hall: Delamination and bondline failures in blades are difficult problems to detect early. These hidden issues can cost you millions in repairs and lost energy production. CIC NDT are specialists to detect these critical flaws before they become expensive burdens. Their nondestructive [00:11:00] test technology penetrates deep into blade materials to find voids and cracks traditional inspections completely miss.

    CIC NDT maps every critical defect, delivers actionable reports, and provides support to get your blades back in service. So visit cicndt.com because catching blade problems early will save you millions

    Well, the wind service sector is consolidating as we’ve all watched over the last year or two, and Mjolner Wind Service is one of the most aggressive buyers in the field. Uh, the Danish company has signed to acquire Cover Wind Solutions of Spain, including Cover Sun Solutions and Cover Renewable, with the deal expected to close by the end of June.

    This is Mjolner’s 11th acquisition since 2023. Now, Cover Wind fills a geographic gap for Mjolner. Uh, they are [00:12:00] involved in Spain and France and, uh, already involved in covering the Nordics a little bit and Central Europe. So there’s a, a big play here, and, and decommissioning is really the, the story underneath of th- all this is on the decommissioning side.

    Uh, Mjolner views turbine end-of-life services as an important future growth area, and obviously it is. Particularly in Spain, there’s been a lot of turbines that will be, uh, brought down and new turbines put up in the next 10 years, and Cover Wind gives Mjolner that ability. And as we all know, Mjolner just recently acquired our Canadian friends, AC883.

    So yeah, they have been on quite the spin recently, and that’s not even Yeah, sl- a sliver of what’s happening on the consolidation effort, uh, we didn’t talk about last week, but we, we should have, which was Fairwind acquiring Rope Partner in the States. And Rope Partner is a [00:13:00] longtime blade repair company and has been seen for years, as long as I can remember honestly, as the go-to blade experts on complex repairs.

    The, the, the most trained up, most, uh, technicians. On the technician side, they’re, they, they, they always had the highest trained people to what I remember, and also they would ta- tackle some of the most complex blade problems, and now they’re part of Fairwind. So there is movement, Matthew. A, a lot more than I thought there would be, because after COVID, a lot of companies just disappeared, but now it does seem like they’re being acquired, which is a, a good result, I guess.

    Matthew Stead: Yeah, I think there’s a strong opportunity, and, uh, and maybe the first point is that actually doing an M&A successfully is actually really hard. Um, I, I’ve personally been through two, uh, two M&As, um, and it is, it is really hard to get an M&A right. And so I think, you know, [00:14:00] these companies are showing that, um, you learn, you can do better, and, you know, it, it, it is hard.

    So congratulations for them for achieving that. Um, but the second part I think is also, you know, the industry maturing, uh, gaining scale is also, you know, necessary and, you know, driving, you know, but– and these people should be able to drive their, you know, better margins and so forth through, through scale.

    So, you know, I, I think, um, I think we had a bit of quick chat about it previously, but, um, this is, you know, a really good thing. 

    Allen Hall: Does it change the way we think about, uh, independent service providers? 

    Matthew Stead: Yeah, I think it’s gonna continue. I mean, this is not the end of it. Um, you know, in– even in what we do, there’s been various, you know, mergers and acquisitions in, in our space or, and investments, you know, cross-investments.

    So I, I just see this continuing. You know, like SkySpecs, um, you know, growing their, their CMS, um, business and their financial arm. Um, this is just gonna continue. 

    Allen Hall: [00:15:00] Is it more activity, uh, related to the availability of AI? It’s– It does seem like that’s playing into some of the decisions that are being made on the mergers and acquisition in renewables, is you start to see more discussion of, hey, we’re going to, uh, apply new techniques, machine learning.

    A lot of times you’ll see that, particularly in Europe, and then here in the States it’s almost all AI, where they’re- In order to have a, a very successful AI venture, you need to bring in the brainpower to feed that AI. And it does seem like there’s a lot of, of senior companies getting grabbed that could be part of a larger artificial intelligence play.

    Matthew Stead: You remind me of the, um, the dotcom boom and bust. I don’t know. I’m, I’m a little bit more skeptical, um, on the value actions on the, on the AI side of things. 

    Allen Hall: Really? 

    Matthew Stead: It certainly… It’s a massive, um, massive, um, transformation for the industry, and you know, I mean, what I, what, what we can all do is, is massive.

    [00:16:00] But, um, my former employer, a consulting business, bought a AI company for a billion dollars, and I, I, I just can’t see the value. So, um, anyway, I’m, I’m a bit skeptical about valuations and AI, and, um, I’m not as bullish as many people are. 

    Allen Hall: Really? Uh, because it does seem like more recently, the shift has been from the number of engineers you have in your company times a million dollars a head, that’s the way it was, uh, not that long ago.

    And now it does turn into how many senior people you have, that’s the multiplier. Because they’re trying to take that knowledge and all that data resource that you have, like at a, a rope partner where they’ve prepared really complex problems for years. That data set is amazing if you could get your fingers on it.

    Matthew Stead: Uh, yeah, yeah. And I, you know, I completely agree with you, but I just think it’s being oversold and overcooked and overbaked. 

    Allen Hall: I see it as growing instead of it declining. I don’t think it’s cooling off. I think we’re just at the precipice of [00:17:00] it. As we get better at using some of these AI tools, if we’re gonna build data centers in space, ’cause that’s gonna be the, the linchpin to all this, is if it gets to data centers in space, then we can leverage massive data sets and learn something from them and get better.

    Matthew Stead: I love change, but, um, I, I think that’s ri- ridiculous, to be honest. Um, I know we’ve spoken about it a number of times, but data centers in space just seems stupid to me. But, but yeah, going back to your original point, Alan, um, yeah, we, we can definitely do better with you know, more insights around our data and getting more out of our data.

    I mean, data is the new oil. You know, we’ve been saying that for the last 10 years. Um, yeah, I’m, I’m full, I’m fully on board with that, but I’m just a little bit of a, a little bit of a negative Nancy on, um, some of these overhype 

    Allen Hall: The line to connect a new wind project to the U.S. grid has been one of the industry’s most stubborn bottlenecks.

    And a new report from Advanced Energy [00:18:00] United drafted by Grid Strategies and the Brattle Group finds that seven major U.S. grid operators have made progress, at least some, on generator interconnection reform since FERC Order 2023 took effect. So that was the order that said we need to fix this interconnect queue problem.

    There are just too many people in line and we need to give some ranking to them. But progress on paper has not yet translated into projects moving through the queue faster. And a newer problem is emerging. Fast track interconnection policies at MISO, PJM, and SPP are directing limited system headroom towards, drum roll, utility-affiliated and fossil-heavy resources at the expense of independent clean energy developers.

    So the game is being rigged a little bit at the moment where they want to push forward [00:19:00] gas and other fossil fuel type generation in front of solar and wind, which are less costly and quicker to get up and running. This can’t last long, right? E- eventually the people living in, uh, MISO, PJM, and SPP are gonna have a little bit of a revolt on how power prices are gonna bump up accordingly.

    Matthew Stead: There’s been numerous other attempts to stifle wind, um, and those numerous other attempts, uh, tend to be overwritten and, uh, ruled out and thrown out in courts. And, um, it, it just seems like this is, well, if that didn’t work, we’ll, we’ll try something else. 

    Allen Hall: It’s a delay tactic. 

    Matthew Stead: Yeah, exactly. Then becomes another one.

    Well, you know, just wait for that one to be thrown out. 

    Allen Hall: I don’t know who said the famous saying, time is money, but time is money, and if you can [00:20:00] delay a project from happening, it costs money to sit on the sidelines and you’re, you’re paying interest on a loan or your investors are getting upset because they’re not seeing the returns.

    So the easy game in most situations like this is just to drive the schedule to the right, even if it’s by a couple of months. It’s expensive. 

    Matthew Stead: Yeah. If there’s two things I wish I didn’t know about, the first one is telecommunications and how rubbish it is. I just wish I didn’t, wish I didn’t know about telecommunications and the need for cellular and satellite and blah, blah, blah.

    I wish I didn’t know about that. The other one I wish I didn’t know about, because I wish it wasn’t a problem, was just grid connections and grid and networks. 

    Allen Hall: How bad it is. 

    Matthew Stead: Yeah. Rosie, if you can jump in, but you know, the New South Wales-South Australian Interconnector Grid, um, is just being energized now.

    I don’t know if it’s one or two years late. Um- And they’re trying to recover a billion dollars from the general [00:21:00] public 

    Rosemary Barnes: Is it only a billion? I thought it, when I looked at the stats, um, it was like near tripling of the, of the project cost 

    Matthew Stead: My understanding is the government screwed it up or the, uh, the, the operator screwed it up in terms of the transmission lines, and then want, wants to claim it back from the general public ’cause they, they screwed up.

    Rosemary Barnes: Yeah. It’s a weird thing ’cause you, you know, it’s like, I think it’s like this everywhere in the world that the, yeah, transmission companies or network companies, they get a regulated rate of return on their, on their project, so they invest. But then it’s like what’s that rate of return for? It’s not money for nothing, right?

    It’s for them, you know, like taking on some risk and y- you know, some sorts of things are, are built into that. Um, but it’s kind of like if you, you get that amount approved and then you stuff up your project management so it drags out and takes a lot of money, then you’re also gonna be compensated additionally for having done a bad job with your project [00:22:00] management.

    The kinds of delays are not unforeseeable. You know, like I’ve been a project manager in my past. You don’t just make your best case scenario and then kind of just assume that that’s, um, how much it will cost and not, y- you know, not come up with, um, contingency plans for if, uh, if predictable things happen.

    It’s not, there’s no like black swan events in here. It’s just, um, you know, things that happen every now and then. And it is one of those like key principles of like delivering on big projects, um, that Ben Slibbert, you know, in that, that book, um, How Big Things Get Done, he goes over and over and over again that you need to keep your project as short as possible ’cause the longer it is, the more like surprises you’ll have along the way and it will cost more.

    And I just don’t think that they, like they need to go read that book and then do a better job with their project planning and scenarios. 

    Allen Hall: You know who’s read that book clearly is, I, I’ll bring up the name, I know it’s gonna cause controversy, [00:23:00] Elon. 

    Rosemary Barnes: I knew you were gonna say that. 

    Allen Hall: Well, you know why I say that?

    Because there was an interview with him and I was skimming through some nonsense and then this little interview popped up, and he was talking about how quickly they need to get things rolling. And it’s like one year you’re getting s- first year you’re getting started, second year you’re just growing like crazy, and third year is infinity.

    And the only way that makes sense is that you’re just pouring every resource on this problem to shorten the schedule That’s it 

    Rosemary Barnes: You, you do. You have, you have to do the, the, you know, the parts of your project where surprises are gonna happen. Like you can… There are surprises and you know, don’t know what they, they are gonna be.

    However, you can guarantee that there will be surprises. Like you, you know going into a years-long project that several things are gonna happen that are, you know, gonna surprise you. And so you can plan for that. And the best planning that you can do is to make sure that once you start actually, you, you know, you’re gonna spend time in planning to, um, get it right, but once you actually start [00:24:00] the phase of your project where delays cost money, then you, you just plan as, do everything you can to keep that as short as possible, and it will be, it’ll be cheaper.

    Even if it sounds more expensive, oh, we’ve gotta, you know, pay crews overtime to, you know, do a night shift or something like that, um, you know, you need to consider, consider that because the, there will be delays and they cost. And it’s just, like at this point, maybe 100 years ago you could get away with being surprised by that, but y- you know, like project management has come far enough now that we know, we know this.

    It’s just basics. 

    Allen Hall: But infrastructure projects are tough because they don’t see the revenue on the backside that much sooner. It’s sort of a very flat 3% growth industry Unlike a lot of other things 

    Rosemary Barnes: But that’s it, like just to contain costs, you have to have a small project. 

    Allen Hall: They will, but they’ve always historically gotten paid for those overruns and continue to make their 3%.

    If there was some sort… Back to Matthew’s point, if there was some sort of, uh, [00:25:00] disincentive to be late, they would hurry, maybe even spend a little bit of their own money, but there would have to be some massive upside, which is the problem, right? They can’t have a massive upside. 

    Rosemary Barnes: But that’s why I’m s- I’m saying that the situation where costs blow out and they still get…

    Like, they get… They make more money by having done a bad job because it costs more. You know, like that is not, it’s not okay. 

    Allen Hall: Is it more money or just paying the bills that they had when they were building the thing? 

    Rosemary Barnes: It depends how much we let them get away with, but their preference is to make, just be, “Oh, we could never have known that there would be a flood.”

    It’s like, okay, yeah, like, was it like a 1 in 50 years flood or something? So yeah, on average, that particular event wasn’t gonna happen, but there’s probably, you know, like 20 different categories of 1 in 50 year things that could have happened, and if your project lasts for five years, you’re gonna have a few of those.

    You just are. You know? It’s not, it’s not bad luck. It’s just like, just normal statistical variation [00:26:00] that y- Yeah, so I, I, I really think it’s important to, um, to not just say, “Oh. Oh, poor you,” ’cause it’s, it always sounds like a sob story. “Oh, a flood. Who could have known?” 

    Allen Hall: Who could have known it rains? 

    Rosemary Barnes: Yeah, I mean, I, I don’t know.

    Like, I often talk about how people don’t know what, um, engineers do, and we don’t get enough res- respect for, for what we do, and people don’t get it. But I think project managers is, if anything, worse. People don’t respect project management as a, um, a, I don’t know, is it a profession? But, you know, as an ex- ex- field of expertise and don’t, don’t know how much of a difference it makes to have a good one, and also that it is not that hard to be a good project manager.

    You just have to actually do it. 

    Matthew Stead: Can I make a suggestion that actually is the reverse of Darwin theory? We’ve got to come up with a name, but you know, the dumber you are, the more money you make. Also, for the record, um, Elon does have a lot of, um, philosophies and approaches which I do support. The efficiency, automating things after you’ve done them manually, only [00:27:00] doing the bare minimum, you know, all those sorts of things, doing things fast.

    Rosemary Barnes: Yeah, there’s a lot, a lot of good product development and engineering that you can learn from Elon, and you do not have to take the, like, weird personal stuff along with it. You are able to pick and choose which aspects you, you learn from. 

    Allen Hall: But it does take a specific kind of person to weather that storm.

    If you wanna play in that sandbox, y- you better be ready because it’ll be hard and fast and not very forgiving. So you just have to know that going in, which can be great, and it can be a great experience, uh, for a lot of engineers, but it isn’t for everyone. 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 [00:28:00]industry veteran or new to wind, PES Wind has the high-quality content you need. Don’t miss out.

    Visit peswind.com today. In this quarter’s PES Wind magazine, which you can download at peswind.com, there’s an article from TGS 4C about vessel traffic around offshore wind farms. And this is kind of interesting bec- because they looked at some major wind farms off the coast of the UK, Dogger Bank B, Dogger Bank C, and Sofia.

    Uh, and obviously there’s a lot of marine traffic around those, but you don’t really realize the scale and how, uh, it affects the, the traffic on the water. The– When they had looked at these three wind farms, they realized, uh, they had about 860, uh, transits in 2021 around that area, and that went to more than 20,000 by [00:29:00] 2025.

    So the amount of economic and commercial activity that was happening around those wind farms exploded. And when you have that many ships in the water, it does change the nature of that area and also how other ships transit through the area, around that area. Uh, it’s an interesting piece because if you look at where those wind farms are, Matthew, th- that’s kind of a narrow stretch in there where there is a lot of ship traffic already.

    So y- you create this, uh, artificial barrier for some of the ship traffic, and you’re trying to understand how that is affecting the flow in and out. But I think the, the bigger piece is you can tell how well a development is progressing on offshore wind by looking at the ships and who’s where and when.

    Matthew Stead: I think this is interesting topic. Um, I, I– To be honest, I don’t completely get it. Can you explain it to me? 

    Allen Hall: If I’m an investor in these projects, if I’m the government, if [00:30:00] I’m the, uh, the power company that’s gonna handle the power coming off these sites, I really need to know how it’s going. And the way that I look at it in the States when I look at offshore projects here, ’cause we could do something very similar, who’s out on, on the ocean?

    Where are they? What tower are they at? How many towers are running? You can kinda tell that. Are they, are they just doing surveys or are they laying cable? Or is there something more active happening? And where are the ships from? Are they installation vessels? Are they driving monopiles? What’s going on out in the water?

    It does give you a really good sense where they are in the project. Kind of back to Rosemary’s point on, on managing big projects, you– schedule is everything You can tell. You can really tell. 

    Matthew Stead: Thinking about it a different way. So it’s a bit more like shadow monitoring. So it’s just a way of, it’s a way of independently monitoring and checking progress, making sure that there’s transparency as to what’s going on.

    Allen Hall: I think there’s a lot of [00:31:00] value in that data set. And as, uh, more operators start to use that data set and more companies start to use that data set globally, uh, they’re gonna be doing offshore projects, I think, differently in, in terms of efficiency. They- they’re learning as they go. 

    Matthew Stead: Yeah. Isn’t that one of the classical, um, sort of mathematical problems about how to optimize, uh, courier deliveries?

    We’ve gotta talk about quantum computing at some point too, so. 

    Allen Hall: We probably should. But for right now, I need everybody to go to peswind.com and download this quarter’s magazine. A lot of good articles in there, and it’s a great free download. Tons to learn. Go to peswind.com. 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. And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover this [00:32:00] show. For Matthew and Rosemary, I am Allen Hall, and we’ll see you here next week on the Uptime Wind Energy Podcast.
  • The Uptime Wind Energy Podcast

    SunZia Switches On, Ørsted Weighs Chinese Turbines

    2026/06/29 | 2 mins.
    Allen covers SunZia coming online as America’s largest wind farm, Ørsted’s stance on Chinese turbines, a record floating platform leaving China, Canada’s first offshore wind bidders, and a centuries-old North Sea shipwreck.

    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 Monday everyone.

    America just switched on the biggest wind farm it has ever built. Out in New Mexico … a vast field of spinning turbines called SunZia. Enough power for more than a million homes across the Southwest. It is a landmark. It may be the last landmark for some time. After this year … forecasters expect annual onshore wind additions to fall … all the way to twenty thirty. The tax credits that powered the boom … expire this year. Add tariffs … supply troubles … local opposition … and a federal permitting freeze. One developer put it plainly. Capital investments … frozen. Solar is cheaper now. Batteries are faster. And the wind industry did not see the breadth of the campaign against it. So the biggest American wind farm ever … arrives just as the road ahead narrows.

    Now … cross the Atlantic to Denmark. Ørsted … the offshore giant half-owned by the Danish state … is being asked a hard question. Will it buy Chinese wind turbines? Its chief executive will not say no. Right now … he says … it is not expected. But they are keeping an eye on it. Analysts call that a wake-up call. Because the Chinese builders offer lower cost … faster delivery … and bigger rotors. And if a European champion turns east for turbines … that is a signal Europe is losing its edge. Not everyone is buying it. Britain has banned Chinese turbines from its offshore projects. The competitiveness fight … is just beginning.

    Now set to sail from southern China. The world’s largest tension-leg floating wind platform. Sixteen megawatts. More than three hundred meters tall … and nearly eight thousand tons. It left port headed for the deep sea. And its power will run straight to an offshore oil field … clean wind … feeding fossil-fuel production. China connected more than three-quarters of the world’s new offshore wind last year. As the shallow sites fill up … the industry moves into deeper water. And the deep water … is where floating wind grows up.

    Across the Pacific … a brand-new frontier is opening. Canada cleared the first bidders for its very first offshore wind farms. Off the coast of Nova Scotia … seven qualified players … from nine countries. The province dreams big. A megaproject called Wind West … forty gigawatts … far more than the region could ever use itself. The first phase alone … an estimated sixty billion dollars. Enough surplus power to supply a quarter of all Canada’s demand. The formal call for bids comes later this year.

    And finally … a story that comes up from the seabed. While surveying the site of a future wind farm in the North Sea … Ørsted found something far older than any turbine. Three lead ingots … resting beside the bones of a wooden shipwreck. Late sixteen-hundreds … maybe early seventeen-hundreds. A Dutch vessel … likely bound for home … lost on the run from England to the Netherlands. Seventy kilograms each … mined, it seems, in the very English hills they will now return to.

    And that’s the state of the wind industry for the 28th of June 2026. Join us for the Uptime Wind Energy podcast tomorrow.
  • The Uptime Wind Energy Podcast

    Everpoint’s BladeBlok Recycles Blades for Drilling

    2026/06/25 | 21 mins.
    James Timmins, VP of Engineering at Everpoint Services, joins to discuss how recycled wind turbine blades become BladeBlok, a drilling fluid additive for oil, gas, and geothermal wells.

    Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

    Welcome to Uptime Spotlight, shining light on wind energy’s brightest innovators. This is the progress powering tomorrow

    Allen Hall: James, welcome to the podcast. Thank you. There has been a lot of activity at EverPoint Services. So I wanna back up first because if you’re not familiar with EverPoint Services, they are a recycler f- for renewable projects. 

    James Timmins: So we’re a, a renewable energy service company that specializes in, um, decommissioning and remediation services for, uh, wind and solar assets.

    Allen Hall: So when a solar farm gets hit by hail and the panels are broken, EverPoint comes up and cleans up that mess to, to allow the repair to happen. 

    James Timmins: Correct, yes. 

    Allen Hall: And on the wind turbine side, you’re t- decommissioning wind turbines, but you’re also taking the [00:01:00] blades. 

    James Timmins: Yes. So it’s our responsibility to haul off the damaged, I guess, the scrap.

    And, um, obviously there’s a very healthy market for scrap steel that you find in the tower base- Yes … but the fiberglass is a little less straightforward when it comes to disposal and/or recycling. 

    Allen Hall: So typically with the fiberglass blades or any composite that’s, that’s being recycled, th- there’s really two techniques that are being implemented right now.

    Uh, well, really three. Let’s go over three of ’em. One of ’em is you can just bury them. They’re c- essentially construction materials, so you can bury them. Not ideal, but it has happened in the past. The second is they grind up the, the blades and use ’em in, uh, c- the cement-making process, where they’re burning some of the things that are combustible there and using it for fuel, but also the fiber can help with the cement.

    Does, does that sound right? Correct. And, and then the third one I’ve seen is just as a reinforcement product. [00:02:00] So it’s, uh, they chop up the fiber in different lengths, they clean it up, and you can u- use it as an additive to different products. Yes. And, and that generally has been the marketplace in the blade recycling area for- Going on 20 years now probably Yes Until now.

    And that’s where Everpoint has really changed the game because you’re thinking about blade recycling a completely different way. 

    James Timmins: Correct. So my background is oil and gas. I was a drilling engineer, uh, for major oil companies, so it was my job to plan, execute, and oversee drilling operations. So I worked kind of all over the world, and this project started as an icebreaker at a friend’s birthday.

    I had never met Tyler Goodell before. I- Wait, 

    Allen Hall: wait, wait. So you’re at a birthday party- 

    James Timmins: Yes … 

    Allen Hall: and your kids are having fun. They’re eating cake. Oh, 

    James Timmins: we were at a dive bar, so we- Oh, okay … yeah, watching a band, uh- … sitting over a bucket of Lone Stars and yeah. 

    Allen Hall: Okay. That’s the [00:03:00] best place for new ideas to occur clearly.

    So you’re, you’re, you’re at a birthday event, you’re hanging out, and what happens? 

    James Timmins: He asked me what, what I would do with tens of thousands of tons of scrap fiberglass. 

    Allen Hall: And you get asked that every day, or is it- No. Okay. 

    James Timmins: And I thought it was a weird question, and I kinda put it in the back of my mind. And about 15 minutes later I was like, “Well, I have an idea that we could, uh- Put at least some of that to work.

    Allen Hall: And what was that idea? 

    James Timmins: The idea was that we could grind it to a specific particle size distribution and use it as a fluid loss additive in oil, gas, and geothermal drilling operations. 

    Allen Hall: Okay. That’s a unique application. 

    James Timmins: Yes. 

    Allen Hall: So I think we need to walk into what happens when we’re drilling an oil well or any sort of well, I suppose.

    Uh, there’s unique things that happen that require specialty fluids or specially … 

    James Timmins: Uh, specialty additives you could say. Additives. 

    Allen Hall: Yes. [00:04:00] So- Okay. That’s a, that’s a good way to describe it. All right. So, uh, I’m drilling a well. I’m in Texas. I’m an oil tycoon. I wanna drill this well. What am I doing? 

    James Timmins: So you have what’s called drilling mud, which is pumped down the drill string through the bit.

    Um, helps cool the bit, um, power down hole tools, and sweep the cuttings out, which is the- Okay … drilled up rock. 

    Allen Hall: Yep. 

    James Timmins: So there’s a, a hydrostatic pressure that the fluid column exerts on the formation. And if that fluid column exerts more pressure than the formation can stand, it splits open like a fracture.

    Allen Hall: Okay. 

    James Timmins: In this case, an accidental fracture. Or you could have just a porous formation of, uh, low pressure. And so you have this pressure imbalance from the wellbore where the fluid wants to flow to the area of low pressure. And, uh, this mud is $300 or $400 a barrel. And if you’re- Whoa … losing 100 barrels an hour, the costs add up really quick.

    Can’t drill ahead. Um, it’s what’s called non-productive time. [00:05:00] So you’re spending 80 or $100,000 a day for all this equipment to be out there, and you’re not drilling ahead, so. 

    Allen Hall: Okay. So as the, the drill bit goes down into the formation, you’re hitting rock. You hit a crack in a rock, or you create a crack in a rock.

    All your drilling mud, and it’s not really mud, right? No, it’s- It’s, it’s a special compound- 

    James Timmins: Yes … that we call mud. Very, 

    Allen Hall: uh, 

    James Timmins: yeah, it’s drilling fluid, I guess, is the technical term. Okay . But, um- I’ve 

    Allen Hall: heard mud used universally. 

    James Timmins: It kinda looks like chocolate milk most of the time. 

    Allen Hall: There you go. Yeah. Okay. So it’s an expensive fluid.

    You’re pushing it down in, but then you get a, a crack or a formation that you run into, and all that precious fluid goes running off somewhere else. Yep. So which it doesn’t allow you to cool the bit, which basically stops all drilling. 

    James Timmins: Correct. 

    Allen Hall: Okay, that’s a big problem. 

    James Timmins: And in worst case scenario, the fluid column falls and the pressure on the formation falls, and then the well starts flowing and you have a well control problem, so.

    Allen Hall: So now you got a big problem. 

    James Timmins: Yep. [00:06:00]

    Allen Hall: All right. So now you have fluid coming back at you that you’re not ready for. 

    James Timmins: Correct, yeah. 

    Allen Hall: Okay, that seems like quite the mess. 

    James Timmins: Yeah, so it’s actually one of the… You know, in some parts of the world, one of the top drivers of non-productive time and cost. So it’s a, kind of a problem as old as the oil field itself, but…

    Allen Hall: Okay, c- ’cause at the end of the day, you would like to have a specific hole tapped at a specific location pulling- 

    James Timmins: Yes … 

    Allen Hall: hopefully petroleum products from that area or whatever you’re going for. It’s could, could be gas- Yeah … uh, off of that site, but you have to have some constraints about it, right? Right.

    You d- d- to control everything. Okay. So n- that sets the problem. All right. We’re gonna run to this, uh, area where we’ve, we’ve cracked the found- the, the rock or there’s porous rock and we’re pumping this, a really expensive fluid down it and we would like to stop that from happening. How does that end up involving wind turbine blade recycling?

    James Timmins: So we grind this material to a specific size and you mix it at a certain [00:07:00] concentration. Could be two pounds per barrel of mud or 80, uh, depending on the severity of the losses. But, um, this mixture is pumped down into the formation and this, um, kind of acts like a… Technical term is bridging. So this, these fibers from the recycled turbine blades cannot fit through all of the pore spaces.

    Sure. And gradually they be- begin to accumulate on the wall of the, the wellbore. So they- Okay … uh, eventually it’s kinda like a clogged sink with… You know, you get enough- So you get enough hair in the sink … chopped vegetables. Yeah. Yeah. It, it eventually will stop flowing. 

    Allen Hall: Oh, well, who hasn’t experienced that?

    So it’s, it’s… So you, you wanna put things down into this hole that prevent the fluid from running off. Recycled blades seems like a very viable option just because it’s in an inert substance, it’s pretty durable. 

    James Timmins: It is. 

    Allen Hall: It’s tough. It can handle high temperatures [00:08:00] and it now can be pumped. 

    James Timmins: Yes. 

    Allen Hall: Wow. All right.

    So that’s a, that’s a remarkable idea. But ideas and products, there’s usually a long distance between those two. 

    James Timmins: Correct, yes. 

    Allen Hall: So from initial concept to where you are today, walk through what you had to go do to make this into a real product. 

    James Timmins: Uh, so we… I basically have- was familiar with these types of products in the past, but at the level I was at, I was not getting into the granular detail- 

    Allen Hall: Sure

    James Timmins: of the qualification of the product, of the spec of the product. So, um, I kind of had to do a lot of research reading technical papers online about product development for this particular type of product. So, um, I started with a, basically in my garage, um, a geologist sieve. Okay. I got a sample of shredded fiberglass, which I think was, was like five-inch shred.

    So I [00:09:00] bought a blender from Target, not knowing what else to use, and I stuffed it down in, with a crescent wrench and blended it up and broke the blender and eventually got enough usable material to, uh, start testing it in a lab. And so- 

    Allen Hall: Oh … 

    James Timmins: there are third-party labs that do these kind of tests, and they’re all industry standard, um, prescribed methods, so they’re called mud checks and, uh, what’s called a pore plugging apparatus, which is like a, either a ceramic disc that’s simulates a formation and it’s porous, it’s got a certain permeability, or you have what’s called a slotted liner, which is a stainless steel plate with two-millimeter slots on it.

    And you put the mixture in, and you pressurize it, and if it stops it, then you know it works. So- So 

    Allen Hall: you’re plugging a hole- Yeah … in a laboratory, 

    James Timmins: basically. Exactly, and it’s under high temperature and pressure, so it’s designed to simulate kinda downhole conditions. But- 

    Allen Hall: [00:10:00] Wow. Yeah Okay, so- Got a 

    James Timmins: little into the weeds, 

    Allen Hall: but So you’re, no, you’re in your garage, you chop up some material, you go, “All right, let’s go check this out.”

    You, you get a, a- an independent laboratory to try it, and they say it works. 

    James Timmins: Yes. 

    Allen Hall: And then it’s, then you’re off to the races now because- Well, that’s what I thought … you opened Pandora’s box 

    James Timmins: Yeah … a 

    Allen Hall: little 

    James Timmins: bit. So I was not expecting how much, how rigorous the t- the qualification would be on the industry side as well.

    Right. Sure. Yeah So, um, that was kind of the starting line for, uh, product qualification, but, um, I had a very coarse particle size, thinking that would be adequate because I was not familiar with what’s actually used. 

    Allen Hall: What the ingredients are, yeah. 

    James Timmins: Right. So, um, I was kinda shopping it around to friends, and they’re like, “It’s a niche product where it is right now.

    It needs to be finer.” So that’s kind of been the process is, okay, it needs to be [00:11:00] this particle size D50, which is 50th percentile mean particle size, basically. And so then the question is how do we get there? And- Right … so- Grinding composites 

    Allen Hall: can be difficult because- It is … they’re tough, and they’re, as you have learned with the, the- The-

    blender experiment 

    James Timmins: Right … chopping them is not easy. Right. Very abrasive, uh, very high tensile strength. It’s basically designed not to be cut or not to be torn. Um- 

    Allen Hall: Right. That’s why we love it … 

    James Timmins: not to be, not to ever degrade in weather. So it has been an ongoing Kind of research project to find out what’s the best equipment for this, uh, can we do this at, you know, a reasonable cost?

    ‘Cause it’s not gonna be as cheap as grinding up or, you know, picking up sawdust from a sawmill or- Right … or chopping up cedar trees or whatever. So- Which 

    Allen Hall: are generally soft and easy to, to chop and- 

    James Timmins: Right. And not nearly as abrasive and so- Right … we [00:12:00] have identified, um, a process that we think is economical, and we’ve demonstrated it in, you know, kind of a small commercial run.

    But, uh, you know, it’s kind of going back and forth to consumers and them saying, “We want this product size,” and then me going back and forth to our partners saying, “Can we do this? Can we do a lot of it? Can we do it-” 

    Allen Hall: Right. The quantity’s gonna 

    James Timmins: be big. Right. Exactly. So, you know, talking to equipment manufacturers, they’ll all tell you that their product, their, their machine can handle this material.

    And they’re usually all right, but, you know- Can they 

    Allen Hall: handle the quantity? 

    James Timmins: Exactly. Without- They can do it for a month, or, you know, six months, and then it’s, well, do we have to overhaul the whole machine now ’cause this- That’s it … yeah. 

    Allen Hall: It’s, those composites are rough on blades. 

    James Timmins: Yep. 

    Allen Hall: So you’ve, you’ve broken through that barrier.

    You obviously have figured out a way to, to chop the material down or grind the material down into the right particle size. So [00:13:00] now you have a material that is, one, clean, is using existing blades right off the turbines, being ground down, and is a, a product that will be consumed by industry in large quantities.

    James Timmins: Yes. 

    Allen Hall: So all these blades that have, that were gonna be recycled anyway because of the age of the turbine now have a home- 

    James Timmins: Yes … 

    Allen Hall: in the oil and gas industry, which is sort of ironic, right? Right. The renewable industry is taking over oil and gas. At the same time, we’re supporting it in a way, but, uh, the product is called what?

    James Timmins: BladeBlock. 

    Allen Hall: BladeBlock. Okay. Great name. So BladeBlock is then, is a product that’s, it comes in a, in a bag, or is it a cylinder? Is it a truckload? 

    James Timmins: Comes in whatever the customer wants it to come in. 

    Allen Hall: Okay. 

    James Timmins: So 50-pound sacks, uh, super sacks, or bulk trucks. 

    Allen Hall: So it must have a really unique, uh, application i- in terms of, I have a big problem where I can’t use off-the-shelf expensive mud.

    I need to f- fill this hole relatively quickly. [00:14:00] I’m just gonna go grab some BladeBlock and solve this problem right now. 

    James Timmins: Yes. 

    Allen Hall: And, and it… So that changes the industry quite a bit. So places that you may have had trouble drilling wells in, you can now drill wells. 

    James Timmins: Yes. 

    Allen Hall: That’s remarkable. So what has been the response from the industry?

    James Timmins: Uh, they love it. Um- I bet … they love the idea. They, they kind of giggle at the irony of- … you know, oil and gas solving a renewable problem. Um, and- 

    Allen Hall: And a renewable problem solving an oil and gas problem. 

    James Timmins: Right. We are selling on the performance and the cost of the product, but there is also a sustainability and circular economy, you know, aspect as well that is marketable, and there’s still an appetite on both the operator side and the oil field service side for that.

    Allen Hall: This is not a… We’re in Texas at the moment, but this is not a Texas, Oklahoma, N- uh, New Mexico kind of problem. You’re actually fixing problems globally with BladeBlock. 

    James Timmins: Yes. 

    Allen Hall: So the product is, [00:15:00] although made in the United States, can be shipped anywhere I would assume. Yep. So, uh, y- are you getting any requests outside of the United States for it?

    James Timmins: We have talked to overseas partners, I guess, kind of industry leaders overseas, and there is definitely some interest. Um, we are also talking to, uh, service companies domestically headquartered who have operations internationally who have expressed interest in, uh, using it overseas. But, I mean, right now, you know, we’re close enough to the ship channel that we can ship it wherever they want it.

    That’s amazing. 

    Allen Hall: And it’s a patented product also, 

    James Timmins: right? Yes. So- We are in the… I guess, we’ve received our notice of allowance, and we’re in the final stages of issuance, so. 

    Allen Hall: So you have a, a patented, US patented, or is it, is it a world patent? Are you, you going outside the United States- Uh, we will … on patent?

    James Timmins: Yes. 

    Allen Hall: Wow. All right. So you have eventually a somewhat global patent, so to speak. That’s not how it works, but it… that’s essentially [00:16:00] what you’ll have, uh, for BladeBlock to solve problems globally. Would, would that also involve, like, offshore wells too? Yes. Do they have the same problem? So I’m thinking of Texas ’cause we’re here, but offshore of the coast of Norway where they’re drilling wells, or in the North Sea or- 

    James Timmins: Persian Gulf.

    Yeah … 

    Allen Hall: Persian Gulf, sure, that they can use BladeBlock to solve some of their problems- Yes … which they couldn’t have solved today. 

    James Timmins: Yeah. 

    Allen Hall: So d- have they abandoned wells because of this problem? 

    James Timmins: Yes. Um, especially in certain formations you have what are called vugs, which are basically just large limestone caves that have been- 

    Allen Hall: Limestone 

    James Timmins: is tough.

    Yeah … so you can put a whole car down there if you want- … and, uh, still not fill it in. So, um, you know, this product, it basically is practically inexhaustible from you know, it’s… We’re kind of only limited by how much we can manufacture on- How much you can 

    Allen Hall: process … 

    James Timmins: right. So, um- It’s kind of a good problem to have for us, but 

    Allen Hall: [00:17:00] Yes.

    It changes the whole dynamic of blade recycling, because the blade recycling effort up to this point has been the operator or the OEM pays the recycler to grind the blades, and then they have to find a way to source out that material. But the, basically everybody’s trying to reuse the material because it, it does have value.

    How do we best reuse this, right? This is what the recycling efforts are on the recyclable blade, uh, resin systems that are happening. But you’re just taking the existing blades that weren’t meant to be recycled and recycling now in a product that has a lot of value. 

    James Timmins: Correct, yes. So obviously the biggest challenge everyone faces is the economics of it.

    And you- 

    Allen Hall: You know how many people have been working on that problem? Literally thousands of people have been working that problem, and you guys figured it out at a birthday event. 

    James Timmins: Yeah, uh- … totally out of left field. Um, it, it just, it’s one of those things that sticks in the back of your head, and you think about it for 10 minutes, and you’re like, “Oh, uh, why-” But 

    Allen Hall: I have [00:18:00] a, I have a solution.

    Like, we can use it here. Yeah, which, you know, most people, that would never have occurred to. 

    James Timmins: Right. And it’s kind of a technical rabbit hole, like the drilling fluid is- It is … it’s, it’s, so it’s not a whole lot of people out there thinking about lost circulation material- … uh, on a daily basis. Um, but that was, you know…

    The problem with so many of these applications is you’re competing with, in some cases, literal dirt and sand. We pay f- five cents a pound for sand or concrete filler, fly ash, whatever, and it’s like, well, you’re never gonna process it that cheap, or you’re never gonna way to, to be able to economically process it that cheaply, so.

    Allen Hall: Sure, but there’s unique applications where those things don’t work. 

    James Timmins: Right. 

    Allen Hall: And you can now make an unprofitable drill hole profitable. 

    James Timmins: Yes. 

    Allen Hall: That’s a game changer. So this is remarkable, and I, I know you guys have been working on this for a couple of years, and it’s, EverPoint has always been, [00:19:00] and we’ve talked to EverPoint for a couple of years now on the podcast of, when we talk to recyclers, we don’t act- we actually have talked to a number of recyclers, but we don’t have them on the podcast because it’s, seems like the amount of material coming into their facility and the amount of material going out are not the same.

    Correct. They’re landfilling them or whatever’s going on, which is, it, it to me is trouble, right? 

    James Timmins: Right. 

    Allen Hall: You, your, EverPoint has always been, “We are actually gonna do what we say we’re gonna do. We’re gonna take the solar panels, we’re gonna recycle, we’re gonna…” You’ll be able to follow it. Correct, yeah. Which is one of the technologies that EverPoint brought, is you could follow your recycling product all the way from the site to where it finally ended up at.

    That was remarkable. That was an industry-changing, uh, idea, and I appreciate that EverPoint was doing that. Now, you’re actually turning it into a viable product called Blade Block. Game changer. Now, our podcast is probably not heard by a lot of oil and gas folk, but the, you know, the word does spread and we [00:20:00] have almost two million YouTube subscribers at this point.

    How do people get ahold of you to purchase BladeBlock? Do they go onto your website? Are they- 

    James Timmins: Yeah. I mean, LinkedIn, website. 

    Allen Hall: Okay. However. 

    James Timmins: Yeah. 

    Allen Hall: So- And, and what’s your website address? 

    James Timmins: It’s everpointservices.com. 

    Allen Hall: Okay. And you’re based in Texas? 

    James Timmins: We are. Houston. 

    Allen Hall: In Houston, right. So the, everybody that is interested in having improved oil and gas drilling mud, uh, can use BladeBlock now, and it’s a viable product that’s being offered, it’s patented, it’s gonna ship globally.

    It’s the right time and it’s the right way to recycle your blades. So if you have a, a wind turbine farm that’s being decommissioned, there’s a lot of repowering happening right now, uh, there should be a lot of, of blade material available to make BladeBlock with. So congratulations. That’s remarkable.

    James Timmins: Thank you so much. 

    Allen Hall: James, so thank you so much for being on the podcast. Of course. It was great to meet you. 

    James Timmins: Nice to meet you as 

    [00:21:00] well.
  • The Uptime Wind Energy Podcast

    Vineyard Wind Battles GE Vernova, UK Funds Blade Innovation

    2026/06/23 | 28 mins.
    Fraunhofer studies uptower carbon blade repairs, Vineyard Wind’s fight with GE Vernova deepens, the UK backs offshore innovation, and a 26-year Horns Rev study tracks how birds adapt to 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!

    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: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Rosemary Barnes, Yolanda Padron, and Matthew Stead. Fraunhofer has published peer-reviewed feasibility research in wind energy science. And Rosemary, I don’t know if you read wind energy science, but there’s a lot of good information there about wind turbines and mechanical aspects.

    Not much on the electrical side, but a lot about mechanical. Uh, in, in, in wind energy science, uh, they had a discussion or an article about repairing damaged pultruded CFRP spar cap planks while the blade stays on the turbine. Using finite element analysis on a 81.6-meter [00:01:00] blade from a seven-megawatt offshore turbine, the researchers found that a shear web window cut out as short as one meter drops buckling resistance from 20.7 times critical load to four times critical load, a reduction of over 80%.

    The fix? Temporary external clamping frames with a pre-tensioned span-wise rod to carry gravity loads, combined with internal push rod assemblies and external stringers profiles to restore buckling resistance, all installed and removed uptower. Wow. I know we’ve discussed the carbon pultrusion repair situation and how critical that is or h- how difficult it is.

    I didn’t realize it was that difficult, Rosemary, that if you actually try to replace a one-meter section of a carbon pultrusion, you’re re- reducing the, the, what, the, the buckling resistance by 80%? [00:02:00] Holy moly. 

    Rosemary Barnes: I don’t think that’s even 100% pultrusion specific, right? They’re talking about cutting a, a window in the shear web.

    Allen Hall: Yes. 

    Rosemary Barnes: So that could be for any kind of repair you might have to do that, including if you need to repair, like sometimes you need to repair the, the shear web. Um, and even though, like, they’re not doing a lot of heavy lifting, um, that’s kind of a structural pun, um, they’re still super important. If they’re not there, then you’re gonna have big problems pretty immediately.

    The way that it works with repairs is that there’s certain kinds of damage that you know that you can just do uptower. The technicians know they can do it. They don’t need to call an engineer. The engineer doesn’t call- need to call the expert engineer. But when you need to do something a bit unusual, like a whole meter of web removed, then you’re gonna need to get an engineer to, um, dial in the, y- the, to rerun the design codes basically, um, but with this weak structure now to see is this okay and is it okay, you know, uh, [00:03:00] obviously a turbine that is just, um, idle or it’s not even idle, it’s just fixed in place while they’re repairing it, that has different loads on it to one that’s operating.

    So, you know, they’ll run that and make sure that it’s safe, um, before they do the repair. So what I really like about Fraunhofer is that they in some ways, like- Maybe it’s not cutting-edge science or engineering because they are largely repeating what is already well known in industry. But the problem is that industry doesn’t tell everybody else.

    And so it is, like, such a vital role to then go and illustrate, um, to everybody else what, what’s happening in industry. And they, they are… Like, there is this problem with wind energy where academia and industry are not, um, talking too much, and a lot of the academic stuff just doesn’t relate at all to what’s happening in the industry.

    But Fraunhofer do, like, 90, 90% of the time seem to get it at pretty right. 

    Allen Hall: When a carbon protrusion is [00:04:00] used, that really localizes where the load is versus in, in some of the more fiberglass designs that I’ve seen, the shell is actually taking some of the load. It’s not all in the shear web, so to speak. So doesn’t that sort of focus the loads into one location a little bit more when you move to carbon?

    Isn’t that the point? 

    Rosemary Barnes: Yeah. Well, the carbon fiber is, is a lot, lot, lot stiffer than, um, fiberglass, and it’s, it’s a lot stronger. So yeah, you are designing… I, I mean, always the spar caps have been the main load carriers, the, um, you know, the main laminate, the bit between the shear webs or over the shear webs.

    Um, but it’s, yeah, it probably is, um uh, e- exacerbated or the increased effect when you add carbon fiber. But the, the thing about carbon fiber is it’s so susceptible to small damages or small deviations, so like a tiny little bit of fiber waviness, like if your fibers aren’t perfectly straight, then you can easily get a, a crack.

    And [00:05:00] carbon fiber can also be a lot less forgiving than fiberglass. It is not uncommon that it will just break, and you didn’t even know there was anything wrong. So that damage intolerance is what led to people moving away from carbon fiber fabric and into pultrusions, because they’re made with perfectly straight fibers.

    Um, but it, it raises some, uh, problems of its own because y- yeah, like how do you repair that? You can’t, um, you can’t get the fibers as straight again unless you repair a whole plank, um, because like they look like, like two-by-fours or something. You know, like they look like little fence palings, basically.

    Black, black fence palings. Um, and so yeah, you, you’d have to repair, replace a whole one, and then you’ve got like a big chunk of structure that’s missing there, so that’s pretty hard to do uptower. I, I don’t know anybody that does those uptower, actually. Um, m- maybe they can now with this reinforcement method, but I would still not enjoy being in a blade that was missing a, a [00:06:00] pultrusion and up in the air.

    Allen Hall: The offshore versus onshore equation, it, it would make more sense onshore to actually drop the blade, I assume. Offshore adds difficulty, but it sounds like with all the rigging a- and assembly that you would have to do offshore, it, it probably is gonna be close in terms of total cost to do an uptower repair versus a downtower repair I would think.

    It, it– Wouldn’t you think it’d be roughly right? 

    Rosemary Barnes: Yeah, like in, in offshore, there’s always more motivation to do complicated, um, expe-expensive uh, things that will save you from having to do something even more expensive, like bringing, um, a whole blade back. Uh, yeah, going out, getting the vessel with the crane, bringing the blade down, and taking it in is just incredibly expensive.

    So you can spend a lot of time faffing around reinforcing a blade uptower before you, um, you know, would come out behind. But you know what? While we’re on topic of carbon pultrusions, I think it, like it, um, it’s almost bypassing the, the biggest risk with them ’cause [00:07:00] what I see is the– Like it’s one thing when you know you’ve got damage that you need to repair, but far more common, I think, is that you don’t even know that you’ve got damage.

    It’s very hard to, to see what’s going on in there. Um, I mean, people aren’t just going up periodically and doing ultrasounds, ul-ultrasound scans of their entire blade. But even if they were, it’s still not that easy to find all of the, the little damages in, in pultrusions. So, um, yeah, that’s something…

    ‘Cause it’s not such an old technology. It’s been around for, I, I don’t know, like not even 10 years these have been, being used consistently, probably more like five, um, that there’s been a lot of them out there. And I just, yeah, I, uh, maybe I’m overreacting because all I see is broken blades in my career, but, um, you know, I am a little bit worried that we’re gonna start to see as, you know, fatigue builds up, that we might start to see some more like sudden breakages in these blades.

    Allen Hall: If Fraunhofer’s working on it, there must be a reason for the [00:08:00] analysis and all the engineering time that they spent on it, that it’s a concern. I don’t know how you would do it offshore, honestly, because of all the wind loads. That you would have this damaged blade, and yes, you would have all the engineering calculations, but I would just see the safety people being very concerned about it.

    Because if it does go free, you have a couple of people up there minimum, and who knows what’s below. 

    Rosemary Barnes: But even the amount of time in between knowing that you have to, um, replace a pultrusion and actually getting up there to do it, like I’d be surprised that it didn’t break in that, in that time because it is such a big, a big, a big thing.

    Um, so yeah. Uh, but super interesting work and I do, I, I do really, really appreciate that the Fraunhofer exists to, you know, do this sort of stuff and, um, give us the information w-we need to get a better understanding.

    Allen Hall: Delamination and bondline failures in blades are [00:09:00]difficult problems to detect early. These hidden issues can cost you millions in repairs and lost energy production. CIC NDT are specialists to detect these critical flaws before they become expensive burdens. Their nondestructive test technology penetrates deep into blade materials to find voids and cracks traditional inspections completely miss.

    CIC NDT maps every critical defect, delivers actionable reports, and provides support to get your blades back in service. So visit CICNDT.com because catching blade problems early will save you millions

    UK government has deployed 15 million pounds, uh, which is about $20 million, uh, through Innovate UK in a coordinated push to move offshore wind technology from prototype stage into commercial supply chains. The package has three components: a 10 million [00:10:00] pound offshore wind innovation program, open competition for high potential businesses, a five million pound wind innovation hub to align industry, government, and research, and a 12 million pound effort for phase one of a large structures innovation center on the Isle of Wight, with Vestas already signed as its first industry partner for sustainable blade development.

    So the, the large structure innovation center is a composite center which is gonna be doing some advanced technology work on blade design. And I think there’s no better place to do that at the moment than in the UK. But it does open the door to a number of UK firms, and even outside the UK firms, to get involved in the UK offshore and somewhat on the onshore side.

    This has massive potential, I think, within the UK and outside the UK, Matthew. 

    Matthew Stead: I, I know from my own firsthand experience that, um, uh, actually getting into the wind space is, like, really [00:11:00] hard. So for this sort of, um, incubator and support around, um, you know, setting up businesses, I, I think this is a really, really good thing for the UK government to be doing.

    Um, ’cause, yeah, how do, how do you build up a future industry if you, if you don’t have the new businesses coming through? So I, I think it’s a, it’s a, it’s a great thing that the UK government’s doing. And yeah, and how do you get small companies working with the larger OEMs? How do you get the innovation?

    Yeah, it’s, yeah, I think that’s probably, you know, got five gold stars for the UK government. 

    Allen Hall: What are the areas that they should be focused on over the next couple of years? Obviously, blades is, is a massive one. I’m sure Vestas is gonna be deeply involved with that. Are there some other areas in technologies that the UK should be orienting its supply chains towards?

    Matthew Stead: I’m personally 100% biased towards blades ’cause w- we know that, you know, um, if we look at the failures and we look at the failure rate, you know, where is the greatest growth in failure rates? It’s blades. Um, [00:12:00]you know, why, why are we still having failures? Why haven’t we learned? You know, where is the knowledge exchange?

    Um, so I- I’m biased, but I think it’s, it’s, it’s, it’s needed in, in the blade space. Yeah, as what, you know, Rosie and you were talking about before, um, you know, knowing more about, um, what’s going on, how it can be repaired, how it can be dealt with, I think is super, super critical. 

    Allen Hall: Well, Vineyard Wind has its 62 turbines in the water south of Martha’s Vineyard, but the project is delivering only partial power while GE Vernova works through its outstanding repairs.

    Now, the financial pressure is breaking into public view on two fronts. Boston landlord BP Hancock LLC is suing Vineyard Offshore, uh, the Avangrid and BP joint venture, for nearly $1.2 million in back rent at its John Hancock Tower offices. Uh, separately, GE Vernova wants out of its turbine supply contract, claiming Vineyard Wind owes [00:13:00] it over $300 million.

    Vineyard Wind fires back that it is actually owed more than 800 million from GE Vernova, so that, that saga will continue for a while. But it is a little odd that the rent is not being paid by Vineyard Wind at, at, in the John Hancock Tower. And if you’re familiar… That’s downtown Boston. If you’re familiar with downtown Boston, that, the John Hancock Tower is one of those iconic buildings you see in pretty much every downtown photo of Boston.

    There must be a lot happening at the moment at Vineyard that they’re not able to pay the rent, or they’re trying to shuffle some money around or, or seek more financing. Sounds like they’re in a refinancing phase, honestly. Yeah, 

    Yolanda Padron: I know that at, at times there’s– it’s really common for, for an asset manager to think, you know, “Oh, we have X amount of money,” and then all of a sudden you– it’s all of the, the additional [00:14:00] repairs or the additional operational costs stack up to a bit more than they thought they were gonna have, and then maybe they don’t even have enough money to go do trash removal or anything.

    And that happens, and it’s more often than, than we’d like to admit. Um, but this is on a bigger scale, right? Like, this is a project that we’ve talked a lot about, everyone’s talked a lot about, and it has a lot of eyes on it. And so for it to, to be so behind on rent on such an iconic place and such an important place and such an important part of the country, backed by a very important company, it’s really, it’s really interesting to, to think about kind of what they’re thinking.

    ‘Cause in, in my mind, right, like, if I was the people backing them, I would think, “Okay, well, the f- first thing’s first, like, let’s not give them any additional reason to hate us right now.” Right? Or like, you know, the public opinion is really big on these kind of things. Um, so I, I don’t, I don’t know what the, what [00:15:00] the exact plan is here.

    Allen Hall: Well, I wonder if this is part of the, the negotiation with GE Vernova, that, uh, the, the payments and the, the power which leads to payments, uh, hasn’t been at it- its desired output from Vineyard Wind and is this an effort to, uh, shore up their legal case with GE Vernova to say, “Hey, look, uh, Avangrid’s not gonna throw a bunch of money in, even for rent.

    This project needs to stand on its own two feet, and it can, but GE Vernova needs to be involved with it and get the turbines up and running to the level at which they were contracted to do”? Is this part of that play? ‘Cause it just feels like it. You know Avon Grid has the money to pay the rent. That’s not even a question.

    It’s, but it’s why they are not doing it is probably the bigger question at the moment. Is, is it just all legal maneuvering at the minute? 

    Matthew Stead: I, I wonder if it’s a bit like, uh, you get the utility billing, you get the [00:16:00] electricity billing, you put it in the, the drawer over there, and then you forget about it, and then you forget to pay it, and- 

    Allen Hall: It’s a million dollars

    Matthew Stead: $1 million out of, uh, 600 or whatever billions, you know? Maybe it was, maybe it was just a simple oversight. 

    Allen Hall: It could totally be oversight, but it’s, it seems like with the amount of attention that Vineyard Wind and GE Vernova are, are getting, and they are literally within a stone’s throw of one another, they can s- I’m– You could probably see the GE Vernova building from the John Hancock Tower, that, uh, you, you think that some of this would get settled, but it’s not.

    It’s still going on. It’s, it’s crazy. It– With, and with Avon Grid and BP still being involved with it somewhat, uh, there’s something happening behind the scenes that has not poked its head up yet. It’s coming, though. This is all coming to a head pretty quickly. The– Massachusetts needs Vineyard Wind to run.

    They really do, and it’s, it is a little surprising at [00:17:00] times that the state of Massachusetts is standing on the sidelines in this. 

    Matthew Stead: As wind energy professionals, staying informed is crucial, and let’s face it, difficult. That’s why the 

    Allen Hall: 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. In this quarter’s PES Wind, there’s a lot of good articles in there. If you don’t have a copy, you can go to peswind.com and download one. A interesting article from Safe Lifting, which is a European-based lifting company that does basically bespoke engineering on lifts, and they’ve been making a push that’s saying that the next wave of projects depends on bigger [00:18:00] turbines, of course, which means bigger lifts, but they need to have some standardization to them.

    Uh, things like spreader beams and rigging systems that are pre-built and pre-validated, uh, just reduce the overall engineering time it takes to do these lifts. Uh, and rental equipment models are a lot lower cost than buying OEM-specific or site-specific lift equipment, trying to keep the capital costs down.

    That’s one of the big pushes in the wind industry is lowering the overall cost of installation. It does make sense, but it– as we were talking off-air a minute ago, a lot of lifts for basically the same kind of turbine are different. The, the connection points are different. There’s a lot of engineering that goes on there, and as the turbine sizes reach 15 megawatts plus, and the cells are massive, blades are massive.[00:19:00]

    But it does seem like in a lot of other aspects of wind, there is some standardization, an IEC spec or some sort of overall guidance document for the industry that like, let’s put the lift points here, here, here, and here and lift with the right equipment. And Matthew, we just haven’t done it in lifting, even in smaller turbines, same thing.

    Matthew Stead: Oh, it’s crazy. Um, I was, I was thinking about it, and, you know, my, my suggestion would be that, you know, when I buy 100 turbines, I should get, um, a blade lifting kit. It’s like when you buy a car, you, you get a, you get a kit to change the tire, don’t you? So I would’ve thought it would be just fundamental. Um, but, but, but we know that the wind industry is not always logical.

    Um, so what is, what might be considered normal in a car is not normal for a wind turbine. Um, but yeah, uh, you know, this sounds like a perfect way of going to have more of a sort of standardized and, you know, not, not wait for the OEMs, but actually lead this and, and [00:20:00] drive this standardization. So yeah, thumbs up from me.

    Yolanda Padron: I think this is really cool. Uh, I really hope that if we can standardize the way that we do that, we can make sure that the teams are trained in, like, the standard ways of, of lifting. I know that, um, I’ve, I’ve seen a few cases where someone didn’t know, there hadn’t- been exposed to a particular blade type and they were in char- you know, in charge of, of lifting it to, to, to do a blade replacement and then, um, they accidentally ended up damaging the blade and so you had this bad crack that they kind of painted over because it was a little bit embarrassing for them at the time.

    And then, you know, a year later it’s like, well, okay, well, maybe next time ask someone, um, if you if you don’t know the, the exact lifting protocols or, or if you mess up, you know, let someone know. Um, but, but [00:21:00] yeah, the, you know, a lot of these, these smaller and, and larger structural cracks that, that come from, from lifting errors would be avoided if everybody was doing the same thing or the same two iterations of Of lifting standards, which is really exciting 

    Matthew Stead: Y- y- if you’ve got a wind farm, y- y- you’re guaranteed you’re gonna have to drop a blade at some point, aren’t you?

    Allen Hall: And a gearbox 

    Matthew Stead: and a generator It’s, it’s pretty much a given. So like, like I said before, I reckon it should just be part of the standard kit that you buy, is you, you, you buy a substation, but you also buy a lifting, a lifting kit as well. 

    Allen Hall: It’s one of the more, uh, dangerous parts of wind is lifting, clearly, and we’ve seen that over time.

    And, uh, having standardized equipment, back to Yolanda’s point, does make a lot of sense because if you’re out there doing this quite often and you have different rigging for every different OEM, you can get crosswise, and things happen. And if we had some standardization there, that would make a tremendous [00:22:00] amount of sense.

    That’s why, uh, Safe Lifting wrote this article on PES Wind. So if, if you wanna read this article, just visit peswind.com. When engineers plan an offshore wind farm, they try to account for everything, including seabirds. And at the Horns Rev wind farm in the Danish North Sea, the layout was meant to leave birds a clear way through, but the birds had, uh, ideas of their own.

    After 26 years of patient monitoring, researchers found that the turbines did not simply chase wildlife away. Instead, they reshuffled the entire neighborhood in the sky, turning some species into avoiders and others into opportunists. So this has been a big discussion in the wind industry for a long time, particularly for offshore wind projects, of what to do with the birds.

    And the early assumption was that, hey, let’s just give them a pathway where they can fly [00:23:00] through, and birds have made up their minds. Some are taking that path. Others are avoiding it because of the change in the which, uh, species are hanging out where. This is a remarkable outcome, and it’s been going on long enough that there’s, uh, some statistical relevance to it now.

    Do we need to get some bird psychologists involved in these offshore projects on how we think of how birds behave? Because I think to the engineering community, you know, like, you, you put a road there for you to fly through, bird, and then you decide not to. This is at a different level than engineering.

    Yolanda Padron: I think it’s great to do as much as you can do, right? It’s amazing that they did all of this work. It is kind of funny. I mean, it’s, it’s sad. I’ve… I’m, I’m gonna get into trouble on LinkedIn or something by someone. I, I mean, it’s, it’s sad, of course, if, if birds get hit, right? But it’s, it’s, we can’t control everything.

    You [00:24:00] know, as much planning that went into this, it’s

    And what’s the next step here? 

    Matthew Stead: Well, first of all, 26 years? Is that correct? Yeah, 26 years. I mean, m- I, my- the thought that came to mind is that sometimes engineers don’t understand the natural environment. Sorry, just, just take that as a, as a observation. But, you know, I- it just reminds me of when, um, when civil engineers lay out paths and pavement, you know, they put a path in, but then people walk around it.

    People do whatever they wanna do. And so, you know, I, I don’t think we can actually design out some of these things because we just will never understand the bird, we’ll never understand the human. Um, so yeah, I think put a little bit of effort in. I think going back to what Yolanda said, just put a, a bit of effort in.

    But yeah, actually, there are some things in this world we can’t control. 

    Yolanda Padron: Yeah, I mean, [00:25:00] there’s, there’s of course endangered species. There’s of course, you know, a lot of, a lot of monitoring companies out there that do a really good job. Depending on what you need and depending on, you know… You can tailor your site needs around w- what’s gonna happen, right?

    Or, you know, if you know that you’re in the migratory pattern of a particular species- There’s, I know there’s a lot of very smart people hard at work to make sure that your site is tailored to fit what needs to, what needs to happen there. And it’s great. I think it’s a great, it’s great to know, you know, that, that people in this industry care about birds.

    I know I once had to go through extra check at TSA because the, the person there said, you know, “Oh, you work in wind? Save the birds.” And then he sent me through this, like, a lot, because he, he thought I was killing birds every day. Um, so I mean, you know, [00:26:00] we’re not killing birds out here, and it’s great, and it’s lovely to see all the hard work that goes into this.

    But it, but it also, it’s, it’s important to note that the plans aren’t gonna be 100% foolproof, and that’s okay. You can just try your best. 

    Allen Hall: What’s the one bird you would assume as an engineer would not care if the wind turbines were there or not? The bird you see absolutely everywhere around the sea.

    Matthew Stead: Seagull. 

    Allen Hall: Seagull. They do not care. They love wind turbines. They’ll use them as perches. I’m sure that, uh, yeah, a lot of, uh, technicians had to deal with seagulls, uh, hanging around the wind turbines. That has to be a thing. So it just depends on the species, for sure. Which is unique, right? E- every species has its own separate personality and things that it likes to do.

    Uh, so in some of the wind turbines, I’m sure the seagulls are probably an annoyance, but they’re gonna let them be. And s- and some other species just don’t wanna be around the wind turbines, so even if you put a pathway through them, they’re just not gonna be [00:27:00] there. That’s an interesting finding. 

    Matthew Stead: It’s like onshore as well.

    I mean, cows and sheep love to stand in the shade of a wind turbine, so they like to hang around. They scratch themselves on the, on the, the stair. You know, they, they rub themselves on the bolt covers. You know, they try and eat stuff. Goats, goats are particularly bad. 

    Allen Hall: Goats are really aggressive on wind farms for finding wires.

    Absolutely. An- anything to eat. 

    Yolanda Padron: Raccoons. 

    Allen Hall: Yes. Raccoons. 

    Yolanda Padron: Snakes. 

    Allen Hall: The snakes do hide out in the shade. That is one thing you gotta be careful about is, uh, especially in Texas, of kicking over a rock and finding a snake, so make a lot of noise when you’re walking in Texas. That’s the plan. 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, and don’t forget to subscribe so you never miss an episode. And if you found some value in today’s conversation, [00:28:00] please leave us a review. It really helps other wind energy professionals discover the show.

    So for Rosie, Yolanda, and Matthew, I’m Allen Hall, and I’ll see you here next week 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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