Connect with us

Published

on

Weather Guard Lightning Tech

Blade Repair Academy’s Expert Technician Training

Blade Repair Academy in Tennessee offers comprehensive blade repair training programs for technicians. Alfred Crabtree, Founder and CEO, and Sheryl Weinstein from SkySpecs highlight the importance of technician competency, hands-on experience, and standardization in the wind industry.

Sign up now for Uptime Tech News, our weekly email update 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 Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!

Allen Hall: Alfred and Sheryl, welcome to the program.

Sheryl Weinstein: Thanks.

Allen Hall: So we’re in Dunlap, Tennessee, not too far from Nashville, uh, and also close to. Chattanooga Chattanooga, and we’re in the Smoky Mountains ish region.

We’re

Alfred Crabtree: no, we’re, we’re, you could consider it Appalachia for sure. Sure. Okay. Uh, we’re on the, in the valley called the Seche Valley, uh, which splits the Cumberland Plateau. So we’re, we’re in a valley and we have hills a thousand feet above us here. Yeah. Either way. It’s beautiful.

Joel Saxum: Yeah. It’s a great drive in here.

Alfred Crabtree: Yeah. It’s a unique place. Yeah.

Allen Hall: And we’re at Blade Repair Academy, which, uh, if you’re not familiar with Blade Repair Academy, you should be. Uh, because a lot of the good training that happens in the United States actually happens to play repair, repair Care blade, repair academy. Uh, yeah, it’s been a long week at uh, OMS this week and we got the introduction today.

This is the first time we’ve been on site. That’s right. And, uh, we wanted to see all the cool things that are happening [00:01:00] here. And it really comes down to technician training competency. Working with blades, working with tools, knowing what you’re doing up tower when you’re on the blade, which is hard to train.

It’s really hard to train, and both you and Cheryl have a ton of experience being up on blades and repairing blades and scarfing and doing all the critical features that have to happen to make blades work today. It’s a tough training regimen. There’s a lot to it and a lot of subtleties that don’t always get transferred over from teachers to students unless you have.

Done it for a number of years. You wanna kind of just walk through the philosophy of Blade Repair Academy?

Alfred Crabtree: Yes. The, uh, you’ve, you’ve outlined quite well some of the issues. The environment where we work is very hard to take a ti the time to put somebody through a training regimen. We’re so constrained by weather windows and then.

You know, even if the weather’s nice, lightning can come, wind [00:02:00] speeds can cut off your workday. So production, production, production is what’s important. And Cheryl and I both come from the rope access method. And in the rope access method, 95% of the time you’re up there alone. And if you’re up there and you’re producing, you’ve got your blinders on.

Speaker 2: Mm-hmm.

Alfred Crabtree: And you’re not ready to share with somebody else what to do.

Speaker 2: Mm-hmm.

Alfred Crabtree: With the basket or platform, you can have two even three people up on Blade, but it still has all these constraints of get the job done, get the job done. There’s a lot of stress up there. And having the bandwidth to take on new information or to challenge some preconceived notions or try, that’s not the place to do it.

So knowing that. Blade Repair Academy is built so that we have an environment that simulates all of the up tower stuff without being up tower. And you’re gonna have the time you need to invest in your learning without consequences. Right. So it’s a very much a [00:03:00] about creating the right environment to uptake the new information.

And we have found a lot of help from. Manufacturers and suppliers in the industry to sponsor us because obviously it behooves them to have their materials in the hands of trainees. So we’re also able to help companies come up with, uh, new solutions, try new products.

Speaker 2: Mm-hmm.

Alfred Crabtree: New, uh, you know, what’s the best practice.

For this, if you’re up on Blade and you have a way of top coating and you get a new product and your way of top coating doesn’t suit that product, well chuck it down. I’ll never touch it again. Yeah. Because I did not perform well here we can, we can give you training. We have, of course, been trained by the suppliers about what’s the best product to use, what’s the best way to go about things, and then, and then we can disseminate it.

So that’s the fundamental reason why the space is. Is [00:04:00] what it is.

Joel Saxum: Yeah. And I think that that’s, that’s a good segue to be honest with you, right here, right behind these doors you have a classroom. That’s right. Right. So in this facility, all composed in one, we have a classroom here we have your additive and subtractive.

I liked how you said that to us when you’re giving us the tour. Uh, but we’ve got a, a grinding booth basically over here and we’ve got, um, a layup area here where you can teach. 16 people at a time.

Alfred Crabtree: That’s right. Yeah. That would be max

Joel Saxum: for sure.

Alfred Crabtree: Yeah.

Sheryl Weinstein: And in a vertical surface, so, ’cause all the stuff that you’re doing in the field, right, is always in a vertical surface.

Mm-hmm. So there’s a, there is a big difference between working where gravity is sort of against you, especially with larger laminations and things like that. So being able to do your training and simulate the same, a similar way that you would work in the field is pretty critical, I would think.

Allen Hall: And actually working on.

Actual repairs. Simulated repairs, yeah. Mm-hmm. Now, don’t explain how you created them, because I know secret sauce. It’s a secret sauce. Yes. But I did look at the blade [00:05:00] damage. It, it looks exactly like a lightly strike. Yeah. Which a predominant amount of repairs are about, unless there’s, you know, serial defects, as Cheryl has pointed out numerous times, but.

Being able to repair something that’s quasi real is critical because we’ve been to other places and the repairs are, well, I’ll take a hammer and I’ll hit this and, okay, sure you got a DA, you gotta repair that. But that’s not real. And getting, getting the people to use the tools in the right way, vertically

Speaker 2: mm-hmm.

Allen Hall: Is the key. Because although the, the, the article, the test sample isn’t moving around like you are up on a blade, it’s still difficult. And unless you have the proper techniques and the approaches, yeah, it’s gonna be dang near impossible. We explain some of the blade repairs that Joel and I have seen more recently is like.

It’s a little rough and it shouldn’t have to be so rough because it is a skill that you have to learn and acquire over time. But you have to know the fundamentals. That’s what Blade Repair Academy is here to teach you those [00:06:00] fundamentals. Like, yes, it’s gonna take time, but if you work it this way, at least you’re gonna be successful.

Alfred Crabtree: Yeah. And if you’re managing a team of employees who are doing this, it, it would be great to have the insight of what your teams. Strengths and weaknesses are, yeah, you can figure out how to deploy people, but also how to, you know, maybe fix some of those problems. Mm-hmm. Our panels that you brought up are standardized.

Everyone looks exactly the same. It’s the exact same makeup, and we standardize the damage. So when somebody has to repair damage here, the core removal size is the same on everyone. That way when we’re comparing the reports, you can actually have a apples to apples comparison of the, the trainees. Outcome.

Speaker 2: Mm-hmm.

Alfred Crabtree: And now you, you know, in, in the model that you talked about where people will go to a, you know, their junkyard of blades and they’ll find spots on blades to put their eight guys on. Those eight people are not gonna be doing the same repair. And even if they are collecting data, what are you [00:07:00] comparing?

It’s not

Joel Saxum: apples to apples. Yeah. It’s not.

Alfred Crabtree: So we really tried to start from the beginning, fresh with a whole new idea of how to approach this. Mm-hmm. By not being attached to an ISP, we don’t have to deal with. Oh, here, use all our leftovers. Yeah. Yeah. That’s your training budget. Yeah. Yeah. And oh yeah. We, you know, we’re an, we’re a owner operator, so yeah.

Go work on that blade in the grass. Mm-hmm. That those limit what precious time we have available to train. Yeah. So this thing from the ground up is about. Making as much advance in the skillset and understanding that technician in the, in the week that they’re here.

Joel Saxum: I think that was a really cool thing we touched on as well.

Your, your team here as well, Cheryl. Thanks for traveling up to, to hang out with us. Offer some insights too. But you guys, because you’ve been in the people that have developed a curriculum yourself, Cheryl, your, some of your team sitting over here, uh, and, and people around the industry that have helped out with the place, you have the ability of like, okay, we have.

Eight brand new technicians. Let’s make [00:08:00] sure we walk through how to measure from the trailing edge to the blade center up, mark this thing out, these kind of things all the way to some stuff that I didn’t really think about that much. Like I’ve used an angle grinder before, right? But I’ve never looked at five different ones and decided which one would be the best for my hands.

Thinking about it up on the blade, how you’d handle it with your fingers, these kind of things like, I was like, man, that’s, those are real insights that you’re not gonna get to learn. Like why put someone up to let them have a whole season or a whole summer, two summers figuring out how to hold a grinder?

Well, when they can learn from someone that’s been doing it for years and years and years and can teach them these things. So from advanced or from very beginners learning fundamentals to advanced training, you guys have gotta cover here.

Alfred Crabtree: There’s something here to glean for everybody, and even if you are a well experienced technician, maybe what you’re gonna get most is learning how to talk the language of the new techs and the new hires who are getting the.

Introductory course training. You know, our, our el our basic course is called support. It’s 40 hours [00:09:00] and it’s really about making, uh, an employee who can support a lead. And then if that person follows up with the lead training in a whatever interval of time of their choice, which is kind of another benefit here, we can train you any week of the year.

That is where we start to really get this, we call it the retention vortex. Right where we layer up technician training and somebody who’s had level two now gets a level one with them. Now there’s some synergies. Now they’re getting some really efficiencies. A commonality of language, a commonality of process, you know, eliminating variables.

Uh, and that’s how you’re gonna have to build new net capacity and build new teams

Allen Hall: and that common language. Is really unique, but that comes from your experience in the field, mostly at rope partner, where you both really got your teeth in this industry.

Speaker 2: Mm-hmm.

Allen Hall: But communicating to one another correctly so you can pass along to the next crew or even explain what you did to the engineer, the.

Properly [00:10:00] there is. There is a culture to it. There is a language to it, and you just don’t pick that up. By going from wind turbine to wind turbine. You pick it up in training from someone who knows how to do it. It’s really critical.

Sheryl Weinstein: It’s pretty critical to have baseline training. I think it is also very important to follow it up with field experience and skills building because every blade model is different.

Every repair is different. You’re always gonna encounter something that deviates from that like standard approach to your repair. You have to kind of know how to problem solve, and that kind of only comes with the field experience, but having a more standardized training to start with, it’s something that industry doesn’t really have and is really needed.

I think across the board it also helps, you know. Owner operators or even OEMs kind of track their ISPs and understand what level of text do you have, what experience do they have and how, how does that differ across their different [00:11:00] levels? If we have one ISP training one way over here and another one training another way over here, and they have different sets of certifications.

It’s really hard to keep that all together and evaluate it as an owner operator or an OEM, you know, using a vendor. So I think having a place like Blade Academy that’s agnostic and separate from like, you know, the actual ISP really helps to standardize that a bit more.

Allen Hall: Yeah, because the key is we’re getting to, well, we’re gonna cross a hundred thousand turbines in the United States pretty quickly.

Yep.

Joel Saxum: Before 2030, or probably rated about 2030.

Allen Hall: Right. That’s. Soon. Mm-hmm. How are we gonna manage that? And there’s a lot of new people coming into the industry, obviously. How are we gonna train ’em up properly? How are we gonna communicate to one another? And there’s just so much movement in the industry. I.

It makes it hard, I think, because weirdly enough, I think ISPs develop their own little culture about how to deal with things, and then they hop to the next company and it’s a different language. Exactly. And that needs to go away. Yeah. There’s a,

Alfred Crabtree: there’s a branch of business that’s [00:12:00] OEM centric and there’s a branch of business that’s asset owner.

Yeah. Post warranty. And those are really two different things. And, and there’s a veil of secrecy between one and the other. Yeah. And we kind of feel here at Blade Repair Academy that we’re like this polyglot that can talk to everybody because we don’t have, we’re not an ip You’re not competing, we’re not an O You’re not competing.

Yeah, we’re not competing. But we, we, you know, we have the, we wanna provide this data as a clearinghouse. You know, we talk about certification in the non standards. Well, the way we deal with it is we’ll give you a certificate. And it’s got our brand on it. But you know, what does that mean? Yeah. What? That And $4 will get you a Starbucks the way we do it, maybe not even then.

Right? The way, the way we, not four bucks

Sheryl Weinstein: for Starbucks, maybe 10

Alfred Crabtree: and a half hour wait in the line. But the way you know, what we do is we provide you with a deliverable. We knew, we knew that. Okay. Our certification is, you know, ether.

Speaker 2: Mm-hmm.

Alfred Crabtree: But [00:13:00] this report. That everybody who comes through here generates that you can compare.

Now you’re gonna have to go to work and study these reports when you get ’em as a deliverable.

Speaker 2: Mm-hmm.

Alfred Crabtree: As a, you know, an employer, but we we’re giving you what you need. Mm-hmm. To make some decisions about what do I have to work on, what else do we need to improve upon?

Allen Hall: Yeah. Not everybody’s built for this job, but you wanna be able to suss that out.

Earlier rather than later. Yeah. Right. I mean, there’s other things to do with wind turbines that don’t evolve blade repair. And if they don’t necessarily have the skillset or the comprehension to do some of these more complex things, maybe blade repair is not it. Right. But rather know that now. Yeah.

Right. And the Blade Repair Academy is a place to do that because there’s a standard there, right? Mm-hmm. And I, I, as Joel has pointed out, yeah, there’s a lot of erratic training that goes on. Mm-hmm. You can’t compare student A to student Z. Blade repair academy. You can.

Alfred Crabtree: We can. Mm-hmm. Right.

Allen Hall: And if, if I’m an ISP, I want that.

Sure. I want you to tell me [00:14:00] who’s on top and who’s kind of the middle so I can make decisions about where to deploy ’em and who and who to put ’em with.

Joel Saxum: Yeah. ’cause at the end of the day, every ISP, uh, every ISP that’s trying to grow and scale effectively is trying to do that at the end of the year, right?

Yeah. They’re looking through, they’re grading their technicians, finding out who’s the next lead, who’s this, who’s that? But this is a great way to do that, sort them through in a controlled setting. I mean, we sat in, in your training facility in the actual classroom here, and you walked us through some of the online, the online training platform that you have built.

Some of the things the students have to do before they get here, and then kind of how you walk ’em through things, and it’s impressive. It’s good stuff, right? So when you have that combined with the both sides of blade repair, subtractive, additive, right? You get to get this, this holistic view of what that blade technician can do.

Yeah. Right? And that’s, that’s one of the things you guys offer here, which I think is fantastic.

Alfred Crabtree: Yeah. And we’re trying to constantly improve, you know, we’re talking with OEMs about dissemination of operating procedures or work instructions, share with us [00:15:00] work instructions. We’ll build analogs. That we can train to.

Mm-hmm. And we can test off of it. We can verify skill sets. You know, we have a lot of serial flaw campaigns out there that are critical. And do we wanna unleash anybody on it or do we want to know that those people can do it? I think everybody wants to know that they can do it, whether they’re the.

Technician themselves, or the person writing the checks.

Speaker 2: Yeah. Mm-hmm.

Alfred Crabtree: Everywhere in that loop wants to Now not everybody wants to pay for it. Yeah. But we all need it.

Speaker 2: Yeah.

Alfred Crabtree: And so somewhere along the line, you’re paying for it in the forms of our favorite acronym, COPQ. That’s

Joel Saxum: right. Cost support, quality. You know, speaking about the idea of serial defects or known problems in the industry and how to prepare people for those, how do you prepare people for those?

Well, they gotta get the experience by just. Grinding away Top coat and getting into him. I walked in here and I looked at this blade sample we have here, and I was looking at it and I go, it looks like a 48.7 C Oh yeah. Buddy walks over you like our 48.7 C I’m like, [00:16:00] man, you guys did a good job on, you know, like, so, so I made a lot of money on 48.7, you know, so to walk in here and see these different tickets that you guys have built, you know, carbon plank and different things with carbon spars and hey, we’re gonna do a carbon spa repair.

We have this boom, now we can work on it. Mm-hmm. You know, and we’ll

Alfred Crabtree: work with you to solve your problem in a really quick, efficient manner. Mm-hmm. You know, I think one of the things that we have is operational readiness. Most people who are training in-house flip their hat around for a couple weeks and train composites.

Mm-hmm. In a limited capacity in the warehouse or at the dock at the truck during January. During January, whatever. And then they flip their hat back on and they go deal with it. And I think the hiring situation is so tough. Like working at Height, you probably need to make sure somebody can tolerate working at height.

Yeah. Before you invest in composite training, I mean. You have so many things you have to juggle in your particular situation. When do I put money in this person? We get that. [00:17:00] And so we’re open all the weeks of the year. So we can do this at any time. Of course, everyone wants it in the end of first quarter.

Mm-hmm. You know, right before the season starts. So we have a, you know, you have to, you gotta schedule with us, but we can really do this anytime. And so you don’t have to one and done and live with it.

Speaker 2: Mm-hmm.

Alfred Crabtree: You know, it. You can fit the training into your hiring schema wherever you feel fit, and you can hire people.

And if there are stars, bring them in for their secondary, they’re execute their lead training whenever you want. You know, so you can, we can be very flexible and in the advanced stages we will make what you need, you know, obviously has to make business sense for us, but we’ll make blades to replicate the problems you’re facing.

Sheryl Weinstein: And I think in terms of like what you were saying when you’re working on, you knows whether we wanna call them recurring issues or serial defects. A lot of it is awareness, right? It’s awareness [00:18:00] of understanding the blade structure, at least at a basic level. It’s awareness of understanding what you’re looking at.

It’s, you know, we’re only gonna better inform the industry and the OEM if our technicians have a level of awareness to sort of bring up things that they see as they’re doing repairs. So if they notice that, for example, the, the fibers are misaligned, right? That could indicate that that was a wrinkle, and them having that level of communication or documentation will only help then inform the OEM.

Like, is this the reason behind that problem? And so I think like. You know, with Alfred and, and the curriculum here at Blade Academy, them kind of, you know, setting a standard for how, how you know, the structure of the blade, the different types of blades you may see, whether they have carbon fiber in them, or you know, fiberglass, UD spars.

Where those things are located, [00:19:00] what to be aware of as you’re removing damaged material. It’s really critical to the overall quality and just the awareness of the tech on the blade and that feedback loop that we’re lacking so much in this industry.

Alfred Crabtree: Yeah, for sure. Yeah, and we have our boilerplate products that come from, you know, like, uh, Cheryl was my mentor at RP and wrote partner, and she taught me a lot and a lot of the.

The, the way we do things here comes from the rope, a rope access paradigm, which, you know, actually is backward compatible because if with rope access, you’re doing things alone.

Speaker 2: Yeah.

Alfred Crabtree: So if we’ve have ways and, and processes that allow that to happen alone, then when you’re on a basket or a platform with an extra person, you can only benefit Yeah.

That much easier. Yeah. Um, it’s where we come from, you

Joel Saxum: know, and, and that’s a good point, right? Like when we’re sitting here, rip Blade Repair Academy. Alfred, you’re here. Cheryll, you’re joining us today. These are two X blade technicians that have been on all kinds of blades. They have been up and down on ropes.

So it’s training by [00:20:00] trainers who have been the technicians that’s important. Who have seen the problems. Yeah, yeah. You know, who have lived, have lived that road life. We talked, you’re joking about living in hotels, right? Mm-hmm. Like that have done, gone through that, right? So you’re learning from people that aren’t just like, oh, I hate the idea of going to a university and learning HR or something, whatever, from someone who’s never done it in the real world.

Yeah. You know, uh, the trainers here have done it in the real world, um, and it shows.

Alfred Crabtree: Thanks, man. And you know, the other thing too is our tagline is practical and contemporary. And the thing is, I’m no longer contemporary. Like I left the field years ago. I rely on folks like Cheryl, who’s still in the, in the Blade Services game over there at Skys Specs.

She’s on, she’s got a full subscription to the cereal floss that are out there.

Joel Saxum: Yeah. Probably the best one in the industry, to be honest with you.

Alfred Crabtree: Well, you know. Uh, I think so. I don’t know anything about serial flaw, but it’s, it’s input from the rest of the industry that’s gonna allow this to continue.

Otherwise, we’re gonna be, you know, [00:21:00] a 10-year-old standard that isn’t relevant anymore and that’s not what we want to do. So, outreach like Cheryl and I are talking about, Hey, what is it in your product line that should be in our product line? And I want to talk to OEMs and, uh. Owner operators, you know, what is it?

What are your pain points? What in your fleet is needing attention? And of course, we’re gonna do all this with the business case, right? Mm-hmm. Like we wanna take LEP products and place them head to head and give a two day clinic or seminar to stakeholders, to purchasers. You know, we wanna give our, our two, our five day course condensed into two days.

Where people who are stakeholders who are making decisions about where to place technicians, they should get out here and gr and grind a little bit and get a little empathy for their position. Hard work. The hard work of the

Sheryl Weinstein: hard work that it is. Yeah. And then kind of understand

Alfred Crabtree: from another side where the [00:22:00] communication breakdown is.

’cause it’s, it’s not all the texts, right? Mm-hmm. You know, they have a, you gotta understand how heavily loaded they are, you know, when they’re in the field. Mm-hmm. Um, so we’re, we’re at the place now where we’re really looking to do some outreach and talk to, uh, regulatory bodies that are starting to come up with standards, right?

Like the IEC group met and pro produce a draft standard and they’re gonna work on the repair standard. And that’s a, a little bit of a ways away, but I can’t sit around and wait for, for standards to come to me. So we got this thing started. If you build it, they will come. You guys came, you know, Cheryl came and, um.

We we’re really proud of where we’re at, but at the same time, it’s like, okay guys, the rest of the industry, now we’re here. Now you need to know, now you need to take advantage of us. Mm-hmm. And help tell us what you need. So I think the

Sheryl Weinstein: LEP thing is a really good call out because I do see a lot of customers questioning what do I choose?

How do I know [00:23:00] what to choose? Absolutely. Should my vendor be telling me what to choose? And that’s what happens in many cases, is that the ISP just kind of tells the owner operator. This is what you should use. Well, why, and, and what, you know, how have we ever really sized up like one against the other?

Like in any true, I don’t know, study? No. And a lot of the, a lot of the like. Those different types of LEP, the, the companies that you know have these, they don’t have a lot of good documentation on showing like how their products stand up. I mean, it’s kind of, it’s more theory based than anything. I mean, they put ’em through rain erosion tests and whatever, but.

It’s, I feel like that’s a tough space. It’s also a very, like, um, a very tough scope of work to have high quality at. So more training around it is necessary. You know, repair companies don’t wanna use their high skilled repair techs for the LEP because they need them for the more complex repairs [00:24:00] yet. The LEP is so susceptible to quality issues, and if you’re gonna pay an extreme amount of money to, you know, put the LEP to fix your erosion, put the LEP on blades, hope for a performance improvement, and then it fails in a year.

I. That’s no help to anybody. So these different products, they also come with different price points. Like, can we really value the shell over the coating? I, I just find that this is a tough space. And so doing something like that and doing more training around LEPI think is probably pretty important. Yes.

You know, unless the robots are gonna take it over and then, well, even then, I think it’s the only app.

Allen Hall: The application, that’s the variable there. And not having people trained up for that particular LEP product is a huge problem because it’s super risky. You’re risking all that money and time and having to do it all over again and removing LEP that has been improperly applied.

It’s a nightmare. [00:25:00] Nightmare. Total nightmare. You don’t want that to happen. And I’ve seen sites where that’s happened, getting technicians. Trained properly for the right material and doing that here up in Tennessee is, is the right approach. It’s risk reduction, which is what the industry is in right now.

Risk reduction.

Alfred Crabtree: Yeah. Yeah, we, we’ve beliefs. That’s a great way to put it. You know, if you hire somebody. We were talking earlier how there are like two models. One is like the New York Yankees, where you’re going to be buying all the expensive free agents. You can poaching people from other, you know, trying to get experienced talent.

You’re paying a premium for them, but you aren’t gonna know until halfway through that season how that person is performing. Yeah. You know, that is a lot of. That was, that is a lot of variability that you could control. Mm-hmm. And in a seasonal business, those weeks are really multiplied by two or three.

Right. In terms of like the impact on your revenue and your opportunity to make money. It’s risk reduction, like Alan was saying. Yeah. It’s

Allen Hall: all risk, right? Yeah. And the, [00:26:00] the way that the industry is moving and the pace at which is moving right now, risk reduction starts to move to the top five years ago.

We do a lot of risky things because we’re making money. Interest rates are low and, but today we cannot afford to do that. And if you watch the industry change right now, it is gonna be more focused than ever in having proper technicians on site that they complete the job that they were intended to do.

Precisely, accurately, and once, not twice. Once. Yeah. And that is gonna be the marker of the, whether this industry grows or not. Mm-hmm. And that’s why Blade Repair Academy is needed so much. Now, Alfred, how do you interface with the ISPs, OEMs, and the operators in terms of getting people out here? How do they, how do they push that button and say, Alfred, I’m gonna send you 40 technicians next week.

How does that, how does that go? I don’t quite have that down

Alfred Crabtree: yet. But, uh, you know, it, we talked earlier, it’s a small world. You know, blade repair is small. There [00:27:00] we mentioned if you, there’s a hundred people in the industry you need to know and then you’ve covered it. Um, our, I think we’ve been, we’ve been kind of riding this new wave of like, oh, who’s this new kid on the block?

And, and we can kind of be quiet and still are mysterious. And I pop up at a conference and host a round table or whatever. Uh, so far. It’s mainly been our personal network, which is large enough in this gig to, to get people in. ISPs are much more likely to do it small is ISPs are much more likely to do it.

Owner operators, they’re trying to build their training centers. They have a little different, that’s a different model though. It’s a different model. Um, they’re, they’re tougher to get. So primarily it’s been ISPs. We have definitely a, a, a curriculum for new hires, right? We call it support, but we’re [00:28:00] reluctant to go sell that to the street or to the public.

Like, Hey, enter the industry here, because we don’t quite yet have that, you know, guarantee that people will recognize our certificate and. Use it to hire people. I don’t quite have that system in place. However, I have so much interest from the Department of Labor to support us in creating an occupation.

They want us to build apprenticeship programs. We need corporate sponsor, we need a big employer or to to buy in, and then we can create an apprenticeship program. Then we can find public money for people to get some support to get into a new, a new industry. So, well, they

Allen Hall: need to come out here. They need to come out to Dunlap.

And visit the facilities, talk with you, understand what the philosophy is, see it up close. There’s a lot of them have been to other places. Sure. And see what the differences are here. And, and that’s gonna be the decision maker. They’re gonna see what the product walking out the door is and [00:29:00] go into the classroom and, and get the grinder, right?

Yes. Get, get your hands dirty a little bit. Yeah. And realize, yes, this is what I was looking for to begin with. I just couldn’t find it. And I found it here in Tennessee.

Alfred Crabtree: Yeah, I, I think you’re right. And, and we, we are slowly, you know, bringing people in that we know, like the reason why y’all are here and some other folks have visited us this week is because o and m was in Nashville.

And I was like, come on, come on. We’re only two hours away. We’ll buy you lunch. Come on. Pretty place. Yeah. You have to see this place to understand it because we are sort of, you know, outsiders, right? I mean, we’re, we’re from the, the industry, but we’re not. We’re not a spinoff of any company. We’re not a division of an ISP.

We’re totally organic and unique in a, in a part of the world that doesn’t have any wind. So, yeah. Uh, but once you get here, you get it. The economics make sense. You know, we couldn’t do what we’ve done anywhere else as cheaply as we’ve done, which means we feel like we’re super value rich for what you’re paying and for the amount of time that you’re spending [00:30:00] here.

Allen Hall: Oh, 100%. Uh. Let’s give the ISPs, the OEMs and the operators, uh, where to go. What’s the website? Where can they find you on LinkedIn?

Alfred Crabtree: We’re at blade repair academy.com. Uh, we’re located in Dunlap, Tennessee. We’re on Blade Repair Academy at LinkedIn. I’m Alfred Crabtree. You can find me there. Uh.

Allen Hall: Yeah, that’s where you need to go because that’s how the process starts.

If you want to have high level technicians that really know how to work on composites and are working with real materials on simulated, but. Pretty realistic damage. Yeah. Weirdly realistic. Yeah. Secret sauce. And to get some sort of validation and to kind of get graded. Mm-hmm. And so you have a, a, a sense of how they’re doing.

You’re going to have to go to Blade Repair Academy. You need to get out to Tennessee and you better check it out because I, Alfred, I gotta be honest, this place is gonna get crazy busy [00:31:00] and I’m gonna have. ISPs calling me saying, can you get a hold of Alfred and get me inside? Can you get me in? No, I can’t because it’s Alfred’s deal and Alfred’s gonna run this thing.

We’re very approachable and, but very approachable. Keep calling, he’ll answer and take care of you, but it’s gonna get busy because the philosophy here is the right one. Thanks. So congratulations for putting this together and thank you for the invite. Uh, it is been a pleasure to see it. It’s uh, it, it’s great to know that you are around and you’re helping the industry.

Alfred Crabtree: Thank you. We appreciate it and you guys are a great clarion for the industry. A great voice. So, uh, those words, uh, right in the fields. And I wanna thank Cheryl too for coming out. I haven’t seen her for a while. It’s funny ’cause today I, on my phone, you know, five years ago today, she and I were here before this business existed as rope partner employees working on r and d week doing infusions.

So, uh,

Sheryl Weinstein: the space has transformed. It’s amazing. Yeah. You guys have done a, a [00:32:00] really great job. Like I, yeah, I think you’re definitely pushing the industry into a, like a new realm. Bringing something that, that it really needs, you know, that we don’t have at the moment or that we didn’t have.

Alfred Crabtree: Yeah, well hopefully, uh, it improves everybody’s quality of product and the bottom line.

’cause uh, you know, that’s what we’ll do. We’ll affect your bottom line for sure.

Allen Hall: So Sheryl and Alfred, thank you so much for being on the podcast. Thanks guys. Right,

Sheryl Weinstein: thank you.

https://weatherguardwind.com/blade-repair-academy-training/

Continue Reading

Renewable Energy

PowerCurve’s Innovative Vortex Generators and Serrations

Published

on

Weather Guard Lightning Tech

PowerCurve’s Innovative Vortex Generators and Serrations

Nicholas Gaudern from PowerCurve joins to discuss SilentEdge serrations with up to 5 dB noise reduction, Dragon Scale VGs for AEP recovery, and their approach to products that actually perform in the field. Contact PowerCurve on LinkedIn for more information.

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 show.

Nicholas Gaudern: Thanks, Allen. Always a pleasure.

Allen Hall: Well, there’s a lot of new products coming outta PowerCurve. And PowerCurve is the aerodynamic leader in add-ons and making your turbines perform at higher efficiency with less loss. Uh, so basically taking that standard OEM blade and making it work the way it was intended to work.

Nicholas Gaudern: Yes. We

Allen Hall: like to

Nicholas Gaudern: think so. Yeah.

Allen Hall: And there’s a, there’s a lot of new technology that you’ve been working on in the lab that you haven’t been able to explore to the, introduce to the world, so to speak. Yeah. And we’ve seen some of it from the inside of, you know, you’re working behind the scenes or working really hard to get this done, but now that technology has been released to the world, and we’re gonna introduce it today, some new trailing edge.

[00:01:00] Components. Yeah. That really, really reduce the noise. But they, they look a little bit odd. Yes. There’s a lot of ADON dams going on with

Nicholas Gaudern: Yeah.

Allen Hall: With these. So what, what do you call these new trailing edge parts?

Nicholas Gaudern: So, so what you have in your hand here? This is the Silence edge, uh, serration. So this is our new trailing Edge Serration products.

Now, most people, when they think of training restorations, they are thinking of triangles.

Allen Hall: Exactly.

Nicholas Gaudern: These Dino tails. Dino Tails, that’s the Siemens, Siemens name for them. Pretty, pretty standard. You see ’em on a lot of turbines now. Sure. And they work, you know, they do do a job. They do a job. They reduce noise.

But like with lots of things in, in aerodynamics, there’s lots of different ways that you can solve a problem and some are better than others. So we’ve worked for a long, long time in the wind tunnel, uh, in the CFD simulations, and we’ve come up with this pretty unique shape. We think,

Allen Hall: well, the, the, the shape is unique and if you, if you look at it, there’s actually different heights to the, the triangle, so to speak.

To mix the air from the pressure and the [00:02:00] suction side to reduce the, the level of noise coming off the blade

Nicholas Gaudern: e Exactly. So we have, uh, we have an asymmetry to the part. We have these different tooth lengths. We have, uh, a lot of changes in thickness going on across the part. So it may be a little bit difficult to see on the camera, but these are quite sculpted 3D components.

They’re not, they’re not flat stock white triangles. No, no. There’s a lot of thickness detail going on here. We’ve paid a lot of attention to the edges. We’ve paid a lot of attention to these gaps between the teeth as well. So all of this is about trying to figure out what is the best way to reduce noise.

And something that not a lot of people will, will admit, but it’s true, is that as an industry we don’t really understand the fundamentals of how serrations work.

Allen Hall: It’s a complicated

Nicholas Gaudern: problem. It’s a really complicated thing. Problem, yeah. Yes. So trying to simulate it in CFD is an absolute nightmare. The, the mesh sizes required, the physics models required are really, really difficult.

So what we found is that you’re probably better off spending [00:03:00] most of your time and money in the wind tunnel. Yes. So, so we go to DTU, they have this wonderful, uh, air acoustic wind tunnel, the pool of core tunnel. It’s one the best tunnels in the industry for doing this kind of work. It

Allen Hall: is

Nicholas Gaudern: because you can measure acoustics and aerodynamics at the same time.

So this allows us to do a lot of very cost effective iteration for this kind of design work. So we know what’s important. You know, we’ve, we’ve studied all the different parameters of serrations lengths, aspect ratios, angles, thicknesses, all this kind of stuff. And it’s about bringing them together into a, into a coherent product.

So this is, this is a result of a lot of design of experiments, a lot of iteration, and combining wind tunnel and CFD to kind of get the best of both of those tools. So,

Allen Hall: so what’s the. Noise reduction compared to those standard triangular trailing aerations. Yeah.

Nicholas Gaudern: So there’s lots of different ways of, of thinking about noise reduction, but I think probably the most useful is the O-A-S-P-L.

So this is the overall sound pressure level. Right. Is kind of what [00:04:00]typically you’ll be measuring in an IEC test.

Allen Hall: Right.

Nicholas Gaudern: And that’s measured in decibels, but a way to decibels because it’s important that we’re waiting to what the human ear can actually hear. Right. Perceive. Exactly. So that’s the numbers we report.

For the field test we’ve recently completed with Silent Edge, we’re seeing up to five decibels of O-A-S-P-L noise reduction.

Allen Hall: Okay. So what’s that mean in terms of what I hear on the ground?

Nicholas Gaudern: So that is an absolutely huge reduction. It’s multiple times of reduction because you know, decibels on a log scale,

Allen Hall: right?

Nicholas Gaudern: So five DB is is enormous. It’s

Allen Hall: a lot. Yeah.

Nicholas Gaudern: And what’s really interesting is that if you have a turbine that’s running in a noise mode, just one decibel reduction. Of power, sound, sound, power level might be three or 4% P loss. I mean, that, that’s, that’s huge. Think about that loss. So if you need to reduce noise by five decibels to get within a regulation, imagine how much a EP you have to throw away by basically turning down the [00:05:00] turbine to do that.

Allen Hall: That’s right.

Nicholas Gaudern: So that’s really what the, the business case for these kind of products is. It means you can escape noise modes because as soon as you use a noise mode. You are throwing away energy.

Allen Hall: You’re throwing well you’re throwing away profits.

Nicholas Gaudern: Exactly.

Allen Hall: So you’re just losing money to reduce the noise.

Now you can operate at peak.

Nicholas Gaudern: Yep.

Allen Hall: Power output without the creating the noise where you have that risk. Right. So, and particularly in a lot of countries now, there are noise regulations. Yes. And they are very well monitored.

Nicholas Gaudern: Yep.

Allen Hall: We’re seeing it more and more where, uh, government agencies are coming out and checking.

Yes. ’cause they have a complaint and so you get a complaint. Oh, that’s fine. Or someone can complain. Yeah. You know, you need to be making your numbers.

Nicholas Gaudern: Yep. And, and the industry needs to be good neighbors, you know? It

Allen Hall: certainly does.

Nicholas Gaudern: Uh, we have to make sure that people are, you know, approving and comfortable with having wind turbines in their backyard.

Sure. And noise is a big part of that.

Allen Hall: It is.

Nicholas Gaudern: So yeah. Ap sure. That’s really important. Being a good [00:06:00] neighbor also important.

Allen Hall: Right.

Nicholas Gaudern: Meeting the regulations. Obviously you have to meet the regulations. So this product, um, has been through a really long development cycle, and we’re now putting the final touches to the, to the tooling.

So this is available now.

Allen Hall: Oh, wow.

Nicholas Gaudern: Okay. Great. Um, and we’re hoping that in the next uh, few months we’ll be getting even more turbines equipped out in the field with, with the technology.

Allen Hall: So, oh, sure. There’s a, you think about the number of turbines that are in service, hundreds of thousands total worldwide.

A lot of them have no noise reduction at all.

Nicholas Gaudern: No. No.

Allen Hall: And they have a lot of complaints from the neighbors.

Nicholas Gaudern: Exactly.

Allen Hall: Trying to expand wind into new areas, uh, is hard because the, the experience of the previous Yes. Neighbor

Nicholas Gaudern: Yep.

Allen Hall: Grows into future neighbors. So fixing the turbines you have out in sight today helps you get the next site.

I know we don’t always think about that, but that’s exactly how it works. Yeah, of course. Uh, we need to be conscientious of the people of the turbines we have in service right now. So that we can continue to grow wind [00:07:00] globally and more regulations on noise are gonna come unless we start taking care of the problem ourselves.

Nicholas Gaudern: Yep. And another really important thing with Serrations is that you have to design them so that they don’t impact the loads on the rest of the turbine.

Allen Hall: Right. And people forget about that.

Nicholas Gaudern: Yes.

Allen Hall: Can you just, can’t just throw up any device up there. And think, well, my blade’s gonna be happy with it. It may not be happy with that device.

Nicholas Gaudern: You have to really carefully understand what the existing blade aerodynamic signature is.

Allen Hall: Sure.

Nicholas Gaudern: How is that blade performing? What is the lift distribution across the span? Yeah.

Allen Hall: Right. Yeah.

Nicholas Gaudern: So what we do, and we, we’ve talked about it before we go and laser scan blades. We build CAD models, we build CFD models so we can actually understand how much lift a blade can take and what’s the benefit or the penalty of doing so.

So these serrations are designed by default to be load neutral. They won’t increase lift. They won’t reduce lift. That’s what

Allen Hall: it should

Nicholas Gaudern: be. That’s where you should start,

Allen Hall: right?

Nicholas Gaudern: And maybe there’s some scope to do something else [00:08:00] on certain turbines, but you shouldn’t, you shouldn’t guess. You, you need to calculate, you need to simulate, you need to think very carefully about that.

So that’s what we do with these, uh, with these serrations, we go through this very careful aerodynamic design process to make sure that they reduce noise and that’s it. They don’t increase loads, they don’t reduce AP by killing lift. And that’s, that’s an important aspect.

Allen Hall: Well, that’s the goal.

Nicholas Gaudern: Yes,

Allen Hall: exactly.

I don’t necessarily want to increase power. I don’t wanna put more load in my blade, but people do that. I’ve seen that happen and man, they regret it.

Nicholas Gaudern: Yeah, regret it. There’s, there’s some pretty wild claims out there as well about observations can and can’t do. And uh, like with lots of things, it’s important to just do the simulations, speak to some experts and, um.

Yeah, maybe take the, the less exciting path, you know, sometimes,

Allen Hall: well, no. Yeah. Well, less exciting path where I don’t have a broken blade.

Nicholas Gaudern: Yeah, exactly.

Allen Hall: Yeah. That’s a lot less exciting. It’s, it’s definitely more profitable. Now, the Dragon Scale Vortex generator has been [00:09:00] around about a year or so.

Nicholas Gaudern: Yep, yep.

Allen Hall: And the thing about these devices, and they’re so unique, interesting to think about because you typically think of a vortex generator as this being this little bit of a fence.

Where you are tripping the air and making it fall back down onto the blade.

Nicholas Gaudern: Yep.

Allen Hall: A really, it works.

Nicholas Gaudern: It works.

Allen Hall: But it’s it’s

Nicholas Gaudern: been around a long time.

Allen Hall: Yeah. Yeah. It, it does, it does do this thing. And they, they were, they came outta the aviation business. We use ’em on airplanes to keep air flow over the control surfaces so we can continue to fly even in close to stall conditions.

All that makes sense. And airplanes are not a wind turbine.

Nicholas Gaudern: Yes.

Allen Hall: So there’s different things happening there. So although they work great on on aircraft, they’re not necessarily the most efficient thing for a wind turbine where you’re trying to generate power and revenue from the rotation of the blades.

Nicholas Gaudern: Exactly.

Allen Hall: So this is a completely different way of thinking about getting the airflow back onto the blade where it produces [00:10:00] revenue.

Nicholas Gaudern: And what’s really nice is to actually see this together with silent edge, because historically, and maybe not even historically. Serrations VGs, they’re triangles. They work, they do a job.

But that doesn’t mean you can’t do it in a different way. In a better way.

Allen Hall: Right.

Nicholas Gaudern: And that’s the same principles from applying with Silence Edge and Dragon Scale. We want to work the flow in the most efficient way possible.

Allen Hall: Right. You’re trying to get to an

outcome.

Nicholas Gaudern: Yeah, exactly.

Allen Hall: Efficiently.

Nicholas Gaudern: We want to, we want to target very specific things on the blade, and that’s where you can see there’s a few different styles of Dragon Scale that we have on the table here.

We have some that are two fins. We have some that are three fins. We have different sizes, and this is because they’re tailored to different parts of the blade. So these three Fin Dragon scales, their focus is ultimate lift. We are creating a really powerful vortex through this combination of three air foils, if you imagine, um, the inside of a Turbo fan.

You have these cascading air force. [00:11:00] You look at the leading edge slacks on an aircraft. You look at the front wing of a Formula one car. It’s that kind of concept.

Allen Hall: It’s like that,

Nicholas Gaudern: and it’s these air force that are cooperating with each other.

Allen Hall: Right.

Nicholas Gaudern: To end up with a more beneficial result. ‘

Allen Hall: cause an air force by itself does a function, but when you combine airflows together in the right way

Nicholas Gaudern: Exactly.

Allen Hall: You can really control airflow efficiently, less losses. More of what you want out the backside. Yeah, exactly. It’s, it’s the backside you’re trying to work on, on a VG or, or dragon scales. You’re trying to create this flow which gets the airflow back onto the blade to create power. We,

Nicholas Gaudern: we want as much attached flow as possible and down exactly down in the roots of a blade.

We have to have really thick aerofoils, you know, blades about round. They’re basically cylinders.

Allen Hall: Yeah.

Nicholas Gaudern: And that, that’s essential, right? We have to have the blade take a lot of load into the root aerodynamically. They’re horrible.

Allen Hall: Yeah.

Nicholas Gaudern: So this is where these, uh, these powerful Dragon Scale VGs come into play because what they do is they’re [00:12:00] reenergizing the flow over the aerofoils, and they’re ensuring that that flow remains attached for much, much longer than if those bgs weren’t there.

So down in the root, you’ll get significant boosts to the lift that those sections can generate. And what’s more lift? It goes to more torque, it goes to more power, goes to more a EP. So these dragon scale VGs in the root are there to boost, lift, and boost EP out on the tip of the blade. Things are actually a little bit different because it’s way different.

You shouldn’t really have stall there to begin with if your blade’s been designed well.

Allen Hall: But if you have leading edge erosion exactly. Or some other things that are happening, you can have real aerodynamic problems.

Nicholas Gaudern: So yeah, as soon as you have erosion, uh, maybe your stall margin is not as big as you thought it was.

You’re starting to get some significant losses of lift Yes out towards the tip of the blade. So that’s where these, uh, TwoFin uh, variants come in. So it’s still a dragon scale vg, it’s still the same concept of these cascading error foils. Yeah, but these are [00:13:00] designed for basically ultimate lift to drag ratio.

Mm-hmm. So we don’t really want more maximum lift outta the tip. We kind of have enough, but what we do want is to keep stable attached flow and we want to do it for the less, uh, least drag penalty possible. So basically we want to get rid of as much parasitic drag as we can. These two fin dragon scales, we are seeing 25 plus percent improvements in lift to drag ratio.

Compared to a standard triangle vg. I mean that’s huge.

Allen Hall: That that is really

Nicholas Gaudern: huge.

Allen Hall: That’s huge, right? Because people have seen these, uh, triangular VGs in a lot of places. And one thing I’m noticing more recently is that those VGs, because they’re so draggy, they tend to flutter and they tend to break in just off.

Nicholas Gaudern: Interesting.

Allen Hall: So you’re having this failure mode because this thing is just blocking the air, getting the air to trip.

Nicholas Gaudern: Yeah.

Allen Hall: It’s not efficient. It does have its downsides ’cause it is. D definitely drag. Just face it, it’s it, is it a draggy [00:14:00] 1940s technology? That’s what it is. Where with the dragon scales, now we’re doing things a lot more efficiently and thinking about how do I get the airflow that the blade designer originally wanted?

Nicholas Gaudern: Yes,

Allen Hall: because the blade designer, they’re really intelligent people. They’re, they’re sitting designing blades. But the reality is what you design is on an ideal airflow, and what you have out in service are totally different things. As, as it turns out, the shape of the airflow is not what you think it is because it comes out of the tool and there’s a lot of touching with by humans that are grinding on the leading edges and doing the things that have to be done to manufacture it.

So you don’t really have an ideal blade when it comes out of the

Nicholas Gaudern: No. You

Allen Hall: never do factory. No, you never do.

Nicholas Gaudern: And it’s not polished either.

Allen Hall: It’s not polished. Right. So

Nicholas Gaudern: when you go to the wind tunnel, you have a perfect profile. Yes. And it’s polished. And it works basically. It

Allen Hall: works great. It

Nicholas Gaudern: works great.

Allen Hall: The theoretical and the actual match.

Yeah. In reality they do. I think a lot of operators are not [00:15:00] connected with that reality of, Hey, that Blade should be producing this amount of revenue for me, and it’s not. And you hear that discussion all the time, particularly in the us. It should be producing this amount of power. I’m doing all the calculations.

We are not producing that power. Why? The blade length’s saying, but the power’s not coming out of it. Well take a look at your leading edge, take a look at your yard full of shape and realize you’re going to have to do something like dragon scales to get that E energy. Exactly. Revenue back.

Nicholas Gaudern: You need to do a full aerodynamic health check.

Basically you do. And see what are all the possibilities to improve my blade performance. And some of it is down to the fundamental shape of the blade,

Allen Hall: right?

Nicholas Gaudern: But some of it is down to blade condition. Yes. Blade Blade manufacturing quality.

Allen Hall: Yes.

Nicholas Gaudern: Uh, what kind of paint did they put on it? What day of the week was it made?

And all these things can be compensated for by VGs and you’ll get more revenue out at the end.

Allen Hall: You say? ’cause what happens? The, the, the scenario which is hard to visualize unless [00:16:00] you’re an A and emesis, is that there comes on the suction side, and it should be, in a ideal sense, rolling all the way to the back edge of the blade and coming off.

What happens is though, is that. When you get leading edge erosion is that the air flow actually separates. Yeah.

Nicholas Gaudern: It

Allen Hall: doesn’t

Nicholas Gaudern: always make it, yeah.

Allen Hall: Doesn’t make it to the back edge. Yeah. And so you can see that, especially if, if there’s dirt in the air, you can look on dirty blades, you can see where that separation line is, and a lot of operators have sky specs, images or Zeit view images, and then go back and look at the blades.

It takes two minutes to go. I have

Nicholas Gaudern: particularly down in the root, you’ll see it.

Allen Hall: Oh, in the root all the time. You, you

Nicholas Gaudern: see it really clearly that that separation line

Allen Hall: all the time, you really see that separation line. I’m seeing it more and more up towards the tip. Interesting. That’s where the lightning protection, yeah.

Systems sit.

Nicholas Gaudern: Yeah.

Allen Hall: I see a lot of airflow that is not front to back on the suc. Well, you

Nicholas Gaudern: have a lot of three dimensional flow out there.

Allen Hall: You do towards the tip you do. And you realize how much power you’re losing there. And I think operators are just throwing away money.

Nicholas Gaudern: Yeah, exactly.

Allen Hall: So you could [00:17:00] put dragon skills on it very efficiently, very quickly.

Get that revenue back into your system and it’s gonna stay. So even if leading edge erosion happens, the dragon scales are gonna compensate for it. It’s gonna get the airflow back where it should be.

Nicholas Gaudern: Exactly. And the nice thing about this is, you know, we are building on well over a decade of upgrading turbines with aerodynamic components.

Oh yes. So this technology stands on the foundations of all of that work. In terms of the materials, the work instructions. Um, the fatigue calculate, you know, everything

Allen Hall: Yes.

Nicholas Gaudern: Is built on thousands of installations that we’ve done. Yes. So, although it’s a new technology aerodynamically, it’s not really new in lots of sensors.

Allen Hall: Well, I look at it this way. If you turn on Formula One today and look at what the new generation of cars running around as you look at the, that front. Yes. Uh. Fin. Yeah. What do I call it? Air foil shape in the front. It’s super complicated.

Nicholas Gaudern: The sculpting of the [00:18:00] surfaces is really impressive,

Allen Hall: right? There’s a lot of thought going into those surfaces versus you turn on a Formula One race or go on YouTube and look at a Formula One race from the 1980s.

Yeah, it’s basically a piece.

Nicholas Gaudern: Yeah.

Allen Hall: To provide down downforce. That’s it. The aerodynamics wasn’t really there, so we come a long way and a lot of that technology that happens in Formula One that happens in aviation eventually rolls down into. Yeah. Wind.

Nicholas Gaudern: Exactly

Allen Hall: right. So we, we, although we are not designing Formula One style blaze today, we’re taking that same knowledge and information and we’re applying that back in.

Nicholas Gaudern: Yeah. We’re

Allen Hall: secondarily we,

Nicholas Gaudern: which is a right thing to do. We’re taking, taking inspiration from all these different aerodynamic fields and, you know, picking the best

Allen Hall: Yes.

Nicholas Gaudern: From what’s available and just allowing ourselves to be a little bit more creative.

Allen Hall: Yes.

Nicholas Gaudern: And thinking outside the box a bit. There’s so many ways to do this as we’ve been saying.

And the import. And the

Allen Hall: data’s there.

Nicholas Gaudern: The data’s there. Exactly.

Allen Hall: The data’s there because you’ve been at the DTU Yep. Uh, wind Tunnel, which also has the acoustic piece to it. Yeah. So you have measured data from a reliable source. [00:19:00] You have field data, and you know, you put all these together, you’re gonna get that improvement back.

You’re gonna get your invest back, you’ll be more profitable.

Nicholas Gaudern: So Dragon Scale, focus on the AP. And that a EP will, uh, vary depending on the turbine.

Allen Hall: Sure.

Nicholas Gaudern: But we’ll assess the turbine and, and decide the best configuration, and then say silent edge. That’s the focus on the noise reduction. And we’re seeing up to five decibels OASP on the field.

It’s, which

Allen Hall: is crazy.

Nicholas Gaudern: It’s even more That’s really good that we were hoping for, you know?

Allen Hall: Yeah.

Nicholas Gaudern: So we, we know this is gonna be a, a great product.

Allen Hall: It looks very interesting.

Nicholas Gaudern: It does.

Allen Hall: It does it. It looks complicated and you think air airflow is complicated. It’s a compressible fluid. It’s not easy to, to just assume it’s gonna do what you think it is.

Yeah. You need to get into the tunnel. You need to replicate, you need to do all that work, which is expensive in time consuming. That’s why you go to someone like Power. Curver knows what they’re doing in the wind tunnel, knows how to measure those things and know when they’re getting nonsense. Out of their computer.

I

Nicholas Gaudern: mean, you, you’ll pay thousands and thousands of [00:20:00] Euros dollars a day to run a wind tunnel.

Allen Hall: You will.

Nicholas Gaudern: You’ve gotta Absolutely. You’ve gotta turn up with your plan in hand, that’s for sure.

Allen Hall: Oh, oh yeah, yeah, yeah. And I think there’s a lot of assumptions because it, aerodynamics is hard. You know, you watch these blade spin around, you don’t realize how complicated these devices are.

They are complicated. Those air force shapes we are running today have been through a lot of history, a lot of history to get to where we are now. Now we’re just gonna take him into the next generation. This, we’re bringing ’em into the two thousands. In sort of a

Nicholas Gaudern: sense, what I’m hoping to see is, you know, with the OEMs, some OEMs do it already, but it’s important to think about these components when you’re designing new blades as well, you should because then that will allow you a much bigger design space to work in.

And

Allen Hall: a lot less customer complaints.

Nicholas Gaudern: Yes.

Allen Hall: Where’s my power?

Nicholas Gaudern: Exactly. You know, these products, particularly the VGs, are really important tools for PowerCurve robustness. And some OEMs have known this for a long, long time.

Allen Hall: Yep.

Nicholas Gaudern: And you’ll see VGs on most of their blades. Mm-hmm. Others not so much. And that’s a design choice.

It’s a design philosophy. Um, and I think it may not [00:21:00] be the right one, you know?

Allen Hall: Well, I think the operators are asking to get the most out of their turbines. Yeah. Why shouldn’t they? They should be asking for that.

Nicholas Gaudern: I think for a, for a long time, and it’s not just in wind devices, like these have been considered, you know, band-aids fixes when you’ve, you’ve messed something up.

But I feel that’s a really negative way to think about products like this. They’re doing something that the kind of raw air fall shape on its own cannot achieve. Sure. Oh no. Right. You know, you might be able to mold some interesting stuff. Uh, as part of the blade, it’s very difficult to, to recreate the kind of aerodynamic effects that these products, uh, have.

Allen Hall: Right.

Nicholas Gaudern: So they shouldn’t be considered bandaids or fixes. No. They should be considered opportunities. And ways that you can maximize performance and unlock areas of the design space that previously weren’t accessible to.

Allen Hall: Sure. Every possible component that deals with fluid air is moving this way.

Nicholas Gaudern: Yes.

Allen Hall: Jet engines, you look at jet engine, how much more is going into those jet engines today in terms of this kind of [00:22:00] technology?

Yeah. All the race colors, doesn’t matter what class, where it is, is all looking at this anything to do with aircraft, it’s all over this.

Nicholas Gaudern: Yeah,

Allen Hall: exactly. Or, or doing this today. It’s just wind that’s behind

Nicholas Gaudern: wind. Wind is

Allen Hall: significantly

Nicholas Gaudern: behind. No,

Allen Hall: it’s not magic. It’s proven technology. It’s

Nicholas Gaudern: just good engineering.

Allen Hall: Well, it’s good engineering and if you call PowerCurve, they’re gonna help you under to to, to understand what you have today and what you could have tomorrow.

Nicholas Gaudern: Yes.

Allen Hall: And how this, these devices will improve your revenue stream.

Nicholas Gaudern: Exactly. You know, we will look at your blades, we’ll give you some good advice and maybe that advice will be that.

You know, a certain product isn’t right for your blade. Right. That’s fine.

Allen Hall: That’s an answer.

Nicholas Gaudern: That’s an answer.

Allen Hall: Yeah, it is.

Nicholas Gaudern: But let’s, let’s look at the blade. Let’s see what’s possible, and let’s just have a, have a proper conversation about it over some real data, some real

Allen Hall: facts. Right. I think that’s the key, and a lot of operators are afraid to talk about aerodynamics is it’s, it’s a difficult area to, to start the conversation on, right?

Yeah. But I think at the end of the day, when I work with PowerCurve, and I’ve worked with you guys for a [00:23:00] number of years, the answers I get back are intelligent and they’re not. Super complicated. This is what you’re gonna see. This is the improvement. And then we can, this is how we’re going to show you can get that improvement.

It’s not magic,

Nicholas Gaudern: no

Allen Hall: power crews backing up with data, which I think is the key, right? Because you’re the, you do hear a lot of noise in this industry about magical products that’ll do all these things. Particularly aerodynamic ones. Yes. PowerCurves, the ones really bringing the data.

Nicholas Gaudern: Yeah. And we have, we have the track record now.

We have like we do 17, 1800 turbines. Should be over 2000 very soon with our products on. Yeah. So we have a lot, we have a lot of data to draw on to know that we’re doing a good thing.

Allen Hall: Well, and speaking of that, because one of the questions that always pops up is, well, we have put these new VGs or trailing edges on, are they gonna stay on?

How durable are they?

Nicholas Gaudern: Yeah. And that’s a, that’s a really important question to ask was it doesn’t matter how fancy aerodynamic product is, if it falls off the blade.

Allen Hall: Right.

Nicholas Gaudern: So, you know, we’ve spent a lot of, uh, time and effort looking at how we should be fixing these products on. [00:24:00] So we use a, uh, a wet adhesive.

We specify a plexus adhesive to put our products in place. Really good adhesive. It’s a great adhesive and it means that they are not going anywhere. Basically. It’s a very, uh, forgiving adhesive. Uh, and it’s a very high spec. So we, we don’t use, uh, sided tape. We might have some of our products for some initial tack to help, you know, get the clear, the clear outta the line exactly.

But in terms of the bond itself, that is with a, a proper structural adhesive. So one thing that we are really proud of is that we haven’t got any, uh, reported failures of our panels over all the installations we’ve made. And that’s a combination of materials, but also geometry, work, instructions, adhesive.

It’s, it’s the full package. So it’s something that, um, yes, say we’re very proud of. And I think it’s, it’s a big part of what we do at PowerCurve, making sure the product is the right shape. Sure. But also making sure it stays on the blade.

Allen Hall: Well, you see it [00:25:00] from OEMs who have all kinds of aerodynamic treatments on there, and they’ll double set a tape to the blade, and then those parts are on the ground.

Nicholas Gaudern: Yeah. And double-sided tape. You can get some really nice spec tape. Sure.

Allen Hall: You,

Nicholas Gaudern: yeah. But it’s not

a

Allen Hall: 20 year device.

Nicholas Gaudern: No. And the installation tolerance required on surface prep is really, really high. So it’s possible. It’s just harder. I think it’s riskier,

Allen Hall: it’s risky.

Nicholas Gaudern: So, you know, I think for us, the adhesive is, is the way to go.

And, and it’s been proven out by the, by the track record.

Allen Hall: And some of the things we’ve seen over in Australia is when trailing ulcerations have come off, it’s been a safety concern. So now you got

Nicholas Gaudern: absolutely

Allen Hall: government officials involved in safety because parts are coming up. Turbine.

Nicholas Gaudern: Yeah.

Allen Hall: You

Nicholas Gaudern: can’t have these components flying, flying through the air.

That’s, that’s not safe.

Allen Hall: That’s because PowerCurve has done the homework.

Nicholas Gaudern: Yes.

Allen Hall: And has the track record. That’s why you wanna choose PowerCurve. So how do people get a hold of PowerCurve? How do they get a hold of you, Nicholas, to start the process?

Nicholas Gaudern: So, um, you’re welcome to reach out to us in lots of different ways.

We’re on LinkedIn. Uh, we have our website, [00:26:00] PowerCurve, dk, um, so yeah, LinkedIn websites. There’ll probably some links on this podcast as well to get in touch. But, um, yeah, whatever way works best for you.

Allen Hall: Yeah, it’s gonna be a busy season. So if you’re interested in doing anything with PowerCurve this year, you need to get on the website, get ahold of Nicholas.

And get started, uh, because now’s the time to maximize your revenue.

Nicholas Gaudern: Thanks a lot and great to talk to you,

Allen Hall: Nicholas. Thanks so much for being back on the podcast.

PowerCurve’s Innovative Vortex Generators and Serrations

Continue Reading

Renewable Energy

Sharia Law

Published

on

Does Sharia Law pose an actual threat to Americans?  Are we on a path to chopping off the hands of shoplifters? Passing laws that concern what people can and cannot eat? Polygamy?  Forcing women to wear the hijab?

Maybe.

Or maybe this congressman is a loudmouth asshole whose constituents are morons.

Sharia Law

Continue Reading

Renewable Energy

Another Thought on Tucker Carlson

Published

on

Carlson’s about-face on Trump is huge, as it signals that public intellectuals who wish to be taken seriously at this point cannot support the president, as his mental condition deteriorates and his criminality becomes ever more brazen.

Another Thought on Tucker Carlson

Continue Reading

Trending

Copyright © 2022 BreakingClimateChange.com