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R&D Test Systems – Pushing the Boundaries of Test Rigs for Massive Wind Turbine Equipment

Allen Hall and Joel Saxum go in-depth with R&D Test Systems Chief Engineer Claus Beck, who reveals the innovation behind their massive test benches capable of rigorously vetting the next generation of multi-megawatt turbines. From building test rigs for machines that don’t yet exist to creating 25MW powertrain test stands, R&D is enabling wind OEMs to thoroughly validate their radical new designs. You’ll be blown away by how critical R&D’s capabilities are for scaling up turbines. This is one episode you won’t want to miss – the thrill of engineering big things to power the future!

Visit https://www.rd-as.com/ to learn more!

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: Pushing the boundaries of innovation often requires testing the limits of today’s technologies. That’s where R&D Test Systems comes in. Over 15 years, this leading test equipment developer has provided cutting edge testing technology to help wind energy companies launch the next generation of products.

From their powertrain test benches to their rain erosion test facilities, R&D Test Systems has built an impressive array of testing capabilities. Their expertise allows clients to validate designs, benchmark performance, troubleshoot issues, and certify products for safety and standards compliance. On this special episode of the Uptime Wind Energy Podcast, Joel Saxum and I will be talking with Claus Beck, Chief Engineer at R&D Test Systems, about the amazing technology they have created and have in their development pipeline.

Claus, welcome to the program.

Claus Beck: Thanks a lot, Allen and Joel.

Allen Hall: Well, the wind industry has a massive problem ahead, as I see it. As wind turbine sizes continue to scale exponentially, there appears to be limited ways to test this equipment to demonstrate lifetimes. And most recently, we’ve seen some OEMs announce this, that they have issues with thoroughly testing complete systems before they get placed in service.

Are you seeing some of these same issues and what are you hearing from the test equipment side?

Claus Beck: Yeah, so it’s of course, something we hear of that there are difficulties in this field and because of the cost of, Taking a turbine down in the wind field or in a North shore let’s say a platform, then that would create a lot of cost.

And because of that, then you need to test. And that’s also a really a focus point for all big OEMs that we are dealing with.

Allen Hall: Yeah, it does seem as the offshore wind turbine sizes have grown so fast where we’ve gone from even during the development phases, we’ve gone from like a 10 megawatt machine to now we’re talking about upwards of 20, maybe 22 megawatt machines.

That’s a huge issue because I think as we’ve, even on blade sizes, and you guys do work with blades also, the blade lengths have, the new blade lengths have created issues that they have might, may not have seen before. So there’s some unknowns out there until you actually test something as massive as a 20 megawatt machine.

And does that, how does that drive you? I mean, what are your thoughts when you see a new announcement of a 22 megawatt machine, what are you thinking about that as these new machines are announced?

Claus Beck: Yeah, so it calls, it implies a lot of difficulties when you scale in this speed, which is the wind industries is doing so that, that causes some difficulties you there’s a lot of scaling loss normally when you design stuff, but these does not always apply and you have a lot of failure modes, which change when you scale to these sizes.

So that’s why we do these tests. Yeah. In order to predict and find, you can say, the errors before you go on on a wind farm with your turbines.

Joel Saxum: One of the difficult things that we talked about off air was the fact that you guys are designing the test equipment. That needs to be built for things that don’t exist.

So it’s we’ve got to figure out how to build a test bench for something that has never been built before, but we’re building the thing that’s actually going to test the thing that’s never been built before. So you guys have to really be on the ball.

Claus Beck: When we use bearings and all kind of, equipment, like big engines and so on, then they are driven by many times.

It’s driven by the wind industry, much of this technology, but the problem becomes a little bit and a big one when, the components are not developed yet because when we need to fatigue a bearing arrangement or a big generator, then we need something more a larger piece of equipment than it’s to be tested.

And in order to do that, we need to develop, you can say the big system. So always we are kind of put to the limit with these systems. So bearing arrangements are developed of course, based on a lot of experience and technologies within bearing companies, but we always need to push the boundaries and limits on many of these, so everything from, yeah, bearings, big steel shaft of several hundred tons. So it creates a lot of difficulties, both in engineering, you can say, but also in logistics. Same problems wind industry is facing when you need to transport these components. So in many cases, we also need to, let’s say, separate components into something where it’s, we can transport it because it’s just not doable.

Allen Hall: So in terms of the technology and the development you’re in the OEMs and the large component manufacturers have a need, they have an immediate need to evaluate their components. So I think they’re going to be driven more and more to demonstrate lifetimes, particularly in light of some of the things that happened over the last 12 months.

And they have to be coming to you for solutions to that. How big, well, how big of a team do you have first off in terms of the engineering staff and machinists and technicians?

Claus Beck: Yeah, so you can say in R&D, we are around 200 people, whereas I think around 170 of them are engineers. And the largest portion of this is related directly into developing new test benches.

So, so currently we are doing a large test bench for a set of wind power in Belgium. Also a validation test where we are, I think we were at maximum around 40 people at the engineering peak. You can say. So, of course it’s always scaled up and down towards when you had the needs for a lot of things to go through engineering.

And then when things are settling, then you can reduce the amount of people.

Allen Hall: Well, it’s an interesting problem to have, right? Because there is a huge demand for bigger generators and turbines and equipment. Where the OEMs can’t man those, they can’t support having a separate test division.

Most of them can’t do that. It’s not cost efficient for them to do that. They need to outsource it to someone who’s knowledgeable. And as an innovative as R&D test systems, does that then just, because of all the new development and the push for larger turbines, just bring a lot of demand at your doorstep to, to deal with?

Claus Beck: Yeah, it’s of course bringing a lot of demands and that’s why we need to stay yeah, ahead of all this and try to also. Think of new solutions that could maybe gain a good solution for a lot of our customers. But you can say by, we have a lot of experience for a lot of customers, but of course, we are not allowed to share the technologies and inputs, and we are not doing that, of course, but we will gather a lot of let’s say, good ideas on how to do smart stuff on our test benches, which of course, all our customers came from. So that’s also what you, when you work with us, you also get this and you can say. So that’s one of the good things about using a third party company like also you’re not an internal division.

So we are working with both. So, most of companies have internal divisions. Maybe we, we help scale these divisions or we work together in a combined let’s say yeah. engineering effort to find the solutions together.

Joel Saxum: I think one of the important things to touch on there as well is if you are saying an end user, if I am.

XYZ wind company and I’m choosing between two OEMs and one OEM. And this is just my brain, right? If one OEM tested the equipment theirself, they say, Hey, we tested our blades. Someone else might have certified them based on drawings and process and whatnot, but we tested our blades and how, so they’re good.

Or I have another company that’s like. Hey, we also have this third party expertise build our test bench and they put us through the ringer to make sure that our things work well, and then someone else certified them too. Well, that to me is well, all right, then you’re avoiding some kind of internal nepotism if you have someone else building your test rigs and, helping people along through that process of the actual testing.

So that’s a value add, in my opinion, to any outside engineering client.

Claus Beck: And in general, you could say the wind OEM would also have a better, let’s say, value of their turbine if it has been tested. So, that is definitely important and in general, it’s just shown that it’s important to test because the cost of downtime in, in the wind farms is just it’s not so good.

Allen Hall: We’re learning it’s billions of dollars at the moment.

Claus Beck: It’s bad business.

Allen Hall: I want to get into some of the technology you have developed because it’s fascinating to me. And I saw the Belgian efforts at some of the conferences. I think I saw that up in Sweden. I, some of the Belgians were there talking about the work you were doing for them.

And you were building a 20, you have built a 25 megawatt. Powertrain test bench in Denmark. And then you’re building, I think it’s something similar for Belgium, right?

Yeah. So, so you can say to some extent, so yeah, the first one was the one in Denmark which included this 25 megawatt drive motor.

So yeah, we couldn’t find this anywhere in the world. So, So we developed internally this star drive from scratch and did heat runs and test on prototypes. And so it’s thrown around in the air together with the load unit. So that’s why we had some difficulties in just finding a a standard product.

And besides that, it’s it’s a quite huge machine. So it’s 16 meter in diameter.

Joel Saxum: The scale of these machines, like I’m, I was looking at it. I was like, I was, and I’m squinting at my other screen right now. So anybody that’s watching on YouTube and I was like, those are people like, Oh my God, how did they build that thing?

Like the size of the rotors of these things. The first time you ever stand underneath one, even if it’s like a GE 1 5, you’re like, holy man, look how big this thing is. That’s nothing compared to a 10 or 15 megawatt machine. But now you look at these test benches that might be used for a 25 megawatt machine in there.

I mean, they’re like five houses, like strung together huge.

Claus Beck: It’s a 20, I think it’s around 21 meter high the test bench at the Lindø Offshore Renewable Center here in Denmark. So it’s very huge. And again, it sets the scale as we just talked about that, that when you need to break or fatigue something, which is already the extreme.

Developments in in the world on wind turbines, then you need to put something in even more extreme on the other side, because otherwise that would just break. So, but that’s the very interesting part of this this engineering you can say. So, so we always need to we come to the edge and we need to move it and develop these new test benches, and they are kind of a prototype, each of them, so we need to make sure they run for the first time and there’s only one shot.

Allen Hall: Lindø Offshore Renewable Center has this 25 megawatt drive stand to evaluate generators and I assume gearboxes and everything else attached to it and the electrical output of those generators, right?

There’s an electrical component to this, it’s not just mechanical failure. They’re looking at electrical performance.

Claus Beck: Yes. So you can say it’s a, it can run full power train. So including, so you starting from cut off the rotor, but then you have the first shaft and the main bearing arrangement and gearbox and the generator, and then the converter system connected to the generator, then we loop the power.

You can say between the converter system and our motor. So. We only feed in the losses you could say of the system. So making it, let’s say also very cost efficient. So we are not utilizing 25 megawatt when we run, only feeding in the losses of the system.

Allen Hall: That makes a lot of sense. That’s a smart way of doing it instead of having a big load bank and trying to get rid of all the heat from that’d be a massive effort, get bored of the ocean with that, so that does that then that.

Technology and the capabilities. Of the electrical and mechanical parameters vary from OEM to OEM or even gearbox manufacturers. Are they looking for specific kinds of failure modes that they know that they have seen in the past? Or are they running a full suite of tests to evaluate their components?

Claus Beck: So you can say, depending on the design, you could have a gear design. You could have a drive design where you don’t have a gearbox and the front shaft and connect the rotor directly to the drive. Generator, you can say interface here, you have different modes. You would like to, let’s say, provoke and try to to push.

So, so for each design, then the engineering department of each knows we, we might have some difficulty in these regions. So they would maybe try to push these boundaries. But on side of that, you would all always just have a, let’s say, a trajectory of loads from field. You would like to transfer into some, let’s say, accelerated load.

And they will be independent of design. So it’s just what you would experience in the field. So, all kind of, let’s say nominal scenarios where you have a lot of hours. And then extreme scenarios hurricanes, all kind of winds. Scenarios where you would arrows let’s say set ups in your controls, which could generate some let’s say very high rotor loads.

So, if you consider, for instance, there’s a pitch in moving where you suddenly start to let’s say pull in the turbine because of, misoriented turbine or something. So you need to, of course, make sure that it will not just break. Because you didn’t expect this scenario to happen, you could say.

So you need to make sure everything is proper.

Joel Saxum: Something interesting to me from a conversation we had was the fact that you guys actually, we’re right now, the conversations were basically focused on hardware. This is how electrically we connect things. This is how we test things mechanically. We’d build these massive rigs, but you guys also build software for testing as well.

And the interesting one for me was. The ability to virtually test against grid issues with the output from a turbine, right? So I think that was an interesting one.

Claus Beck: Yeah. Yeah. So you can say when you have a large wind farm and you connect it to the grid, then there are certain, let’s say error which could happen on the grid, which could be thrown against such a turbine park.

And if your software and your control systems and also the electrical hardware does not react in a correct way on these fall right through and all kind of errors, then you could. Let’s say that’s like breaking a shaft. Then you could also destroy your wind turbine. And so in order to check this, then you are running these script test where we can, we have test systems where we can say emulate the grid and send in these responses to the or errors to the turbine.

And then you check, If you react in the correct way on your turbine, and it can handle the arrows. So, it’s a significant part as well as similar to the mechanical testing, then it’s the electrical is very important. And for each country, you can say, then you have great coach. And you need to comply with those.

And for each of these grid codes, then you’ll have different testing scenarios you need to comply with. So these, this is also something we do here at R&D these grid emulators.

Allen Hall: Which is becoming an important part of the, sort of the electrification of the world at the moment, in Texas, we’ve had a couple of situations where the stability of the grid has been compromised because.

The solar mostly, but a little bit of wind the way that the turbines and the electrical equipment interact with upsets can be different between manufacturers and coming up with standards and Texas is talking about creating a standard for themselves at the moment, that is really critical to catch up front in the design phase of a turbine, because doing it post when the turbines are deployed is extremely expensive and creates a nightmare.

Claus Beck: So that’s really, and you could say. We have a field here in Denmark where you do let’s say onsite testing. So, reality test where it’s called where you run these turbines and then you also connect it to a grid. You need to wait for the right wind conditions and the right errors to come in.

So it takes some time. It’s still part of the test, but in order to accelerate the test. Then you’re doing these validation tests in parallel. So, so then you can run the test over and over again until you have made sure that your controls are tweaked to the right let’s say parameters and all your hardware is designed correctly.

So it’s a faster way.

Joel Saxum: So that would be like okay, so let’s dumb it down for people like me to understand. If we were to say we’re building a brand new car, say like a Ford, Chevy, whatever here in the United States are building a brand new car. And one way to test it would be to hand that car to I don’t know, one of the engineers and just say, hey, drive it every day for six months and see if anything pops up.

Well, that’s a real world test, but that’s not an accelerated test. That’s not going to find all the errors. And in parallel, you have other teams of engineers that have carbon copies of this car and they’re out there running it on a racetrack, putting 100, 000 miles on it, running it in 130 degree weather, putting it in a freeze chamber, bouncing it off of concrete, all kinds of stuff.

So it’s kind of like the same thing. Östrell would be giving someone that brand new car just to go and just go drive it, see what happens. And then the accelerated test, what you guys do, is in the background.

Claus Beck: I’m not so much into the details of this part, you can say. I’m more into the main test of the test bench, as you could say.

But to my understanding, then, it’s still a necessity to do the real life test in order to get approval, you could say. But this is something that is being worked upon. We have people here in R&D who’s working in these. These organizations to try to to mitigate some of these to make it. Faster to market, you could say but this is why grid emulation is very important to, to do the emulations in reality.

But do it in a controlled manner. But also the digital part, you could say, this is also a great focus from R&D. So, in order to test the things as much you can test on a computer. The better you can say, this is something that will take time and we are working a lot in it, but we are, let’s say building on you could say bricks on top of each other all time.

So, but you can say to make it simple, then you do these, hardware in the loop. You can try to imagine a kind of street where you want to test a motor before it’s running in the test lab, then you could actually do a emulation. So a computer model of the full motor. And then connect it to your controller for the motor and then the controller thinks it’s connected to all the sensors and all the inputs and then you do a very high level simulation model, which then predicts a lot of the, things happening in the motor, and then you can do a lot of development of on your, let’s say, controller prior to going to test. So this is also done in our, so sometimes you cannot put all the test equipment in. So then we do let’s say part of the test bench in a digital way and put it, let’s say, running in parallel to the test bench.

So the turbine is actually think it’s connected to all the other. Okay. Let’s say subsystems. So then you can verify even more of your system. You could say.

Allen Hall: That makes complete sense. It sounds like a lot of things that have been happening in aerospace lately to reduce costs, is to do simulations, emulations of hardware because it does give you a highly accelerated development cycle and saves, saves tons of money.

And speaking of development cycles, what’s on the docket at the moment? What are the new areas you’re being asked to look into in terms of test equipment on large scale wind turbine generators. Where are they driving you to?

Claus Beck: It goes very fast. You could say with turbines looking at just five years back, then we were talking about eight megawatt turbines, and now we’re talking 15, turbines.

So we, we take a, it takes some time to develop a test bench. So you can also say in that respect. When we need to give a test bench 10 years of, or 20 years of service life, then we need to really shake the crystal ball and look for what we expect from the future. So, and then this is it’s yeah it still goes fast.

You could say. Without saying a lot. So, there’s a lot of requirements for the future and they are still going upwards.

Allen Hall: So look for bigger generators in our future. That’s pretty exciting. And I, because you have completed a couple of tests sites and you’ve have these 25 megawatt test benches already in service, what are the customers saying back to you at this point, they got to be thrilled.

This is amazing.

Claus Beck: Yeah. It is. It is amazing. It’s you. If you’re just a little bit like big stuff or mechanical engineering or electrical. When you are at these sites just standing behind, beside it you’re just overwhelmed by it’s just, it’s very impressive. We even have people coming out and then, where is the test bench here?

But you need to look up, it’s right in front of you because the foundation was standing in front of it.

Allen Hall: It’s one of those it’s from an engineering standpoint. It’s cool, right? Can we just say that right now? The building big things is cool.

Joel Saxum: Yeah, yeah, it’s just cool. Yeah, it’s just cool.

Allen Hall: Forget about Legos for a minute.

This is cool. In Denmark, this is cool. Yeah.

Claus Beck: You can also feel it from all the colleagues here in R&D that it’s just amazing. So you’re always. Brought up with new tasks. So now we need to develop this. We need to double the size of this. So we need to, what can we do, but we’re already at the limit last time.

Yes, but now we need to move it again. So, so, but that’s very interesting, but it’s always based. You can say on very detailed engineering, because you could imagine that we cannot we need to make it work the first time. So that’s, of course, also what it’s setting the difference between us and an OEM.

So we, we are a little bit more allowed to use technology. Which maybe costing a little bit more because we need to push these limits. So we are not bound to series production when everything needs to be counted down to the smallest dollar. So, it’s we need to make sure it works and our customers are satisfied and they get what they need at the very end and get the tested the equipment out in the field.

So that’s kind of the essence.

Allen Hall: Well, the wind industry cannot grow without R&D Test Systems being out in front. All this new technology we want to have cannot happen unless there’s a test bench equipment and guidance and knowledge at R&D test systems to make sure that this, the new generation of OEM equipment actually works like it’s intended to.

So, for that we’re very appreciative, Claus of all the work that you guys are doing and the effort that goes into it, because if, when you do see it, and when everybody sees this video, you can go to YouTube and watch the size of these components we’re talking about, it’s scary. And it’s amazing at the same time.

So at the wind industry, applauds the work that you guys are doing.

Claus Beck: It’s really nice to be part of this. And it’s amazing. If

Allen Hall: a company hasn’t used your services, I don’t know why they haven’t, but if they haven’t used your services, how do they reach out to R&D test systems and connect with you

Claus Beck: Yeah, we have a homepage, so, rd-as.com. So, here you would find a lot of our services.

And you could say the wind industry is one portion. So we are also in, in aerospace, but you can say the main portion of our work is going into the wind industry.

Allen Hall: If you haven’t checked out R&D test systems, LinkedIn page, make sure you do that because there’s a lot of cool pictures and technology on there on their LinkedIn page.

So check that out also. Claus, This has been amazing. Thank you for taking the time to spend with Joel and me today. It has, we’ve really learned a lot and we’re continually impressed and we’ll see you down the road. I’m sure we’ll see you at the next conferences. We’re coming your way pretty soon.

So hopefully we cross paths.

R&D Test Systems – Pushing the Boundaries of Test Rigs for Massive Wind Turbine Equipment

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

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

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

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

[00:00:00] The Uptime Wind Energy Podcast brought to you by Strike Tape protecting thousands of wind turbines from lightning damage worldwide. Visit strike tape.com and now your hosts.

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

Saw some cool factories. What all happened?

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Technology.

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

Allen H: all built in country

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

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

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

Allen H: shop

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

And now it looks fantastic for the state of Massachusetts

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

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

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

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

It’s, it’s not that big of a deal.

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

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

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

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

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

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

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

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

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

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

Right? So

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

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

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Yolanda Padron: you millions.

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

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

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

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

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

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

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

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

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

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

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

Allen H: Oh, maybe that’s it.

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

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

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

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

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

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

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

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

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

Rosemary Barnes: I, I would be highly surprised.

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

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

Allen H: Sounds like pirate bounty in a sense.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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America Is a Gun

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I’ve enjoyed quite a few works from the poet whose work appears at left, but this one speaks to me most clearly.

Money means everything, and the value we put on the lives of our children pale in comparison.

America Is a Gun

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Bizarre Moments in Western Philosophy

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Schopenhauer’s pessimism is essentially everything he left us, and his quote here is representative of that.

We can’t change our birthplace, but does anyone want to do that anyway?  We can change anything else about us that we choose, and we certainly don’t spend the rest of our lives defending anything.

Bizarre Moments in Western Philosophy

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